CompositesWorld
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OCTOBER 2017 38 CompositesWorld PLANT TOUR a chemical foaming agent or nitrogen gas (the MuCell process). In addition, robotic handling of heated organosheet and preforms can be integrated with this machine for overmolding (see Learn More). Adjacent to the Engel machine is a display of semi-structural reinforced foam automotive parts that Roch's group has produced for prototyping, including an underbody shield and instrument panel (IP) carrier for several automotive Tier 1s. Also on display are structural D-LFT parts (PA6 with 30% glass loading). Roch says that, in his opinion, the future of automotive composites will be shaping of organosheets (continuous fiber thermoplastics) that are subsequently overmolded via injection: "We're at an early stage now, but we believe there's a lot of potential." SMC, preforming and RTM Roch leads the way out of Building 90 and walks past several office buildings towards the polymer engineering group's new labora- tory and shop building. Built to house the group's massive Dief- fenbacher 3600-ton compression press, it's the center of ICT's long fiber-reinforced thermoset activities — primarily work related to sheet molding compounds (SMC). Although a signboard blocks the doorway, with a chalked message prohibiting entry due to OEM partner molding trials, Roch enters, and gets the all-clear for the visit. Although those not involved in the market might be hard- pressed to know what part for which car model they were seeing, Roch explains that sharp-eyed automotive industry visitors could tell at a glance from a mold shape what types of trials were being Automotive-capable robotic preforming ICT's high-pressure resin transfer molding (HP-RTM) process building is equipped with a Dieffenbacher preforming center within a safety cage, equipped with a robot to transfer material from an automated cutting table to a preform-shaping mold with multiple elements that operate sequentially for wrinkle-free preforms. A structural part for Mercedes Benz is shown at left, as preformed (top) and as the final molded part (below). Source | Fraunhofer ICT Keeping current to stay current Shown here is ICT's RELAY 2000 machine, which has since been moved to another facility in Augsburg, Germany. A new RELAY tape laying machine from Dieffenbacher now operates in combination with a new injection unit for thermoplastic co-molding of organosheets, either fabric or unidirectional tapes, situated adjacent to its 3,600-ton press. Source | Fraunhofer ICT