Dosing equipment for precise injection and mold engineering for innovative near to net-shape dry preform for HPRTM CFRP composite part with rapid cycle time
Caronno Pertusella, (Varese), Italy, October 19, 2022
Cannon Tipos, a Cannon Group company specialized in tooling processes for a wide range of technologies for polymer and composite materials, collaborated with Coriolis Composites for the fast and precise high-pressure resin transfer molding (HPRTM) of a near to net-shape dry preform manufactured with Coriolis’ patented automated fiber placement (AFP) technology.
Coriolis Composites is a world leader in the supply of AFP robotic equipment and machines which enables the laying of continuous or discontinuous fibers with minimum material wastage, in various orientations, even for complex geometrical surfaces, and has developed an innovative and exclusive process to make dry fiber functionalized preforms of composite parts for a range of industrial sectors, notably aerospace and automotive.
“It is only in the last decade that advanced, cost-effective engineered preform technologies have emerged replacing the need for labor-intensive and accurate alignment of several preforms in a HPRTM mold. The innovative near to net-shape dry preform developed through Coriolis’ AFP process and our steel mold, polished to a mirror finish, and high-pressure dosing machines and injection equipment helped realize a complex body-in-white structural part for local reinforcement using a single preform in a fast and easy process with high productivity and sustainable costs.”
Andrea Castelnovo, Technology and R&D Manager at Cannon Tipos
The AFP 2D dry preform is composed of an optimized fiber orientation of unidirectional (UD) non-woven carbon fiber layers (280g/m2 – 8.25oz/yd2 ply) with a 55 percent fiber volume fraction (FVF) – for superior mechanical properties in the final part – and proprietary binding technology compatible with a fast cure epoxy resin system ready to be injected. The functionalization improves formability, permeability, and trimming (3D waterjet) to obtain a net-shape contour and can achieve an overall reduction of up to 50 percent in scrap.
Cannon Tipos engineered the steel mold to withstand up to 120bar (1740psi) thereby avoiding microporosity; to maintain constant temperature to within 2 degrees to ensure optimal resin reaction with the hardener; to minimize counterpressure during the infusion phase and maximize vacuum time to avoid washout and air bubbles; and due to the highly polished cavities fully exploit the surface aesthetics of the final molded part obtainable with Coriolis’ superior preform technology.
The resulting BIW local structural part for series production is undergoing qualification trails. It has a 20 second takt time and displays equivalent mechanical performance when compared to incumbent application while offering up to 80 percent weight reduction.
To learn more, visit the Cannon Group at K2022, Düsseldorf, Germany (Oct. 19-26), in Hall 13 Booth B87.
About Coriolis Composites
At Coriolis Composites, we are passionate about industry and innovation. We started from scratch 20 years ago! That’s why, today, we stand as strong relays of the French Fab and the European industry as a whole. Thanks to our history, we embrace the culture of no limits: we have carried out ambitious projects despite all the difficulties, without ever failing. Today, we master a unique combination in the composite materials industry: machinery, software & expertise. This allows us to support our customers from the beginning of their projects by defining their needs and designing the part itself, all the way to the implementation and optimization of AFP machines.
About Cannon Tipos
Cannon Tipos is specialized in tooling processes for a wide range of technologies for plastics and composite materials. With over 50 years of experience in different applications and sectors, Cannon Tipos uses its vast expertise to supply dedicated, tailor-made solutions. Through Cannon Laboratories, the company guides customers to develop their production projects through the realization of prototype molds, the production of trial parts to tune the process, and part validation.
About Cannon Group
Founded in 1962, Cannon Group comprises 30 companies, with a global presence in more than 40 countries and is recognized as a market leader in technologies, processing and molds for polyurethanes and urethane elastomers for the plastics and composites industries. The Group designs and manufactures high- and low-pressure dosing machines and mixing equipment, for continuous slab and discontinuous molded polyurethane foams. Dedication to continuous innovation now positions Cannon Group as a driving force offering the design, manufacture, servicing, and maintenance of equipment also in other key technology areas including: Energy – industrial boilers for standard and special applications, comprising steam boilers, hot water heaters, heat recovery boilers, and thermal oil heaters, with in-house engineering and fabrication services; Water & Wastewater Treatment – deareators, condensate treatment and recovery, effluent treatment plants, sanitary water treatment and sewage treatment, injection water treatment, demineralization, produced water; and Automation, where Cannon Group offers process digitization and condition monitoring, connect-IT and emissions monitoring. Cannon Group is committed to reducing the ecological footprint of all the Group’s technologies and industrial processes offered to the market through energy efficiency, resource consumption reduction and emissions reduction. Cannon Group delivered net sales of €230 million in 2021. To learn more, visit www.cannon.com
Head of Corporate Marketing Communications
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Cannon Tipos and Coriolis Composites merge technological expertise to mold a complex automotive structural part from a single preform.
Photos: Cannon Group