This document discusses fiberglass car bumpers, including their purposes, material description, properties, and manufacturing processes. It is presented by a group for a class on manufacturing processes. Fiberglass car bumpers can provide aerodynamics, cooling, safety, and aesthetics. They are made of glass fibers and resins. The document outlines the physical and mechanical properties of fiberglass and describes common manufacturing processes like hand layup molding. It also discusses a Malaysian company that produces fiberglass composites and lists additional products and references.

2. Faculty of Engineering and
Built Environment
Department of Mechanical and
Manufacturing Engineering

3. Who’s presenting?
IVIN HAZWAN MUAZ AINA ZULHAFIQ
SCRIPT WRITER VIDEO EDITOR VIDEOGRAPHER DATA COLLECTOR SLIDE EDITOR

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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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13. OTHER PRODUCTS
OTHER PRODUCTS
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14. Facilities
Facilities
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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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