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Design and Processing of Carbon Fibre Epoxy Resin Moulding Compound Hybridised w

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Design and Processing of Carbon Fibre Epoxy Resin Moulding Compound Hybridised with Selectively Placed Uni-Directional Reinforcement for Low-cost Automotive Structural Parts 


This paper presents design and manufacturing solutions for low cost and high production rate automotive structural parts, made from compression processed carbon fibre moulding Compound (SMC) and local Uni-Directional (UD) fibres reinforcement. The work is focused on an automotive structural Magnesium alloy to Carbon Fibre Composite (CFC) redesign case study. Multiple structural optimisations were carried out, through simulation and experiments, and following Bentley Motors specifications. The optimised model presented a 52% weight saving with an increase of 25% stiffness compared to Magnesium, for a structure comprised of only 2.3% UD material (97.7% random fibre). In order to validate this performance, a representative structural element was manufactured using a novel method which utilised UD Bstaging to maintain fibre straightness during compression moulding. Test results confirmed the mechanical performance predicted, and also indicated a major improvement in repeatability compared to simple SMC structures.


Authors: A. Brasa, A. R. Millsa, E. Walcha 


Conference: SAMPE Europe Conference 2016

SKU/Code: Euro2016-5

Pages: 8

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