Cannon Tipos, a Cannon Group company has collaborated with Coriolis Composites for the fast and precise high-pressure resin transfer moulding (HPRTM) of a near to net-shape dry preform manufactured with Coriolis’ patented automated fibre placement (AFP) technology.
Coriolis Composites is a world leader in the supply of AFP robotic equipment and machines which enables the laying of continuous or discontinuous fibres with minimum material wastage, in various orientations, even for complex geometrical surfaces, and has developed an innovative and exclusive process to make dry fibre functionalised preforms of composite parts for a range of industrial sectors, notably aerospace and automotive.
“It is only in the last decade that advanced, cost-effective engineered preform technologies have emerged replacing the need for labour-intensive and accurate alignment of several preforms in a HPRTM mould,” said Andrea Castelnovo, technology and R&D manager at Cannon Tipos. “The innovative near to net-shape dry preform developed through Coriolis’ AFP process and our steel mould, polished to a mirror finish, and high-pressure dosing machines and injection equipment helped realise a complex body-in-white structural part for local reinforcement using a single preform in a fast and easy process with high productivity and sustainable costs.”
The AFP 2D dry preform is composed of an optimised fibre orientation of unidirectional (UD) non-woven carbon fibre layers (280g/m2 – 8.25oz/yd2 ply) with a 55% fibre volume fraction (FVF) - for superior mechanical properties in the final part - and proprietary binding technology compatible with a fast cure epoxy resin system ready to be injected. The functionalisation improves formability, permeability, and trimming (3D waterjet) to obtain a net-shape contour and can achieve an overall reduction of up to 50% in scrap.
Cannon Tipos engineered the steel mould to withstand up to 120bar (1740psi) thereby avoiding microporosity; to maintain constant temperature to within 2Ëš to ensure optimal resin reaction with the hardener; to minimise counterpressure during the infusion phase and maximise vacuum time to avoid washout and air bubbles; and due to the highly polished cavities fully exploit the surface aesthetics of the final moulded part obtainable with Coriolis’ superior preform technology.
The resulting BIW local structural part for series production is undergoing qualification trails. It has a 20-second takt time and displays equivalent mechanical performance when compared to incumbent application while offering up to 80% weight reduction.
To learn more, visit the Cannon Group at K2022, Düsseldorf (Oct. 19-26), in hall 13, booth B87.
