Lightweight Design worldwide

, Volume 11, Issue 3, pp 12–17 | Cite as

Ready-to-install sandwich components at minute intervals

  • Johannes Knöchel
  • Mathias Mühlbacher
  • Joachim Starke
  • Jonas Beck
Cover Story Large-Scale Production

Neue Materialien Bayreuth teamed up with BMW, Werkzeugbau Siegfried Hofmann and six other partners to develop a technology for manufacturing thermoplastic structural components using a sandwich construction. It ensures a high degree of functional integration through local injection and shortens cycle times.

Structural Components

Besides their potential for lightweight design, sandwich structures with foam cores offer excellent thermal and acoustic insulation properties. Thermoplastic materials offer the potential for further savings in regard to the system costs through a high degree of functional integration. Until now, however, process technologies permitting sandwich construction methods to be implemented economically for high production rates were only used for trim parts, not structural components. As part of the MAI Sandwich joint project funded by the MAI Carbon Excellence Cluster, a technology for the efficient production of thermoplastic sandwich structural components has now...



The authors would like to thank the other co-authors of this article, Dr. Thomas Neumeyer, Head of the Plastics Business Unit at Neue Materialien Bayreuth, and Prof. Volker Altstädt, Managing Director of Neue Materialien Bayreuth GmbH and holder of the Chair in Polymer Materials at the University of Bayreuth.

The authors would also like to thank the participating project partners: Airbus, BASF, BMW, Nennah Gessner, Neue Materialien Bayreuth, Werkzeugbau Siegfried Hofmann, Foldcore, TU Munich and SGL for the successful collaboration.

This article deals primarily with the process that was developed. The project also tested various core and surface layer systems of the partners, as well as foldcores and an injection-molded honeycomb core.

The authors also thank the Federal Ministry of Education and Research (BMBF) for funding the MAI Sandwich research initiative as part of the MAI Carbon Excellence Cluster (FKZ: 03MAI32).


  1. [1]
    Mühlbacher, M.; Hornfeck, C.; Neumeyer, T.; Altstädt, V.: Thermoplastische Sandwichstrukturen aus Luftfahrtmaterialien. In: 9 (2016), No. 4, pp. 44–49CrossRefGoogle Scholar
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    Grünewald, J.; Parlevliet, P.; Altstädt, V.: Manufacturing of Thermoplastic Composite Sandwich Structures — a Review of Literature. In: Journal of Thermoplastic Composite Materials 30 (2015), No. 4, pp. 737–464Google Scholar
  3. [3]
    Knöchel, J.; Neumeyer, T.; Mühlbacher, M.; Altstädt, V.: Funktionsintegration in thermoplastischen Sandwichstrukturen durch Spritzgießen. In: Tagungsband LLC 2017, No. 3, pp. 106–115Google Scholar

Copyright information

© Springer Fachmedien Wiesbaden 2018

Authors and Affiliations

  • Johannes Knöchel
    • 1
  • Mathias Mühlbacher
    • 1
  • Joachim Starke
    • 2
  • Jonas Beck
    • 3
  1. 1.Neue Materialien Bayreuth GmbHGermany
  2. 2.BMW GroupMunichGermany
  3. 3.Werkzeugbau Siegfried Hofmann GmbHLichtenfelsGermany

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