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18th September 2017, Stamford, CT

Footrest bracket made with CFRP technology

Hexcel’s HexMC-i moulding compound and HexPly carbon fibre prepregs have been selected for an innovative high-rate manufacturing process demonstrator produced through a collaboration with Cranfield University and Metisse Motorcycles. The project displays a new rapid production process for the high-rate manufacturing of structural components with the demonstrator part being produced in under three minutes.

Cranfield University’s Aurele Bras and Andrew Mills developed the process for the rapid production of lightweight carbon fibre parts as part of an EPSRC funded project run by CIMComp. Hexcel, Cranfield and Metisse Motorcycles then collaborated on a composite demonstrator to validate this process and its benefits within high-rate manufacturing applications such as automotive.

Project

An aluminium footrest bracket was chosen as the component with all parties working together to optimise the part design for composite production. A detailed stress analysis, steel tooling design and fabrication were carried out before arriving at a finished prototype that was over 50% lighter than the original component. Hexcel’s HexMC-i moulding compound with HexPly carbon fibre UD prepregs were specifically selected for the project.

Combining the latest CFRP technology with classic design. © Hexcel Corporation

All mounting holes and attachment points were moulded in their final shape and position, with the demoulded part ready to use with no secondary machining steps.  As a result, overall production time for the composite bracket was just under three minutes in a lab environment, with a complete cycle time of less than two minutes being deliverable with an automated production cell.

Finished part

The finished part, made from combined prepreg and HexMC-i (which is made from chopped fibre), weighs just a small percentage more than a fully continuous fibre prepreg solution. The Cranfield team has also shown that this Hexcel material combination delivers a significant performance and weight improvement over traditional SMC solutions that may be considered too heavy for key composite structural parts. Hexcel’s snap-cure HexPly M77 resin, used in both the HexMC-i and HexPly UD prepreg, delivers reliable and consistent rapid curing with a common resin matrix throughout the part.

Press tool for composite bracket. © Hexcel Corporation

“Our collaboration with Cranfield and Metisse Motorcycles has validated the use of a HexMC-i and HexPly UD hybrid part design in replacing complex cast or forged metallic parts that could not previously be formed with composites in a cost-effective high-rate production process,” commented Claude Despierres, Sales & Marketing Director – Automotive at Hexcel.

“This demonstrates the effectiveness of the technology for components such as battery boxes, brackets, enclosures and even steering or suspension parts, that all could be made lighter and more rapidly with this new production process.”

www.hexcel.com

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