JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 41

Process Class-A quality. Gurit has also worked closely with DuPont to develop a paint system specifically designed to achieve a Class-A painted finish using Gurit’s composite materials (with an in-mould surface film). This system is up to 80% lighter than steel of equivalent stiffness. Moreover, it cures rapidly, in either one hour at 120°C or 30 minutes at 130°C. It is expected to be used alongside SF 95 to produce body and closure panels for automotive applications and other similar panel mouldings. The material has been designed for simple vacuum bag processing. SF 95 is a kind of veil made of thermoplastic resin which nearly melts during the process to ensure a really smooth surface. Cross section of a body panel potential of the carbon body panel solution: high-precision nickel tooling, CNC machining, and coordinate measurement machines are all crucial for achieving part geometrical accuracy and stringent quality standards. The Gurit approach to providing solutions requires an integrated relationship with customers, giving them access to the company’s technical strengths and capabilities, and ensuring the delivery of specific requirements and expectations. This kind of strong relationship with customers helps drive cost down and quality up. The award-winning SPRINT® CBS materials technology has provided the breakthrough enabling the production of Class-A carbon body panels directly from the tool. The materials and process have also been developed to guarantee this exceptional surface quality throughout the vehicle’s lifecycle. Behind the surface, composite processing techniques and material optimization provide a design flexibility that cannot be attained with incumbent metal panel technology. Combining the functionality of the materials with the robust and efficient processing techniques results in some outstanding benefits for the customer: Class-A carbon composite technology; customized strength, stiffness and weight; and ultimate freedom for stylists and designers. Part production process Gurit’s development partnership with Aston Martin culminated in the building of a world-class part manufacturing facility to support the production of their flagship vehicle, the DBS. The facility utilises a wide range of innovative technologies that are essential to maximise the potential of the carbon body panel solution, and to provide a clear competitive advantage for customers. Special features - Class-A finish - Low weight - Can be in production in less than 3 months (6 for metal) - Tooling far cheaper than for steel - Best price versus metal (for low and medium volumes) Material kitting To enable rapid material deposition and maximise tool utilisation, a kitting system was developed using computer modelling techniques. The kitting models are transferred to the SPRINT® CBS and surfacing films using a CNC ultrasonic cutting machine. The kits are subsequently assembled on trays and placed into the Kanban storage racking system. Achieving smooth surfaces and strong parts The patented SPRINT® CBS technology is combined with Gurit’s patented in-mould surface film to produce high-quality panels with a sandable Class-A surface directly from the tool. CBS consists of a low-density syntactic core film sandwiched between two layers of single-sided SPRINT®. The syntactic core retains the flexural stiffness of a monolithic panel but also benefits from lower cost, reduced lay-up times (only one ply required) and paintability to Tools and moulding These 2D kits are then applied to preform tools to further reduce cycle times and optimize output before being transferred to the nickel shell tools and being enclosed by a specially-developed vacuum system. The three main functions of the vacuum system are to provide rapid tool closure, to remove air and volatiles from the materials during processing thereby consolidating the material, and No53 November - December 2009 / jec composites magazine

JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009

Cover
Editorial
Contents
NEWS WORLDWIDE - Companies
 - Advance FRP: Choosing success
 - Agenda of events
 - Equipment: Mould
BUSINESS
 - Market survey
 - Trends
 - Niche market
FEATURE - AUTOMOTIVE
 - Thermoplastics
 - Nanotubes
 - E-LFT process
 - High-temperature
 - Coating
 - Software
 - Process
USERS' PLATFORM
 - Composites in the world
 - Successful partners
 - Application
KNOW-HOW
 - Process
 - Localized heating
 - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Cover
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 2
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Editorial
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 4
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 5
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Contents
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 7
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - NEWS WORLDWIDE - Companies
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 9
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Advance FRP: Choosing success
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 11
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 13
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Equipment: Mould
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Market survey
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Trends
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Niche market
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 19
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 20
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - FEATURE - AUTOMOTIVE
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 22
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 23
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 25
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 26
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 27
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Nanotubes
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 29
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - E-LFT process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 31
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 32
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - High-temperature
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 34
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 35
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Coating
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 37
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Software
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 39
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 41
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 42
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Pub
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - Pub
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 45
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Successful partners
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 47
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Application
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 49
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 50
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 53
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Localized heating
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 55
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 56
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 -  - Process
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 58
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 59
JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 60
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