The document discusses advancements in thermoset continuous fiber pre-pregs aimed at high-volume manufacturing, highlighting the challenges of affordability and predictability. It presents a hybrid approach combining pre-preg and molding compounds to enhance strength, geometric complexity, and manufacturability, showcasing significant improvements in load-bearing capacities. Future steps include optimizing materials and processes to further address challenges associated with automotive composite applications.

1. 2018 SPE ACCE
Advances in Thermosets
Continuous Fiber Pre-Pregs Optimized
for High Volume Manufacturing
September 5 - 7, 2018
Novi, Michigan
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Locations
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About Norplex-Micarta pre-pregs | sheets | shapes
250
Employees
300+
Standard Products
100 years of thermoset composite
manufacturing and innovation
Material
Development
Applications
Engineering
Material
Characterization

3. Materials x Process
Materials + Process
not
Start with a winning equation:
The challenge:
affordability, predictability, high volume

4. The challenge:
affordability, predictability, high volume
Chart courtesy of the National Research Council of Canada
Continuous Fiber
• Strength
• Predictability
• Repeatability
Compression Molding
• Existing automotive
process
?

5. The approach:
material optimization for an existing process
Graphic courtesy of the National Research Council of Canada
Prepreg can be fast:
• Quick (‘Snap’) Cure Resin Matrices
• Stronger = Thinner  Faster Cure
• Internal Mold Release  Less Mold Prep
• Tack Free Systems  Automated Processes

6. The approach:
material optimization for an existing process
Prepreg can be fast:
• Quick (‘Snap’) Cure Resin Matrices
• Stronger = Thinner  Faster Cure
• Internal Mold Release  Less Mold Prep
• Tack Free Systems  Automated Processes
Prepregs are limited:
• Difficult to Vary Cross Section
• Limited Geometric Complexity  Difficult to mold in inserts
Hybrid Prepreg/Molding Compound is a viable approach:
• Prepreg: Strength and Predictability
• Molding Compound: Geometric Complexity

7. Case studies
Hybrid Prepreg/Molding Compound is a viable approach:
• Prepreg: Strength and Predictability
• Molding Compound: Geometric Complexity
Addition of Pre-preg
improved flex strength 300%
Ribs improve stiffness with
minimal addition of mass

8. Pre-preg adds strength:
The addition of continuous fiber reinforced pre-preg has a
significant effect on the load bearing capacity of a
composite part.
22% reduction in thickness
66% increase in max load
300% increase in flex strength
Change in thickness is the driver of
the change in deflection under load
The part did not fully break, even
after being compressed 0.700 inches

9. This part has a nominal 0.032
inch (0.8 mm) wall.
This thin wall could not be
molded with compound alone.
Pre-preg makes thin walls possible:
Thinner sections are possible with
continuous fiber pre-preg.
Max load carrying capacity came at the
expected 3 layers of plain weave fiberglass
This 6 inch part did not require a more
expensive satin weave to properly form

10. Use geometry to add stiffness:
Features common in plastic design excel in minimizing
deflection in composite parts.
Excellent minimization of deflection
with minimal use of mass
Molded in inserts, bosses and ribs
are all possible

11. The next steps:
optimization in material and process
Material Optimizations:
• Heavy Weight Reinforcements
• Non-Crimp Fabrics to minimize layup procedures
• Hybrid reinforcements to tailor modulus, strength, and
NVH characteristics
Reliable Micromechanical
Models
Process Optimizations:
• Improved methods to control fiber alignment
• Automation of “preform” stage
• Incorporation of rapid and high resolution heating
methods
Reliable Process
Simulations
Materials x Process =
Successful Application
Design Tools
Accelerate Adoption

12. Addressing the Challenges
for Composites in Automotive Applications:
Affordable
Predictable
High Volume
www.norplex-micarta.com
Dustin Davis
Director of Business Development
ddavis@norplex-micarta.com
cell: +1.317.498.0149