Germany develops renewable composite automotive parts

Researchers at the Fraunhofer Institute for Production Technology (FICT) in Pfinztal, Germany, have developed a method for producing thermoplastic fiber reinforced composites for large vehicles.

According to FICT, the materials produced can be produced into new high-quality parts by means of chipping, melting and reuse at the end of life. The researchers also said that the impact of this material in the collision of cars is far better than the existing materials. They say that the thermoplastic parts reinforced by the fabric structure can absorb the impact of the collision without the occurrence of chipping by the viscoelastic deformation of the base material.

Automakers have traditionally used composites based on thermoset substrates to produce such parts. However, FICT believes that this traditional process is dangerous except that it is difficult to use it effectively for mass production because the thermoset composite breaks into sharp fragments in the event of a collision. Not only that, thermoset materials are also more difficult to recycle.

According to FICT engineers, after the injection molding process of thermoplastic resin, up to 100,000 parts can be produced each year, and the composite materials used can be completed in a single step.

As a proof, FICT engineers produced a luggage compartment liner for Porsche Carrera 4, which weighed 50% less than the original aluminum part.

In order to improve the collision behavior of the overall structure of the vehicle, FICT engineers also calculated the optimal fiber placement. According to FICT, the cost of thermoplastic substrate materials and T-RTM processing is 50% lower than the cost of thermoset structures.

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