JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 42

LAND TRANSPORTATION coating
The one-shot process is, consequently,
an attractive option for less complex
parts at lower build rates. The main
advantage is that a single tool is used to
make the composite part and apply the
coating, minimizing total investments.
Two-shot process
The key characteristic of this concept is
the thermal separation of the part production from the coating process. This
can be realized by using two tool sets, or
by first producing the CFRP parts, and
subsequently using the same mould for
the coating process (see Figure 5).
By separating the two steps, the thermal
shrink issue can be overcome. In the first
step, the part is produced at a higher
temperature (typically 120-130°C),
allowing higher build rates.
The part can then be cooled to 80-100°C
before the coating process is carried
out. The coating can cover the fibre
print-through generated by the higher
moulding temperature. This concept can
be used to maintain a very high surface
quality in combination with short cycle
times. Part-to-part cycle times of less
than 3 minutes are possible. In the end,
the achievable cycle time is mainly
dictated by the acceptable surface quality, which needs to be evaluated case by
case. While the need for a second tool
set increases the investment, significantly higher build rates can actually result in
a lower fixed cost per part.
By using a second adapted tool set, real
3D parts with a consistent applied coating thickness are possible. Also, other
processes, such as edge trimming, can be
integrated to ensure the coverage of all
relevant areas.
The two-shot process is mainly attractive
when higher build rates are targeted or
when exacting surface requirements
must be fulfilled.
Cost model
The cost to produce a coated composite
back seat panel using a traditional spray
process was compared with the cost
utilizing the IMC process (see Figure 6).
Material costs; investments in presses,

42

Fig. 6: Cost comparison for a back seat structure manufactured using various coating methods

tools and injection equipment; and the
impact of the build rate and cycle time
were all taken into consideration for the
IMC process. Compared with the typical
cost for the spray process, the two-shot
process can achieve part cost savings of
up 50%. The savings are mainly realized
by avoiding the high fixed cost of a spray
coating line. The break-even point in the
evaluated part is achieved at a build rate
of roughly 5000 parts/year.
A variety of investment scenarios are
possible and allow manufacturers to
focus on limiting capital expenditures
for the IMC process, or alternatively, on
maximizing the build rate.
Summary
The PuriCoat platform combines a stateof-the art fast-cure epoxy resin with PU
RIM technologies, enabling the production of visible parts in a short cycle time,
with very high surface quality.
In a close technical collaboration, the
compatibility of the epoxy matrix and
polyurethane coating, as well as the
process conditions, were optimized. The
result is a very good coating durability
and inter-coat adhesion, a high surface
quality, and the availability of suitable
internal mould release agents for the
composite resin as well as the RIM
coating. The absence of solvent and negligible emissions address a growing drive
for environmentally better solutions.

jec composites magazine / N°121 May - June 2018

Depending on the surface requirements,
pre-existing infrastructure and target
build rates, the production concept may
be optimized in the form of either a onestep or two-step process.
Significant cost savings compared with
traditional spray coating make this an
attractive solution for large build rate
manufacturing and opens a window of
opportunity for coated exterior parts.
More information:
www.hexion.com
References
[1] http://www.compositesworld.com/articles/bmw-7-series-plant-dingolfing-germany
[2] https://www.kraussmaffei.com/rpm-en/
surface-rtm-s-rtm.html

Main features
- Cooperation by Hexion and
Votteler to develop the PuriCoat
platform, combining epoxy-based
RTM/LCM technology with a polyurethane-based RIM process
- Material technologies optimized
for best adhesion and self-releasing performance
- High productivity with potential
cycle times below 3 minutes, for
higher build rates
- Significant cost savings in comparison to conventional spray
coating
- Environmentally preferred low-emission coating solution


http://www.hexion.com http://www.compositesworld.com/arti https://www.kraussmaffei.com/rpm-en/

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #121 - May 2018

Cover
Edito
Opinion: Lighter, faster, smarter
Contents
NEWS
In brief
JEC World 2018 Report
JEC World 2018 gathered the whole composites industry in Paris
JEC innovation Awards Winners 2018
Startup Booster - A springboard for innovative talents
Injection - lnjection moulders who have made bioplastics work
Agenda
BUSINESS
Acquisition - Huntsman acquires Nanocomp Technologies
Simulation - "We want to bring the story of composites to the end user in a different way"
Trends - Overview of the North Amaerican composites market
MANUFACTURING
Additive manufacturing - The Energica dashboard reinvinted through professional 3D printing and composite materials
Prototyping - Injection moulding: running tests earlier with 3D printing
Mass-production - Fast RTM: a techincally and economically optimised solution
Covers - Opportunities for composite profiles in the residential housing market
SOLUTIONS
Building - CompoHouse, the demonstration building made of composites
Construction - Textile concrete makes thin, large-sized curtain walls possible
In the world
TECHNOLOGY
Multi-material - High-confidence performance predictions for hybrid thermoplastic composite applications
Experimental techniques - 3D tectile-reinforced composites: from manufacturing to structural design
Index
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JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Cover
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 2
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Edito
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Opinion: Lighter, faster, smarter
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 5
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Contents
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 7
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - In brief
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 9
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - JEC innovation Awards Winners 2018
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 11
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 12
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 13
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 14
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 15
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 16
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 17
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 18
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 19
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Startup Booster - A springboard for innovative talents
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Agenda
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 22
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 23
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Acquisition - Huntsman acquires Nanocomp Technologies
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 25
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Simulation - "We want to bring the story of composites to the end user in a different way"
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 27
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Trends - Overview of the North Amaerican composites market
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 29
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Additive manufacturing - The Energica dashboard reinvinted through professional 3D printing and composite materials
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 31
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Prototyping - Injection moulding: running tests earlier with 3D printing
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 33
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Mass-production - Fast RTM: a techincally and economically optimised solution
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 35
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 36
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 37
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 38
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 39
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 40
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 41
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 42
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 43
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 44
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 45
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 46
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 47
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Covers - Opportunities for composite profiles in the residential housing market
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 49
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 50
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 51
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 52
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 53
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 54
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 55
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Building - CompoHouse, the demonstration building made of composites
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 57
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 58
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Construction - Textile concrete makes thin, large-sized curtain walls possible
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - In the world
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 61
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Multi-material - High-confidence performance predictions for hybrid thermoplastic composite applications
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 63
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 64
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 65
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 66
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Experimental techniques - 3D tectile-reinforced composites: from manufacturing to structural design
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 68
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 69
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 71
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 72
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