X-Shell : High volume production of organo sheet reinforced thermoplastics

Purpose and goal

The project aimed at the development of a quality-assured process to develop and manufacture structural components of thermoplastic and fiber fabrics which are over molded with a thermoplastic matrix in a subsequent injection molding operation at high volumes. To verify the technology, development methodology and manufacturing process two demonstrators have been used. The aim of the project was to lift the technology readiness level 6 which is considered to have been achieved.

Expected results and effects

The technology concept aims to be used for the design and manufacturing of composite solutions in a cost-effective manner that reduces weight and produced at high volumes, i.e. 10´s of thousand to several hundred-thousand. The demonstrators that have been developed, manufactured and tested within the project clearly shows this possibility. Among other things, a seat backrest of a car (weight reduction of about 30% in comparison with corresponding steel solution) was crash tested with approved test results.

Planned approach and implementation

The project has been executed mainly by focusing on the developed demonstrators - a component of office furniture (subframe for office chair) and a component for the automotive industry (back frame to the front seats tires). The focus on real components have given the opportunity to verify and further optimize the development methodology (material models) and process parameters.