Hennecke (Sankt Augustin, Germany) will present a lightweight roof and a carbon seat shell to show how ultra-short cycle times and an optimized overall process allow high-quality fiber composite parts to be produced economically on a large scale. The lightweight roof, developed by Fehrer Composite Components for the new smart fortwo, consists of a material mix of polyurethane, glass fiber and paper honeycomb and is coated with a thermoplastic outer skin. It provides the same stability as the series roof of its predecessor while being 30% lighter. Compared to traditional composite parts, the individual layers are not bonded in a multi-step process, but in a single operation.
Another part on display at Hennecke's booth will be the seat shell for the BMW i3. The carbon fiber component is a combination of lightweight construction and sustainability because it largely consists of carbon fiber recycled from the production of the BMW i3 car body. And there is another special feature: For the first time, carbon fiber materials combined with a PUR matrix are used in a series-produced car. The production of this composite part is made possible by Hennecke's high-pressure resin transfer molding (HP-RTM) process.
In addition, dashboard parts for the Hyundai Kia Automotive Group are presented. The focus here was not on lightweight construction, but on the particularly high-quality of look and feel and manufacturing precision. The thermoplastic composite consists of a thermoplastic substrate, a decorative film overlay and a foam layer made from polyurethane and are manufactured in automated process steps using a single compact plant network. In contrast to other soft-touch production processes, this Varysoft process is characterised by even greater softness.
Editor PickWinners of JEC Innovation Awards announced
The JEC Innovation Awards ceremony will highlight 13 innovators on stage and will take place on Wednesday, March 15 at 5 p.m. at JEC World in Paris.