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30th October 2017, Stuttgart

Savings with Audi one shot process

Audi AG and its partner Secar Technology, based in Hönigsberg-Mürzzuschlag, Austria, have together developed a one-shot technology for directly combining continuous fibre-reinforced profiles with short fibre reinforced moulding materials.

This is enabling the production of composite components with a new range of properties without the use of additional adhesives. It also enables manufacturers to integrate reinforcement in specific areas to optimise mechanical performance. Areas with the highest properties can now be combined with others featuring significantly reduced properties in a single component. The profiles are manufactured in a pultrusion process and offer outstanding mechanical properties at a moderate cost.

The profiles are manufactured in a pultrusion process and offer outstanding mechanical properties at a moderate cost. © Audi AG – F. Eidmann, O. Stoll

The profiles are joined using moulding materials which offer remarkable freedom for designers and the option to integrate further functions.

In addition, the process offers efficiency gains by eliminating the need for joining technology. The predicted weight savings compared to metal designs have been proven.

The use of the technology in a specific vehicle project has already demonstrated its safety and confirmed the static and dynamic strength of the joins between the profile and the moulding materials. It is ready for use in series production and a type approval certificate is available. The process significantly reduces costs for lightweight construction compared to other fibre composite technologies. Structures manufactured using this technology are typically 15-25% lighter than the comparable parts made from aluminium, and 50-60% lighter than those made from high strength steel.

The achievement recently received the 2017 AVK Innovation Award for innovative processes.

AVK, the Federation of Reinforced Plastics, is headquartered in Frankfurt and the oldest association of the German plastics industry.

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