Composite 4.0 Research Project Achieves Half-Cost CFRP Part Production

Schuler AG and its partners tested a new production process from the iComposite 4.0 project using carbon fiber-reinforced plastic automotive prototype parts. Within the scope of the research project called "iComposite 4.0," Schuler AG and its partners announced details on the production of carbon fiber-reinforced plastic (CFRP) prototype parts that reduce costs by 50% and have a 40% faster production time compared to traditional automotive composite materials. The reference component is a floor panel mounted beneath the engine and passenger compartment of a British sports car. The design features include front impact protection, high torsional stiffness, and a structure designed for seat loads. Schuler stated that traditional production costs amount to approximately EUR 400 (USD 443.00) per part, while the iComposite 4.0 prototype version of this part was produced using approximately EUR 150 (USD 166.44), and production times decreased from 73 minutes to 46 minutes. In the first step, a robot sprays short glass fiber base structure, performed by RWTH Aachen Institute for Plastics Processing (Aachen, Germany). Subsequently, individual tensile strength is calculated by an algorithm developed by Aachen Integrative Lightweight Construction Center (AZL) and Teijin Carbon (Wuppertal, Germany). Following this, another robot developed by Siemens (Munich, Germany) and Broetje Automation Composites (Rastede, Germany) then prepares the carbon fiber tension threads and component variations in a process that compensates for variations. Optical inspection is carried out using a 3D measurement system from Apodius (Aachen, Germany). Schuler stated that the iComposite 4.0 process uses only the required material and generates no waste, while simultaneously improving cycle time and production. Additionally, an integrated RFID chip from ID-Systec is noted as providing traceability of production data. As a result, all components of the iComposite 4.0 production line at RWTH Aachen AZL are cross-linked with each other. Schuler indicated that its next steps will be to incorporate the research project's findings into industrial application.