OCT 2018


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OCTOBER 2018 70 CompositesWorld INSIDE MANUFACTURING • Roller-blind operating speed of at least 75 mm/sec at 23°C achieved after each test. "e idea of converting extruded aluminum guide rails to a plastic solution on a sunroof roller-blind is a Webasto idea and one that has been patented for a long time," explains Jacques Vivien, Webasto R&D, design to cost, industrial expert. "However, until recently, no engineering plastic achieved the tough require- ments of this function." He reminds us that the plastic candidate had to fulfill requirements for dimensional accuracy; stability over time, resistance to temperature and humidity changes; retain stiffness and sliding capability; exhibit excellent bondability; and do all of that and remain cost-competitive. We were very pleased with the selection of Polyscope's XIRAN SGH30EB, which made the project a full success for everyone involved." Exceeding expectations With more than two years of manufacture and sale, the composite guide rails are performing as predicted and many benefits have been seen at the tier, OEM and customer levels. For example, ARRK-Shapers' clever tooling has cut significant costs from the program. Webasto's use of a design with significantly greater functional integration than the legacy aluminum assembly, and the choice of injection molding to create the complex structures in a single shot eliminated hardware and post-mold finishing, also Mold design for composite guide rails To keep tooling costs manageable, the team optimized the mold design to allow the top and bottom parts of both left (teal) and right (rose) composite rails, the front cross-beam (beige), plus three pieces of bonding interface (magenta, green, and lavender) that connect to the rear GR-PP cross-beam (molded separately) to be produced in each cycle. Another cost-saving step was the use of modular blocks (which are inserted/removed to run both long and short rail versions) rather than costly slides (tooling action). To mold all eight GR-SMA/ABS compo- nents in the large family tool, an injection press with a clamping force of 1,500 KN was needed. Ultrasonic welding was selected to join the top and bottom rails and a special assembly jig was designed and built. Source | Webasto SC PRESENTED BY 2018 THANKS TO OUR SPONSORS SILVER DIAMOND PLATINUM GOLD REGISTER EARLY AND SAVE! Register by October 23 and SAVE $400! A product of Gardner Business Media, Inc. KEYNOTE PRESENTATION BY: BRETT SCHNEIDER President, Global Fibers | Hexcel Corporation DECEMBER 4-6, 2018 Hyatt Regency La Jolla La Jolla, CA USA Plan to attend Carbon Fiber 2018 to connect with thought leaders in the carbon fiber composites industry. ERIC HAISS Executive Vice President, Continental Structural Plastics MERLIN THEODORE Director, Carbon Fiber Technology Facility Oak Ridge National Laboratory CONFERENCE CO-CHAIRS:

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