" Light weight Technology - new approach Thermoplastic RTM / Surface RTM and Fiber Form Technology "

" Light weight Technology - new approach Thermoplastic RTM / Surface RTM and Fiber Form Technology "

KraussMaffei KraussMaffei Berstorff Netstal Page 2 Basis for 175 years of impressive industrial history 1838-1931: Mechanical engineering pioneers become partners Joseph Anton von Maffei (1790 1870) Background: Locomotive manufacture Georg von Krauss (1826-1906) 1838: Founding of the company in Munich 1866: Founding of the company in Munich 1931: Merger to form Krauss & Comp. J.A. Maffei AG

KraussMaffei KraussMaffei Berstorff Netstal Page 3 Creation of a worldwide leading industrial group 1931 2000: Formation of group structures after the merger Since 1931: Headquarter in Munich 1945 1999: Mixed group with the main sectors Plastics technology, traffic engineering, defense technology, process engineering 1999-2001: Partition of Group and concentration on plastics technology

Lightweight portfolio covers the entire range of requirements Schematic Lightweight technology portfolio RPM IMM RTM LFI Organic sheets (FiberForm) Injection Molding Compounder (IMC) for long fiber Short fiber reinforcement Increasing cost efficiency Increasing structural strength

A tour around the plant Manufacturing Cell of CRFP Parts (RTM Process) Press Cell with shuttle table for quick tool changes Milling Cell Metering Machine

Which are typical applications for HP-RTM? Structural parts and carbon designer parts Underbody structure Side Frame Seating/Crash Elements Roof and Bonet

RTM process family selection of the technologies according to part design/property HP-RTM C-RTM T-RTM Wet pressing Surface RTM

Summary K-Show Application World premier Surface RTM World-new two-step RTM infusion and overmolding process High quality paintable surface for CFRP automotive exterior parts Joint project among technological leaders of PU and light weight manufacturing companies Combination of high-performance light weight parts with high quality surface enhancement Overall cost reduction for painting around 40% www.surface-rtm.com

Surface RTM Technology Motivation of the joint development Sink marks due to different shrinkage of reinforcement and matrix In general direct conventional spraycoating is not possible Sink marks and other surface defects can be covered by In-Mold Coating with ColorForm technology paintable surface Post shrinkage must be controlled >0,2 mm Weld line Sink mark Pore, pinhole Streak (fibers, humidity)

Lightweight design & high quality surfaces efficient combination of two megatrends force further developments 2013 Roof element Roding R1 Key characteristics Process principal Dimensions Total part weight 772x585 mm 2.570 g Substrate thickness 2 mm Surface layer thickness 0,2 mm Fiber content (by volume) 50% Fiber Layup quasiisotrop Cycle time 6 min

Cooperation among company research Team VW, BASF, KM Tailored to Reactive Polyamide 6

Cooperation among company research Team VW, BASF,KM Project GFRP B-Pillar

Combination of two processes = Technology fusion Motivation for injection molding Part complexity high Injection Molding Benefit of the combination: Excellent fiber orientation Short cycle time High impact strength High design freedom High part complexity low Thermoforming of textiles low high Stiffness, Strength, Energy Absorption

New Functional Parts by means of Technology Fusion Joint research project SpriForm The aim of this project is a production process that combines the advantages of thermoplastic injection molding and thermoforming of semi finished endless fiber reinforced products. Besides the process identification material data has to be determined and a simulation basis has to be established.

Partnership permits efficient Project Realization FiberForm Project at K2010 Technology Carrier component door impact beam (automotive) cycle time: <55s weight: 580 g steel component: 841 g material laminate: PA6 GF 3mm injection moulding material: PA6GF Realization in only 6 months together with partner companies

FiberForm manufacturing cell CX 300 1400 IMC at K 2010: successful interdisciplinary partnership

Combination of Injection Moulding and Thermoforming Possible version One Stage Process Handling Heating Handling Thermoforming Handling Cutting Handling Injection Moulding Handling Stacking One Stage Prozess Handling Heating Handling Thermoforming and IMM Handling Stacking

Thank You For Listening! Erich Fries Head of Business Unit Composite & Surface KraussMaffei Technologies GmbH Krauss-Maffei-Strasse 2 80997 München Germany Phone +49 (0)89 8899 2464 Fax +49 (0)89 8899 2982 Mobile +49 (0)1728190569 Mail: erich.fries@kraussmaffei.com