Resource-Efficient Production of Large-Scale Lightweight Structures

S. Nendel, H.-J. Heinrich, L. Kroll
Cetex Institut für Textil- und Verarbeitungsmaschinen gemeinnützige GmbH, Chemnitz, Germany

Abstract:
Within the BMBF-funded innovative regional growth cluster thermoPre® new processes were developed: for the single, direct impregnation of the unidirectional (UD) fabrics with a thermoplastic matrix and for the continuous production of multi-layer, load-capable optimized organic sheets as continuous fibre-reinforced semi-finished products. By means of using this new semi-finished part in the example of an engine subframe of VW e-Golf, the proof was provided that it is possible to substitute a die-cast aluminium component with additional steel elements for glass fibre-polypropylene in a pure thermoforming process. This does not only considerably reduce weight but, by means of functional integration and a new production technology, also save costs significantly.