Press release. T-RTM fit for large series. KraussMaffei presents Thermoplastic Resin Transfer Molding (T-RTM) at K 2016

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1 T-RTM fit for large series KraussMaffei presents Thermoplastic Resin Transfer Molding (T-RTM) at K 2016 Short cycle time for automotive demonstrator in hybrid design made of fibers, plastic and metal New metering system enables just-in-time material supply Near-net-shape production minimizes material and process costs (Munich, October 19, 2016) Continuous fibers, short cycle times, welding and recycling capability. KraussMaffei's T-RTM procedure unites the benefits of reaction process machinery, thermoplastic materials and shaping in the transfer molding procedure (resin transfer molding, RTM) and is thus the perfect combination for modern lightweight construction. At K 2016 (October 19 to 26, Hall 15, Booth B27/C24/C27/D24) in Düsseldorf, KraussMaffei will be demonstrating the production of an automotive fiber composite structural component with metal inlays under series production conditions. Frames for the roof shell of the Roding Roadster R1 sports car will be created several times a day at the trade show booth. Focus on series production "The Roadster roof frame is based on a hybrid construction of fibers in conjunction with plastic and metal. This makes it possible to process both glass and carbon fibers with reliability. The production process at the KraussMaffei K 2016 trade show booth will last just a few minutes. The system thus demonstrates the feasibility of automated and process-reliable integration of metallic loaders into T-RTM components," explains Erich Fries, Head of the Composites/Surfaces Business Unit at KraussMaffei. The individual steps prove how complex the process is while being cycletime-optimized at the same time. The four sub-preforms and the aluminum and steel insert are first positioned on a gauge. This is followed by riveting the steel insert with one of the sub-preforms. A handling robot then positions Publication free of charge Sample copy requested 1

2 the aluminum bracket and the preassembled hybrid components in the T- RTM mold. Here, the caprolactam is injected and the subsequent chemical reaction tales place in which the material cures into the thermoplastic Polyamide 6. After the reaction time expires, the handling robot removes the finished component. The use of what is called the near net shape approach, which takes the part close to its final form, means there is no need for complex post-mold processing such as milling the border area. Melting the material on an on-demand basis KraussMaffei functions as the system provider for the complete production cell. An important component is the new RimStar 8/8 T-RTM metering system, which makes the melting process on-demand. Only the material for a few shots is melted at a time. This makes it possible to prevent a material aging of the two caprolactam components (caprolactam base material and activator or catalyst) by minimizing the thermal load on the melt. The new metering system also offers outstandingly accurate temperature control, from melting to injection into the cavity. "These properties, taken together, ensure consistently higher product quality and thus underscore the suitability for series production," says Fries. The new metering system enables processing at temperatures of up to 180 C and thus is ideally suited for Polyamide 6. Other products optimally designed for the high temperatures include the MK 10-2K high-pressure injection head with a shot weight from 250 g at 100 g/s and the highpressure injection pump, which KraussMaffei can customize thanks to its inhouse pump manufacturing. Precision and space-saving handling of the T- RTM mold is ensured by a KraussMaffei compact mold carrier of type FTR with a clamping force of 3800 kn. Advantages for fiber content, material consumption, post-mold processing The T-RTM process has various benefits over parallel plastics processing processes, e.g. the familiar RTM with epoxy resin or polyurethane (PUR). The low viscosity of just five millipascal-seconds (mpa s) similar to water allows the matrix material caprolactam to penetrate the fiber layers even with low internal mold pressures. For the application demonstrated at the Publication free of charge Sample copy requested 2

3 exhibition, a clamping force of approx kn is sufficient, meaning lower costs for investment and energy. In addition, the high flow capacity allows for low minimum wall thicknesses and allows the fiber volume content to be as high as about 60 percent. A so-called near-net-shape approach, that is closely contoured production, allows the material input rate of plastic and expensive carbon fibers to be reduced. That in turn reduces material costs. In addition, the post-mold finishing steps are also kept to a minimum. While non-near-net-shape processes require the component to be separated via methods such as milling the edge areas, a punch solution can be implemented for this component, for example. Besides the near-net-shape approach, the multipreform concept also effects a further reduction in fiber waste and allows a (sectional) load-dependent fiber architecture. Compared to the three-dimensionally networked thermosets, the chain-like structure of thermoplastics constitutes a unique attribute: they can be reheated and reshaped, making them weldable and recyclable. The roof frame material can be regranulated and used together with its fiber content to produce parts in the injection molding process, for example. High impact strength and more ductile fracture behavior The mechanical properties of PA6 are also interesting for structural components. The thermoplastic features higher impact strength and more ductile fracture behavior than thermosets. That means that forces can be absorbed by the material deforming before a fracture occurs. When T-RTM is compared to injection molding, the classic area of application for thermoplastics, its benefits can also be seen in its high fiber content and low viscosity, which allow the production of parts with very thin walls. "For structural components, T-RTM represents a useful supplement to the familiar RTM technologies and KraussMaffei is making full use of its extensive expertise in plastics processing. KraussMaffei is the only supplier on the market to manufacture both mixing and metering technology and presses smaller than 1000 tonnes in its own facilities, enabling us to drive development of the overall system," explains Fries. Publication free of charge Sample copy requested 3

4 Besides KraussMaffei, the following development partners were also involved in producing the Roding Roadster R1 technology demonstrator: Forward Engineering (component design, hybrid concept), Alpex Technologies GmbH (T-RTM mold), Dieffenbacher (production of preforms/handling), Saertex (fiber layers), Henkel (bonding), Handtmann (aluminum inlays), TUM / LCC (fiber selection) and Keller (extraction technology). KraussMaffei at K 2016 Hall 15, Booths B27/C24/C27/D24 PM_RPM_2016_10_T-RTM Bauteil.jpg In zebra look: Frames for the roof shell of the Roding Roadster R1 sports car will be created several times a day using the T-RTM process at the KraussMaffei trade show booth. This enables processing of both glass fibers (white) and carbon fibers (black). PM_RPM_2016_10_T-RTM RimStar.jpg Melting on demand: The new RimStar 8/8 T-RTM metering system enables on-demand melting of the caprolactam components. Photos: KraussMaffei Enclosure: Pictures and more information can be found at Press contact: Petra Rehmet Press officer KraussMaffei brand Phone: +49 (0) petra.rehmet@kraussmaffei.com (Number Words: 949 / Number Characters: 6,372) About KraussMaffei The KraussMaffei product brand is internationally recognized for its groundbreaking, multitechnology system and process solutions for injection and reaction molding technology and factory automation. With its standalone, modular or standardized machinery and systems, and a wide, customizable service offering, KraussMaffei is a full-system partner for customers in many Publication free of charge Sample copy requested 4

5 industry sectors. KraussMaffei bundles many decades of engineering expertise in plastics machinery and is headquartered in Munich, Germany. For more information: About KraussMaffei Group The KraussMaffei Group is among the world s leading suppliers of machinery and systems for producing and processing plastics and rubber. Its products and services cover the whole spectrum of injection and reaction molding and extrusion technology, giving the company a unique position in the industry. The KraussMaffei Group is innovation-powered, supplying its products, processes and services as standard or custom solutions which deliver sustained added value along the customer s value-adding chain. The company markets its offering under the KraussMaffei, KraussMaffei Berstorff and Netstal brands to customers in the automotive, packaging, medical, construction, electrical, electronics and home appliance industries. Continuing a long tradition of engineering excellence, the international KraussMaffei Group currently employs around 4,500 people. With a global network of more than 30 subsidiaries and more than 10 production plants, supported by around 570 sales and service partners, the company is close to customers around the world. KraussMaffei has been headquartered in Munich since For more information: Publication free of charge Sample copy requested 5