Material+energy efficient processing of composites for automotive lightweight parts

Abstract

By using conventional manufacturing methods, hybrid lightweight composite structures are formed in multi-level and therefore cost-intensive process chains and are assembled in additional production steps like gluing or welding. From a processspecific view, you can reach the greatest cost savings at large-series products by having the shortest possible cycle time. In collaboration with project partners (Evonik Industries AG, Toho Tenax Europe GmbH, Johnson Controls GmbH, RWTH Aachen University, Institut für Kraftfahrzeuge (ika) und Institut für Textiltechnik (ITA)) process integrating production methods have been developed at HBW-Gubesch Thermoforming GmbH for the project CAMISMA (Carbon fibre/Amides/Metalbased Internal structure-component in the Multimaterialsystems-Approach). These methods are combining forming-, master forming- and joining processes in one procedural step, whereby a high level of functional integration is reached. In combination with a low material input / material efficient and weight optimized lightweight design and by using energy efficient materials, it is possible to produce lighter and costoptimized components.