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Carbon Fiber Automotive Parts Production Industrialized Via C-RTM Process
It was reported on Dec. 3 that ESI Group (France), a worldwide firm with a give attention to digital prototyping software program and companies, supported Nissan Motor Co. (Yokohama, Japan) in its use of the Compression Resin Transfer Molding (C-RTM) manufacturing course of, which sped up the development of car parts made from carbon fiber strengthened plastics (CFRP), a cloth that is commonly thought-about too time-consuming and too expensive to industrialize for the automotive sector. “We have at all times thought of CFRP as a material for future generations of cars,” says Hideyuki Sakamoto, EVP of Nissan Motor Co. “But when it comes to reality, CFRP can only be used for restricted fashions and seems to be extra challenging for mass market production. Indeed, costs are high, and complicated designs are required to form the fabric. ESI Group has been supporting Nissan’s CFRP challenge since 2015 through the evolution of its industrial product design and manufacturing methodologies for various vehicle fashions. The partnership was strengthened in 2018 with the CFRP mass production venture. To beat the issue in shaping CFRP components, Nissan’s engineers, aided by ESI’s solution, discovered a new strategy: the C-RTM process. The existing technique involves forming carbon fiber into the correct form and setting it in a die with a slight gap between the higher die and the carbon fibers. Resin is then injected into the fiber and left to harden. Nissan’s engineers developed methods to accurately simulate the permeability of the resin in carbon fiber, while visualizing resin movement habits in a die utilizing an in-die temperature sensor and a clear die. The results of the simulation was a high-quality element with a development time decreased by 50% and reduced by 80% for single molding. Incorporation of digital prototyping additional validated the product’s design.

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