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FIBERGLASS CAR
BUMPER
MANUFACTURING PROCESSES | KM2833
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NATIONAL UNIVERSITY OF MALAYSIA |
DEPARTMENT OF MECHANICAL &
MANUFACTURING ENGINEERING
FACULTY OF ENGINEERING AND BUILT ENVIRONMENT |
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INTRODUCTION
PURPOSES APPLICATIONS
•Aerodynamics
• Create downforce at the front of the car
• Decrease drag force
•Cooling
• Direct air to the intercooler and brakes
•Safety
• Crumples in the event of a crash
•Aesthetics
•Modification or replacement of existing car
bumpers
•Sports cars
•Rally racing
•Drag racing
•Truck bodies
6. o Made of fibers of glass strands, turned into
fabric.
o The fiber; mixture of silica and other
materials (recycled glass).
o The mixture is heated and extruded into fine
strands.
o The strands are collected into bundles called
rovings.
o The fabrics include chopped mat,
unidirectional , as well as woven.
MATERIAL
DESCRIPTION
MATERIAL
DESCRIPTION
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Fiberglass Bumpers
7. •ELECTRICAL CHARACTERISTICS
Excellent electrical insulator.
Mechanical strength and behaviour in different
temperatures
• LIGHTWEIGHT
Lower weight than steel make them easier to work
with.
Help with increasing speed
• INCOMBUSTIBILITY
Naturally incombustible. However, at high enough
temperatures, fibreglass can melt.
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PHYSICAL
PROPERTIES
PHYSICAL
PROPERTIES
8. •GREAT TENSILE STRENGTH
Glass has greater tensile strength than steel.
Material that do a better job of resisting damage in
minor impact is needed to minimize the bumper
deflection, impact force and stress distribution
• CORROSION RESISTANCE
Fiberglass composite is resistant to most acids, bases,
oxidizing agents, metal salts, reducing gases and sulfur
gases.
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MECHANICAL
PROPERTIES
MECHANICAL
PROPERTIES
9. MANUFACTURING
PROCESS
MANUFACTURING
PROCESS
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Fiberglass Car Bumper
Molding Process
Robotic Spray Up
Molding
Compression Molding
Hand Lay Up Molding
Vacuum Molding
Common
Processes
10. MANUFACTURING
PROCESS
MANUFACTURING
PROCESS
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Hand Lay Up Molding
- Manually conducted
- Simplest and oldest open
molding method for fabricating
composites.
Create Mold Layer Fiberglass Sheets Roll Repeat
11. MANUFACTURING
PROCESS
MANUFACTURING
PROCESS
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Important Things to be
Considered
Production volume over time
Product size/ surface
finish/shape
Cost
Mechanical Properties
Materials: Reinforcement
Fiber +Resin + Filler
1. Mixing
2. Molding Process – Apply
(Heat+Pressure)
3. Finishing; e.g. Painting
Moulding process by automated machine
12. Malaysian high-tech company
based in Melaka
Since 1990
Subsidiary of DRB HICOM,
owned by DefTech
COMPOSITES
TECHNOLOGY RESEARCH
MALAYSIA (CTRM)
COMPOSITES
TECHNOLOGY RESEARCH
MALAYSIA (CTRM)
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15. VIDEO LINKS
VIDEO LINKS
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• https://www.youtube.com/watch?v=vqBKYrGhCek
• https://www.youtube.com/watch?v=THvdMXDEb30
• https://www.youtube.com/watch?v=obviEptYOm8
• https://www.youtube.com/watch?v=GzFB6QpkWQY
16. REFERENCES
REFERENCES
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• Davoodi, M.M., Sapuan, S.M., Ahmad, D., Ali, A., Khalina, A. & Jonoobi, M. 2010. Mechanical properties of hybrid
kenaf/glass reinforced epoxy composite for passenger car bumper beam. Materials & Design 31(10): 4927–4932.
• Sapuan, S.M., Maleque, M.A., Hameedullah, M., Suddin, M.N. & Ismail, N. 2005. A note on the conceptual design of
polymeric composite automotive bumper system. Journal of Materials Processing Technology 159(2): 145–151.
• Tar, A.F.M., Hambali, A., Nasiruddin, S.M. & Nurhidayah, M.H. (n.d.). A Review: Application of Polymer Based
Composite for Automotive Bumper System.
• Find the Best Composite Molding Processes for Your Product | MFG. (2020, March 24). Retrieved May 23, 2021,
from Molded Fiber Glass Companies website: https://www.moldedfiberglass.com/processes/
• ctrm. (2016). Composites Technology Research Malaysia. Retrieved May 23, 2021, from Ctrm.com.my
website:https://www.ctrm.com.my/
• Fiberglass – Types, Properties, and Applications | Phelps Industrial Products. (2021). Retrieved May 23, 2021, from
Phelpsgaskets.com website: https://www.phelpsgaskets.com/blog/fiberglass--types-properties-and-applications-
acrossindustries#:~:text=A%20fiberglass%20is%20a%20form,fiber%20is%20the%20reinforced%20plastic.&text=The
%20glass%20fiber%20is%20usually,of%20different%20types%20of%20glass.
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MANUFACTURING PROCESSES | KM2833
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