ShapeTex preforms successfully overmolded with short fiber SMC
Shape Group successfully combines continuous carbon fiber preform with epoxy sheet molding compound using compression molding.
Shape Group (Witney, UK) has successfully compression molded the first batch of parts that combine short fiber sheet molding compound (SMC) over an optimized, continuous carbon fiber ShapeTex preform. This process is commonly referred to as overmolding. Typically, the overmold is an injection molded compound, but in this case ShapeTex used a compression molded SMC.
The ShapeTex preform uses a continuous tow of carbon fiber that gives significant strength to the finished part, including both radial and axial reinforcement. The short fiber SMC uses epoxy resin. The finished part is 4.5mm thick.
“The potential of this technology is quite significant,” McCool continues. “We have been working on this combination for quite a while and feel that now is the time to bring it to market. We have several customers that like the aesthetic look of the SMC and the ability to press and cure parts with channels, ribs and fixing bosses means that we can incorporate features into a single composite part that would otherwise require multiple operations and parts. This process has been developed using epoxy thermoset resins and offers closed molded parts with optimized strength using approved resin systems.”
Although these trials were conducted in a flat mold the process lends itself equally to complex and double curvature parts. Shape is targeting high volume applications in the automotive and sports equipment market with this process.
Related Content
-
Natural fiber composites: Growing to fit sustainability needs
Led by global and industry-wide sustainability goals, commercial interest in flax and hemp fiber-reinforced composites grows into higher-performance, higher-volume applications.
-
Manufacturing the MFFD thermoplastic composite fuselage
Demonstrator’s upper, lower shells and assembly prove materials and new processes for lighter, cheaper and more sustainable high-rate future aircraft.
-
Combining multifunctional thermoplastic composites, additive manufacturing for next-gen airframe structures
The DOMMINIO project combines AFP with 3D printed gyroid cores, embedded SHM sensors and smart materials for induction-driven disassembly of parts at end of life.