Belzona: How to repair and protect hydro equipment with polymeric technology

Given the expected and necessary growth of the hydropower industry over the upcoming decades, it could be argued that polymeric technology has a valuable role to play in supporting this growth. Applications, such as the one identified below, demonstrate how assets that would otherwise be decommissioned or sent to landfill can be given a new lease of life thanks to a combination of epoxy repair composites.

Given the expected and necessary growth of the hydropower industry over the upcoming decades, it could be argued that polymeric technology has a valuable role to play in supporting this growth. Applications, such as the one identified below, demonstrate how assets that would otherwise be decommissioned or sent to landfill can be given a new lease of life thanks to a combination of epoxy repair composites.

Hydropower capacity set to double by 2050

According to the International Energy Agency’s (IEA) Net Zero by 2050 Roadmap [1] (revised version 2021), the hydropower industry needs to be the ”third largest energy source in the electricity mix by 2050” – this involves a doubling of hydropower capacity by this date. This is in order to keep the planet aligned with a net zero by 2050 pathway.

To support this colossal scale-up of hydropower capacity, polymeric technology has an important part to play in terms of its role within hydropower plant maintenance. In order to keep a growing fleet of hydro plants running as efficiently as possible, systems such as epoxy repair composites and high-performance coatings can be deployed to repair and protect damaged assets.

Not only does this technology enable asset owners to make significant financial savings, but this circular economic business model is also extremely beneficial for the planet. It mitigates the carbon footprint that would otherwise be incurred through the process of replacing a damaged asset and sending it to landfill. In turn, by helping asset owners to avoid asset replacement, it could be argued that polymeric technology has an important part to play in supporting the transition to net zero by 2050.

Rebuilding sealing faces of hydro equipment

A common application area where polymeric technology can be deployed in hydropower plants is dam or lock gates. These gates are highly susceptible to substantial erosion at their sealing surfaces. Factors such as pressure, water flow and consistent friction contribute to compromised seals over time. Over the years, authorised Belzona distributor, Protecmo, has conducted a series of applications designed to repair and protect the sealing faces of hydro equipment for the long term.

For rebuilding the damaged substrate, Protecmo specify the 2-part epoxy paste, Belzona 1111 (Super Metal). As this system is specially designed for metal repair and resurfacing, it is perfectly optimised to rebuild damaged metal substrates in dam or lock gates. A solvent-free epoxy resin reinforced with silicon steel alloy, this composite repair material is corrosion-resistant, and also resists a wide range of chemicals. Thanks to its cold-curing properties, this successfully mitigates the need for hot work. The ceramic polymer, Belzona 1311 (Ceramic R-Metal), is also specified for metal rebuilding, but for situations where additional erosion resistance is required.

In order to provide long-term protection to the lock gates, Protecmo specifies the metal repair composite, Belzona 1321 (Ceramic S-Metal). This system provides excellent corrosion-erosion resistance for applications up to 60°C (140°F). This solvent-free epoxy coating also has outstanding chemical resistance and will bond to almost any rigid surface. Belzona 1331 is also used to protect assets against the effects of corrosion-erosion for temperatures up to 50°C (122°F). In addition, as Belzona 1331 can be spray applied, this makes it a practical choice for larger applications.

Polymeric technology supports the transition to net zero

Considering the expected growth of the hydropower industry, it is critical that vital assets are safeguarded against damage and degradation for the long term. Polymeric technology has an important role to play in facilitating this. By repairing and protecting a damaged asset instead of replacing it, epoxy repair composites and high-performance coatings are key drivers in supporting the transition to net zero.

About Protecmo:

From power generation to paper production, steel mills to petrochemical plants, Protecmo, the Belzona exclusive authorised distributor for the South of France, provides epoxy repair composites and high-performance coatings to solve a myriad of maintenance issues. The distributorship provides local, 24-hour technical support and on-site assistance.

#composites #repair #HydropowerPlant

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Autocomposites market is expected to double revenue by 2032

Increase in demand for lightweight vehicles, stringent regulations and a rise in EV adoption are factors that are currently driving growth in automotive composites, according to a recent report.

Allied Market Research (Wilmington, Del., U.S.), a full-service market research and business consulting wing of Allied Analytics LLP (Portland, Ore., U.S.) has published an analysis and forecast report for the 2023-2032 automotive composites market. According to the report, the market was valued at $7.4 billion in 2022, and is estimated to reach $16.4 billion by 2032, growing at a CAGR of 8.3% from 2023 to 2032.

The global automotive composites market is driven by rapid technological advancements. According to Allied Market Research, advances in composites manufacturing technologies — e.g., resin transfer molding (RTM) and automated fiber placement (AFP) — are making them more cost-effective and suitable for mass production. Furthermore, the rise of electric vehicles (EVs) is creating new opportunities for composites, to extend battery range and improve performance.

However, one of the primary restraints still impacting the automotive composite market is the high cost associated with composite materials as compared to traditional metals such as steel and aluminum; the manufacturing processes involved in producing composite materials, including molding, curing and finishing, tend to be more complex and capital-intensive; and, in addition, the cost of raw materials used in composites, such as carbon fibers and resins, remains relatively high. As a result, automakers face challenges in justifying the higher upfront investment required for integrating composites into vehicle structures.

Carbon fiber segment

By fiber type, the carbon fiber segment accounted for the largest share in 2022, contributing to more than two-thirds of the global automotive composites market revenue. Carbon fiber’s lightweight can improve fuel efficiency and overall performance of vehicles, especially in terms of acceleration, handling and braking. Furthermore, stricter emissions standards such as Bharat stage (BS-V and BS-VI) and fuel efficiency requirements are pushing automakers to explore lightweight materials like carbon fiber to reduce vehicle weight and meet regulatory standards; lighter vehicles generally produce fewer emissions and consume less fuel.

Thermosets segment

By resin type, the thermoset segment accounted for the largest share in 2022, contributing to more than half of the global automotive composites market revenue. Thermoset resins offer high strength, stiffness and dimensional stability, which are crucial for automotive applications. These resins provide durability and resistance to heat, chemicals and fatigue, making them suitable for various components in vehicles. Moreover, thermoset composites can be molded into complex shapes, enabling novel designs and integration of multiple functionalities into a single component. This flexibility enables automakers to optimize the design of automotive parts for performance, aesthetics and functionality.

Exterior segment

By application, the exterior segment accounted for the largest share in 2022, contributing to nearly half of the global automotive composites market revenue. Composites’ light weight make them particularly attractive for exterior components where reducing weight is crucial. Additionally, composites can be molded into complex shapes with ease, providing automakers with the to create distinctive exterior designs that not only enhance the vehicle’s aesthetics but also improve aerodynamics.

Asia-Pacific to maintain its dominance by 2032

By region, Asia-Pacific held the highest market share in terms of revenue in 2022, accounting for one-third of the global automotive composites market and is projected to register the highest CAGR of 9.0% during the forecast period. The Asia-Pacific region is a major hub for automotive manufacturing, with countries like China, Japan, South Korea and India leading the production.

Within the report, Allied Market Research also provides a detailed analysis of list of leading market players in the autocomposites space. These players have adopted different strategies such as new product launches, collaborations, expansion, joint ventures, agreements and others to increase their market share and maintain dominant shares in different regions:

• Toray Industries Inc.
• SGL Carbon SE
• Teijin Ltd.
• Hexcel Corp.
• Owens Corning
• Mitsubishi Chemical Holdings Corp.
• Gurit Holding AG
• Syensqo (previously Solvay S.A.)
• Toray Advanced Composites (previously TenCate Advanced Composites)
• Huntsman Corp.

It is noted that the report is valuable in highlighting business performance, operating segments, product portfolio and strategic moves of market players to showcase the competitive scenario.

#composites #Autocomposites #market

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Carbon fiber metro train to hit the rails in China

An 11% weight reduction and 7-15% less energy consumption make this upcoming vehicle a more eco-friendly transportation option.

Several sources are highlighting the build of a carbon fiber commercial metro train in China. The Cetrovo 1.0 prototype, featuring a composite body shell, is a joint project between CG Rail, Chinese-German Research and Development Center for Railway and Traffic Technology Dresden founded as a spin-off of TU Dresden, and rail vehicle manufacturer CRRC Sifang based in China. The “Next Generation Metro Train” project reportedly makes new strides in eco-friendly urban transportation, with an 11% weight reduction compared to metal models, and between 7-15% reduction in energy consumption.

Additional project partners include Qingdao Metro Group, Harbin FRP Institute, Weihai Guangwei Composite and AVIC Composite.

“Lightweight vehicles are a key technology for developing eco-friendly and low-carbon rail vehicles,” Lyu Xiaojun, a senior designer at CRRC Qingdao Sifang, told ChinaDaily.com.cn, adding that carbon fiber — with its light weight and high strength, as well as its fatigue and corrosion resistance — is an ideal material for the purpose of improving China’s urban rail sector.

Cetrovo 1.0 features carbon fiber for its main load-bearing structures, as reported by CG Rail and JEC World. The system’s composite content exceeds 70%:

• CG Rail implemented a composite front cabin, car body, underfloor paneling and bogie frame.
• Harbin FRP Institute developed and produced Cetrovo’s carbon fiber bogie crossbeam component
• Guangwei Composite provided carbon fiber, fabrics, prepregs and other materials support
• AVIC Composite assisted CRRC Sifang in conducting research on composite side wall materials, processes and connection forms, as well as completed the design and optimized manufacturing of the main and connection structure.

Of additional interest is the metro’s use of digital twin technology platform, called SmartCare, that is capable of “self-diagnosing and detecting potential problems, ensuring safe and efficient operation while minimizing maintenance costs, which are projected to be 22% lower over the train’s life cycle.” The car is designed for fully automated operation at a maximum speed of 140 kilometers/hour, compared to the 80 kilometers/hour of previous designs.

CRRC originally presented the carbon fiber metro at InnoTrans 2018. The train, still under testing, is expected to go into passenger trial operation later this year.

#composites #CarbonFiber #China

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Vertical Aerospace releases new VX4 prototype, begins initial testing

Initial powered ground tests are underway for the U.K.-built composite eVTOL vehicle, ahead of a more robust flight program with CAA Permit to Fly approval.

Vertical Aerospace (London, U.K.) has unveiled its next-generation, full-scale VX4 prototype, claimed to be the only electric takeoff and landing (eVTOL) vehicle designed, built and assembled in the U.K. The company has started with initial powered ground tests, including propeller balancing, which have been successfully completed.

The VX4 is reported to be more powerful than the previous full-scale prototype, with a 20% increase in power-to-weight ratio, enabling the aircraft to reach speeds of up to 150 miles per hour. The aircraft has been designed and built alongside global aerospace partners, including GKN Aerospace (composite wings and empennages and wiring harness), Honeywell (flight control computers, avionics and flight control software), Hanwha (electro-mechanical actuators and mechanisms), Molicel (lithium-ion cylindrical cells for the battery cell), Leonardo (composite fuselage and pylons) and Syensqo (composite materials). It also features carbon fiber propellers and proprietary battery technology, designed and manufactured at its Vertical Energy Centre (VEC) near Bristol.

The VX4 prototype has successfully completed systems and aircraft testing and commissioning. Vertical is now working closely with the UK Civil Aviation Authority (CAA) as it rigorously evaluates the engineering, design, test data and aircraft ahead of issuing a Permit to Fly, effectively conducting a “mini certification” program. Vertical will then begin a robust flight test program at the VEC, with a focus on achieving piloted flight.

Vertical is currently developing an identical full-scale prototype which will accelerate the VX4’s flight test program and demonstration capability. The company will take flight test learnings from both prototypes into the design and development of the certified VX4 model.

Over the coming days, the company will conduct powered, propulsion system testing of its powertrain, which includes proprietary battery packs capable of producing 1.4 megawatts of peak power. The company will then move onto its “wheels up” phase with tethered flight tests before progressing to low-speed untethered flights, once it has been issued its Permit to Fly. Together, they will ensure the VX4 meets the highest standards of operational safety which are needed for piloted flights.

“These tests are a crucial step forward in our mission to certify the VX4 and make a cleaner, quieter and safer way of air mobility a reality,” says David King, chief engineer at Vertical, says. “Every day we are seeing progress from the team at our Flight Test Centre, each test providing valuable insights to help shape the next.”

#composites #VerticalAerospace #VX4prototype

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Goodman Technologies, partners scale up AI-empowered 3D printing of nanocomposites for spacecraft TPS

NASA project addresses the capability gap in TPS production and installation for space exploration and hypersonic systems, delivering an ARMs system, nanopaste and prepreg tapes, manufacturing verification coupons and more.

Goodman Technologies LLC (Largo, Fla., U.S.), a rapid growth nanocomposite ecosystem platform company, with the University of Hawaii at Manoa Hawaiian Nano Laboratory (UHM-HNL) and the Wichita State University (WSU) National Institute of Aviation Research (NIAR), performed work under a NASA (Washington, D.C., U.S.) Phase II STTR that sought to explore the AI-empowered scale-up of additively manufactured continuous fiber ceramic nanocomposites (CFCNC) to revolutionize the manufacturing of thermal protection systems (TPS). These efforts addressed the critical capability gap in the production and installation of these advanced materials for NASA space vehicles and beyond that is affordable and non-labor intensive.

The advanced materials and manufacturing techniques developed in this project are expected to play a critical role in NASA’s Human Exploration and Operations Mission Directorate (HEOMD) Lunar and Mars missions, as well as the Science Mission Directorate (SMD) planetary missions, which require hypersonic entry through an atmosphere.

The overarching objectives of this project, spanning Phase I through Phase III, focused on:

• Manufacturing efficiency of TPS approaches: A comparative study of “top-down” and “bottoms-up” TPS approaches was conducted, with the aim of mitigating any disadvantages associated with each method. This dual approach ensured that the most efficient and effective manufacturing process was identified and implemented.

• Design of GTNANO automated robotic manufacturing system (ARMS): This system incorporates a range of advanced manufacturing techniques, including milling, fiber patch placement (FPP) of ceramic nanocomposite prepreg and the printing of ceramic nanopastes. The integration of these processes into a single automated system represents a significant advancement in the field of composites manufacturing.

• Development of nanopaste and prepreg tapes: Critical to the success of the project was the development of a low-shrinkage printable silicon carbide (SiC) nanopaste, as well as continuous roll-to-roll ceramic nanocomposite prepreg tapes. These materials are essential for producing a new category of high-quality continuous fiber ceramic nanocomposites (CFCNCs) with consistent properties.

• Production of a manufacturing verification coupon: Using the ARMS system, an 18-inch manufacturing verification coupon was produced. This coupon serves as a proof of concept, demonstrating the capabilities of the manufacturing process at scale.

During the past 4 years, the GT/UHM-HNL Team has multiple patent filings on the topics of SiC-based nanopastes which are 3D printable, moldable via a proprietary Z-process and have been used to make SiC (Hi-Nicalon)-reinforced prepreg for the molding, curing and joining of CFCNCs. CFCNCs are said to overcome the issue of delamination and segment separation, advancing the potential of spacecraft TPS and hypersonics in general.

GT’s TPS uses the 3D printable and moldable nanopaste for the shell and the Hi-Nicalon SiC/nanoSiC prepreg CFCNCs for the structural layer, which is bonded to a high-temperature CFOAM insulation core with a nanopaste adhesive. The process is amenable with other types of lightweight insulation. According to GT, the nano particulate used in the shell layer enables the system to have increased thermal conductivity, thermal stability and density. GT’s TPS is designed such that during entry through an atmosphere the outer shell will ablate and sublimate leaving the hot structure, which can then have a new shell 3D printed onto the surface for reuse. Arc-jet testing at NASA Ames Research Center proved that the hot structure was reusable. Notably, other printable ablation layers could be deposited on GT’s reusable hot structure.

The GT team was selected for a Phase II award where the automated manufacturing of the improved TPS was scaled up to about a half meter, though it is reported that there is really no limitation of scale for the process. To accomplish this, GT developed a large-scale ARMS which consisted of a six-axis robotic arm with the capability of swapping between a nanopaste extrusion end effector, milling attachment and FPP attachment. Alternately, multiple robots and cobots can perform the process.

Ultimately, FPP offers improved performance over the alternative of tape laying. The robotic arm places patches of material in a programmed pattern over the surface of the CFOAM core. Each patch was about 2 × 4 inches and was placed in such a way as to strengthen the areas of the TPS surface which GT has identified will be under higher levels of loading. The use of AI was pervasive throughout the process.

Partners note that each deliverable in this project represents “a quantum leap” in the field of composites manufacturing, particularly for spacecraft and hypersonic systems, including:

• The design of industrial large-scale printer/end effector: The development of a large-scale printer and end effector capable of handling the demands of ceramic nanocomposite materials is a critical step forward. This printer enables the production of large-scale components with the precision and consistency required for aerospace applications. Notable, the robotic arm introduces multiple degrees of freedom beyond the Cartesian and Polar coordinates systems that constrain 3D printers. Likewise, robots and cobots allow scaling of 3D printing beyond conventional build beds.

• Optimized low shrinkage printable SiC nanopaste: This nanopaste reportedly addresses one of the most significant challenges in additive manufacturing — material shrinkage. By optimizing the paste formulation, this project ensures that components maintain their intended dimensions and properties, even after processing.

• Design of scalable roll-to-roll ceramic nanocomposite prepreg: The development of a scalable roll-to-roll prepreg enables the continuous production of ceramic nanocomposite tapes. This capability is essential for manufacturing large components and structures, reducing costs and production times.

• Two-inch ceramic nanocomposite T300/n-SiC prepreg tape: This deliverable provides a practical and scalable material solution for aerospace applications. The 2-inch prepreg tape combines the strength of T300 carbon fibers with the thermal and mechanical properties of SiC, making it ideal for use in high-temperature environments.

• Four-inch bottoms-up and top-down TPS approaches: By refining the bottoms-up and top-down approaches to TPS, this project ensures that the most effective method can be selected based on specific mission requirements. These approaches offer flexibility in design and manufacturing, accommodating a wide range of applications.

• Eighteen-inch ARMS produced manufacturing verification coupon: The production of this coupon demonstrates the viability of the ARMS system for manufacturing large-scale components. This coupon will be subjected to rigorous testing to validate the material and manufacturing process.

Building on the success of this project, GT plans to participate in an investor-matched NASA Commercialization Readiness Pilot Program. This program will combine and test NASA’s 3D printable phenolic with GT’s reusable Hot Structure, with material validation at NASA Ames ArcJet facility. The ultimate goal is to manufacture a spaceflight test demonstrator using the ARMS system.

Moreover, the project has garnered interest from “New Space” companies in exploring GT’s CFCNC materials. These materials also offer retrofit opportunities for missiles, missile fairings, aeroshells and other strategic air platforms, particularly for hypersonic applications in Department of Defense (DOD) Programs of Record and System Primes.

#composites #NASA #nanocomposites

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Low-dielectric quartz fibre prepreg from Teijin Group’s Renegade Materials Corp. is first to achieve NCAMP certification

Teijin Limited announced that an epoxy thermoset prepreg on quartz fabric from its carbon fibre subsidiary, Renegade Materials Corporation, is the first such material to qualify for certification by the U.S. National Center for Advanced Materials Performance (NCAMP).

The high-performance, low-dielectric prepreg, made by impregnating woven quartz fabric with epoxy resin, is used for aircraft radar domes (radomes).

NCAMP is a private certification organization run by Wichita (Kansas) State University in the United States. NCAMP works with the U.S. Federal Aviation Administration (FAA) to qualify material systems and populate a shared database. Both the FAA and the European Aviation Safety Agency (EASA) accept composite specification and design values developed using the NCAMP process.

NCAMP certification of Renegade Materials’ low-dielectric prepreg benefits aircraft manufacturers and aircraft part suppliers by reducing production costs and accelerating the process from design to production. By utilizing the database published by NCAMP, they avoid having to perform time-consuming certification work on individual materials in house. This approach helps them obtain certification from government agencies that oversee civil aviation safety with greater efficiency and lower costs.

Renegade Materials’ low-dielectric prepreg certified by NCAMP not only provides excellent electrical insulation and enhanced signal integrity, but also has value-added capabilities such as reducing electromagnetic interference (EMI).

Renegade Materials is a leading U.S. manufacturer of high-heat-resistant thermoset prepregs for aerospace applications. Established in 2007, it has been part of the Teijin Group since 2019. Through successful applications, Renegade Materials’ products have earned the trust of aircraft manufacturers and aircraft engine manufacturers in Europe and the United States.

The Teijin Group aims to become “a company that supports the society of the future” according to its long-term vision, and will continue to provide solutions in a variety of fields.

#composites #Teijin #FibrePrepreg

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Taiwanese company AIM manufactures high-tech wheels with KraussMaffei

Golf clubs, bicycles – and now automotive too: together with KraussMaffei, the Taiwanese composite specialist Advanced International Multitech (AIM) is expanding its portfolio to include High Pressure RTM. AIM is now producing high-quality carbon rims on a complete system with sophisticated tools.

Anyone who plays golf and is thus aware of the importance of weight has (most certainly) had an AIM product in their hands. The company has a market share of around 80 percent of carbon-fibre golf clubs (under different brand names), and also has success in the bicycle market. For around 30 years, various composite technologies have been a part of the standard repertoire. When AIM first ventured into the automotive sector, however, know-how from KraussMaffei was in demand. This would be the first time they put a high-pressure system (HP-RTM / High Pressure Resin Transfer Molding) into operation.

In comparison to low-pressure processes, HP-RTM requires more complex dosing technology, but also delivers consistently high-quality components with particularly precise surface quality – and with shorter cycle times. Short cycle times are particularly important in the automotive industry. In the beginning, the AIM team first wanted to get to know the new technology of the system. As Tyson Hsiao, R&D Manager explains: “Fredrick Su, our sales partner at KraussMaffei, listened carefully, and then put together a package that we could use in an HP-RTM cell to recreate both high-pressure transfer molding as well as wet molding and compression RTM for small production series. We were really impressed by this.

A concrete project was soon to follow. Carbon rims tend to occupy a niche in the automotive sector, yet are extremely lucrative because they are in the high-price segment. A material mixture is common in this case: A rim body made of CFRP (carbon fibre reinforced plastic), to which the visually-appealing aluminum wheel spider is bolted. These wheels are approximately 20 to 30 percent lighter than those made of pure aluminum and, at the same time, are around 20 percent stronger than aluminum rims. Sporty and ambitious drivers can accelerate faster thanks to the reduced weight and, with more of the unevenness of the road able to be dampened by the suspension, the driving experience is also more pleasant. If you want to deck out your vehicle with carbon rims, you have to dig deep into your pockets: 10,000 to 15,000 € per set is common.

The entire production cell for the carbon rims measures just 16 x 12 meters, including the enclosure, and is therefore very compact.

Overall expertise from KraussMaffei

So, when the time came to implement the AIM project, KraussMaffei demonstrated its expertise. Project Manager Thomas Eilhammer actively supported the customer and coordinated the comprehensive package consisting of an MX press with a clamping force of 10,000 kN, the RimStar Compact 8/4 HP-RTM metering system, two robots for metering and handling (with different grippers) and a sophisticated mold solution. His enthusiasm has not faded. “The system now has, at 16 x 12 meters, quite a compact design, and all its components are perfectly well tuned to one another. This, simply said, reflects our strength as a full-service provider“.

The mold carrier forms the heart of the system. The MX press has a clamping force of 10,000 kN.

René Ring’s team at the plant in Georgsmarienhütte, Harderberg was responsible for the mold development. “We apply a master mold and use several mold packages for the different rim diameters. This gives the customer a lot of flexibility.” The subsequent process is then as follows: A carbon preform, prepared by the customer, is placed over the inner core of the mold, and four sliders, which form the round outer contour of the rim, then move simultaneously. The press closes and the epoxy matrix material is metered through a distribution star. After a curing time of approximately 15 minutes, the mold opens, the sliders open and an ejector ring presses the rim body, which has shrunk to the core (diameter 20 inches), upwards. The mold is flexible from diameter 18 inches to 22 inches with the rim width from 8 inches to 12 inches. The finishing takes place through a series of downstream processes.

Care was taken to minimize space when installing the system components.

The know-how is in the mold

The many moving parts in the mold were cause for the greatest challenge, which was to seal the complete system at a high cavity pressure. Normally, the pressing force alone is sufficient to seal a mold, where the horizontal sealing surface is located solely between the upper and lower parts of the mold. In the case of the rim project, however, the undercuts and C-shaped contours of the part required the four sliders to make demolding possible at all, not to mention the moving ejector ring. To retain the vacuum in the mold and thus prevent low-viscosity material from escaping, the team strove to achieve the best possible manufacturing precision and with it a good design. The locking force is generated by four barrels on the top of the master mold, and locking elements mounted underneath, which move into recesses on the sliders and block them. With a mold temperature of 120 to 130 degrees Celsius, it was necessary to protect the pneumatic and electronic components with insulation boards.

The team came up with something special for the rim tool: The movable cylinders lock and unlock it and thus ensure the seal

The mold weighs a total of 4.9 tons. It was manufactured in 2023 in Harderberg, then prototyped in the KraussMaffei TechCenter in Munich, where it was optimized once again, and finally delivered with the complete system to the customer. Since the fundamental requirement of a rim is that it is round, René Ring’s team is particularly proud of the fact that, “we achieved a concentricity precision of less than 2/100 millimeters.” But not only that. Another remarkable achievement was successfully producing a good part with the very first shot.

Ready from the mold carrier: the carbon rim.

The carbon rim has already been exhibited at the JEC Composites Show in Paris and R&D Manager Tyson Hsiao praised the excellent collaboration. “It was important for us to have an experienced, full-service provider for HP-RTM at our side, who offered great proficiency in systems, processes and mold technology. This gave us the ability to concentrate on our role: the production of the carbon blanks. As a result, the cogs meshed, producing a perfect wheel.”

#composites #KraussMaffei

Photo: KraussMaffei.

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