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FORTAPE ICAutoC 016

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FORTAPE Project - Manufacturing of complex parts based on UD tapes

Published in: Automotive
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FORTAPE ICAutoC 016

  1. 1. Raquel LEDO BAÑOBRE CTAG – Automotive Technology Centre of Galicia raquel.ledo@ctag.com This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 636860
  2. 2. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Contents Brief presentation Context The project Challenges 2 Sectors Acknowledgments
  3. 3. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Brief presentation CTAG Automotive Technology Centre of Galicia • Created in 2002 • 4 Main Operative Areas: • Process and materials • Testing • Passive safety • Electronics • 400 Employees (75% Engineers & PhDs) • International Presence: 40% Exports • 25 7FP / 4 H2020 • 2 main research lines • New Materials • Electronics and ITS
  4. 4. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Context Manufacturing of complex parts based on unidirectional tapes
  5. 5. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Context - Automotive Source: OICA
  6. 6. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Context - Automotive Source: Onatus
  7. 7. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Automotive / Use of UD-tapes Current situation UD-tapes with very high prices Lack of automation Lack of predictive models Faulty parts production rate is really high Innovative solutions Reduce of 50% in material and energy savings for UD-tapes manufacturing  30% cost saving UD tape automated placement New predictive models (crash & overmoulding process)
  8. 8. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Context - Aeronautics Boeing 787 airframe; Source: Compositeslab
  9. 9. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Context - Aeronautics NormalizedTensileStrength Source: Composites Forecasts & Consulting LLC / Compositeworld
  10. 10. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Aeronautics / Use of UD-tapes Current situation Consolidation in-situ using PEEK  high performance / high price Lack of material adapted to small and repetitive components Lack of PA composites complying fireproof regulations for interior cabin applications Innovative solutions Consolidation in-situ using PA66  medium performance / low price Reduction of production wastes New fireproof PA grade
  11. 11. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 FORTAPE Project
  12. 12. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 UD-tapes manufacturing Innovations: • Fluidized bed of thermoplastic powders • Melted supercritical fluid- aided thermoplastic polymer • Replacement of the slitting and splicing stages • Novel heating up techniques
  13. 13. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Overmoulding technology Automotive parts Injection-compression moulding Automated tape laying
  14. 14. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 In-situ consolidation
  15. 15. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Modelling technologies ESL modelling to support the structural design and crashworthiness behaviour MOLDFLOW: Characterization of the UD tape as an orthotropic insert
  16. 16. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Expected Impact Description FORTAPE targets (Automotive) FORTAPE target (Aeronautics) Reduction of material usage (%) 40% 75% Energy savings (%) 35% 45% Elimination of faulty parts Elimination of at least 85% To keep performances (average value 7%) More efficient industrial processes Lightweight parts Reduction of CO2 emissions
  17. 17. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Acknowledgement FORTAPE Consortium
  18. 18. Manufacturing of complex parts based on unidirectional tapes – ICAutoC2016 Acknowledgement Thank you for your attention www.fortapeproject.eu Raquel LEDO BAÑOBRE Head of Material Innovation Area raquel.ledo@ctag.com Vanessa VENTOSINOS LOUZAO Senior Engineer / Materials Innovation Area vanesa.ventosinos@ctag.com This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 636860

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