JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 37

Bright Lite Structures specifies Hexcel carbon multiaxials for safety-critical application

produced on the A and B sides.

Fig. 2: The chassis
comprises five carbon
composite parts
bonded to a central
aluminium spine.
Hexcel's HiMax fabrics play an integral
role in reinforcing
areas of the floor pan

Fig. 3:
The moulded
Zenos chassis floor

adhesive bonding, resulting in lower assembly costs.

The right combination
Bright Lite Structures, who collaborated
successfully with Hexcel Reinforcements
UK on a number of previous projects,
contacted the company for advice during the E10 chassis design phase. After

Fast, cost-effective manufacture
Bright Lite Structures manufactures the
composite chassis components at its production facilities in Peterborough, UK,
using its proprietary wet compression
moulding process. This technique is capable of moulding complex, deep-draw designs in one step and, because the core can
be compressed, a different surface can be

Bright Lite Structures delivers the cured
parts to a machinist for trimming prior
to delivery to Zenos for assembly. The
total cycle time, including reinforcement and core kit cutting, lay-up and
post-mould trimming, is 15-20 minutes
per part. The exterior of the body sides
and rear bulkhead are painted black to
produce an acceptable aesthetic surface.
This patented technology offers several
advantages over conventional composite manufacturing processes, which rely
on costly preforming techniques and
autoclave equipment. The carbon fibre
components produced are up to 20%
lighter than those manufactured using
conventional processes, yet still meet
stiffness requirements. The parts are
also less expensive and faster to manufacture in high volume, and less carbon
fibre and resin are required, leading to
lower total materials costs. As a result of

Fig. 4: Spraying resin onto the reinforcement/core
stack at Bright Lite Structures

No110 January - February 2017

/ jec composites magazine

Feature Automotive

The chassis is made up of only five parts -
front and rear bulkheads, a floor pan and
left and right body side panels - bonded
to a central aluminium spine. The parts
are manufactured as a sandwich structure.
At the centre of the structure is a sheet of
core material made from hollow tubes of
recycled polycarbonate. Either side of this
core is a laminate based on one ply of recycled chopped carbon fibre in the form
of a multiaxial mat and a resin blend of
polyurethane and RTM-grade epoxy. For
the 1.6 m x 1.7 m chassis floor, two carbon
fibre multiaxial reinforcements produced
by Hexcel Reinforcements UK (formerly Formax) were also specified. Should
the vehicle be involved in a crash, these
reinforcements are engineered to spread
the seat belt pull-out load over the largest
possible area, ensuring the metal seat belt
inserts positioned under the floor remain
in place.

studying the requirements for the additional reinforcement of the chassis floor,
Hexcel recommended a combination of
two multiaxial fabrics that would provide
optimal performance for this challenging
application. Rolls of the chosen materials
were supplied to Bright Lite Structures for
testing purposes. The results were excellent and the two products were specified
for the chassis. On the floor interior, on
top of the recycled carbon mat, one ply of
HiMax™ 300 g/m2 (75 g/m2, 150 g/m2, 75 g/
m2) carbon fibre triaxial is added over the
complete surface of the part. Additionally,
one ply of HiMax™ 0/90° 300 g/m2 carbon fibre biaxial is used in the areas of the
seat belt inserts and seat mounting inserts,
which are co-moulded into the floor.
Although employed primarily to handle
crash loads, the Hexcel fabrics are also
very attractive in visual appearance and
the moulded floor remains unpainted.

In the first step of the process, the dry
materials (cut to shape) are stacked together by hand to form a flat sandwich
(reinforcement/core/reinforcement).
This stack is clamped in a frame, which
is then attached to a robot arm. The robot moves the assembly under a spray
machine and the resin is sprayed onto
the reinforcement. The frame is turned
over and the other side is sprayed. The
part is then placed into a compression
moulding press at 130°C for 8 minutes
at 6 bar pressure.

37



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017

Cover
Edito
Opinion: Mobility
Contents
NEWS
In brief
Startup competition
Construction & public transport
Investment
Agenda
BUSINESS
Trend
Startup booster
China
MANUFACTURING
RTM
WPC
Sandwich
Feature Automotive - El dorado, or a lure
3D printing
Cycle time
Raw materials
Reinforcements
Compression moulding
Compression moulding
Lightweighting
Interior part
SOLUTIONS
Marine
Motorcycle
Medical
In the world
TECHNOLOGY
OPLC
Draping
Damping
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 60
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Opinion: Mobility
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Startup competition
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 11
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Construction & public transport
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Investment
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 17
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Trend
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 19
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Startup booster
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - China
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 22
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - RTM
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 24
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - WPC
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Sandwich
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 3D printing
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 29
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Cycle time
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 31
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Raw materials
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 33
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 35
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Reinforcements
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 37
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Compression moulding
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Compression moulding
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Lightweighting
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 41
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Interior part
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Marine
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 44
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Motorcycle
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Medical
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - In the world
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - OPLC
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 49
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 50
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 51
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 52
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 53
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Draping
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 55
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Damping
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 57
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #110 - January/February 2017 - 59
https://www.nxtbook.fr/newpress/jeccomposites/jcm2001_132
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_131
https://www.nxtbook.fr/newpress/jeccomposites/jcm1909_130
https://www.nxtbook.fr/newpress/jeccomposites/jcm1907_129
https://www.nxtbook.fr/newpress/jeccomposites/jcm1905_128
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_Special_Issue1
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_127
https://www.nxtbook.fr/newpress/jeccomposites/jcm1901_126
https://www.nxtbook.fr/newpress/jeccomposites/jcm1811_125
https://www.nxtbook.fr/newpress/jeccomposites/jcm1810_124
https://www.nxtbook.fr/newpress/jeccomposites/jcm1808_123
https://www.nxtbook.fr/newpress/jeccomposites/jcm1807_122
https://www.nxtbook.fr/newpress/jeccomposites/jcm1805_121
https://www.nxtbook.fr/newpress/jeccomposites/jcm1804_120
https://www.nxtbook.fr/newpress/jeccomposites/jcm1803_119
https://www.nxtbook.fr/newpress/jeccomposites/jcm1802_119-Supplement_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm1801_118
https://www.nxtbook.fr/newpress/jeccomposites/jcm1711_117
https://www.nxtbook.fr/newpress/jeccomposites/jcm1710_116
https://www.nxtbook.fr/newpress/jeccomposites/jcm1708_115
https://www.nxtbook.fr/newpress/jeccomposites/jcm1707_114
https://www.nxtbook.fr/newpress/jeccomposites/jcm1706_113
https://www.nxtbook.fr/newpress/jeccomposites/jcm1704_112
https://www.nxtbook.fr/newpress/jeccomposites/jcm1703_111
https://www.nxtbook.fr/newpress/jeccomposites/jcm1701_110
https://www.nxtbook.fr/newpress/jeccomposites/jcm1611_109
https://www.nxtbook.fr/newpress/jeccomposites/jcm1610_108
https://www.nxtbook.fr/newpress/jeccomposites/jcm1608_107
https://www.nxtbook.fr/newpress/jeccomposites/jcm1607_106
https://www.nxtbook.fr/newpress/jeccomposites/jcm1605_105
https://www.nxtbook.fr/newpress/jeccomposites/jcm1604_104
https://www.nxtbook.fr/newpress/jeccomposites/jcm1603_103
https://www.nxtbook.fr/newpress/jeccomposites/jcm1601_102
https://www.nxtbook.fr/newpress/jeccomposites/jcm1511_101
https://www.nxtbook.fr/newpress/jeccomposites/jcm1510_100
https://www.nxtbook.fr/newpress/jeccomposites/jcm1509_99
https://www.nxtbook.fr/newpress/jeccomposites/jcm1507_98
https://www.nxtbook.fr/newpress/jeccomposites/jcm1505_97
https://www.nxtbook.fr/newpress/jeccomposites/jcm1504_96
http://www.nxtbook.com/newpress/jeccomposites/jcm1503_95
http://www.nxtbook.com/newpress/jeccomposites/jcm1501_94
http://www.nxtbook.com/newpress/jeccomposites/jcm1412_93
http://www.nxtbook.com/newpress/jeccomposites/jcm1410_92
http://www.nxtbook.com/newpress/jeccomposites/jcm1409_91
http://www.nxtbook.com/newpress/jeccomposites/jcm1406_90
http://www.nxtbook.com/newpress/jeccomposites/jcm1405_89
http://www.nxtbook.com/newpress/jeccomposites/jcm1404_88
http://www.nxtbook.com/newpress/jeccomposites/jcm1403_87
http://www.nxtbook.com/newpress/jeccomposites/jcm1401_86
http://www.nxtbook.com/newpress/jeccomposites/jcm1311_85
http://www.nxtbook.com/newpress/jeccomposites/jcm1310_84
http://www.nxtbook.com/newpress/jeccomposites/jcm1308_83
http://www.nxtbook.com/newpress/jeccomposites/jcm1307_82
http://www.nxtbook.com/newpress/jeccomposites/jcm1305_81
http://www.nxtbook.com/newpress/jeccomposites/jcm1304_80
http://www.nxtbook.com/newpress/jeccomposites/jcm1303_79
http://www.nxtbook.com/newpress/jeccomposites/jcm1301_78
http://www.nxtbook.com/newpress/jeccomposites/jcm1212_77
http://www.nxtbook.com/newpress/jeccomposites/jcm1210_76
http://www.nxtbook.com/newpress/jeccomposites/jcm1208_75
http://www.nxtbook.com/newpress/jeccomposites/jcm1207_74
http://www.nxtbook.com/newpress/jeccomposites/jcm1206_73
http://www.nxtbook.com/newpress/jeccomposites/jcm1204_72
http://www.nxtbook.com/newpress/jeccomposites/jcm1203_71
http://www.nxtbook.com/newpress/jeccomposites/jcm1201_70
http://www.nxtbook.com/newpress/jeccomposites/jcm1111_69
http://www.nxtbook.com/newpress/jeccomposites/jcm1110_68
http://www.nxtbook.com/newpress/jeccomposites/jcm1108_67
http://www.nxtbook.com/newpress/jeccomposites/jcm1107_66
http://www.nxtbook.com/newpress/jeccomposites/jcm1105_65
http://www.nxtbook.com/newpress/jeccomposites/jcm1104_64
http://www.nxtbook.com/newpress/jeccomposites/jcm1103_63
http://www.nxtbook.com/newpress/jeccomposites/jcm1101_62
http://www.nxtbook.com/newpress/jeccomposites/jcm1011_61
http://www.nxtbook.com/newpress/jeccomposites/jcm1010_60
http://www.nxtbook.com/newpress/jeccomposites/jcm1009_59
http://www.nxtbook.com/newpress/jeccomposites/jcm1006_58
http://www.nxtbook.com/newpress/jeccomposites/jcm1005_57
http://www.nxtbook.com/newpress/jeccomposites/jcm1004_56
http://www.nxtbook.com/newpress/jeccomposites/jcm1003_55
http://www.nxtbook.com/newpress/jeccomposites/jcm1001_54
http://www.nxtbook.com/newpress/jeccomposites/jcm0911_53
http://www.nxtbook.com/newpress/jeccomposites/jcm0910_52
http://www.nxtbook.com/newpress/jeccomposites/jcm0909_51
http://www.nxtbook.com/newpress/jeccomposites/jcm0907-08_50
http://www.nxtbook.com/newpress/jeccomposites/jcm0906_49
http://www.nxtbook.com/newpress/jeccomposites/jcm0904_48
http://www.nxtbook.com/newpress/jeccomposites/jcm0903_47
http://www.nxtbook.com/newpress/jeccomposites/jcm0901_46
http://www.nxtbook.com/newpress/jeccomposites/jcm0811_45
http://www.nxtbook.com/newpress/jeccomposites/jcm0810_44
http://www.nxtbook.com/newpress/jeccomposites/jcm0809_43
http://www.nxtbook.com/newpress/jeccomposites/jcm0807_42
http://www.nxtbook.com/newpress/jeccomposites/jcm0806_41
http://www.nxtbook.com/newpress/jeccomposites/jcm0805_40
http://www.nxtbook.com/newpress/jeccomposites/jcm0803_39
http://www.nxtbook.com/newpress/jeccomposites/jcm0801_38
http://www.nxtbook.com/newpress/jeccomposites/jcm0712_37
http://www.nxtbook.com/newpress/jeccomposites/jcm0710_36
http://www.nxtbook.com/newpress/jeccomposites/jcm0709_35
http://www.nxtbook.com/newpress/jeccomposites/jcm0707_34
http://www.nxtbook.com/newpress/jeccomposites/jcm0706_33
http://www.nxtbookMEDIA.com