AFFORDABLE PRODUCTION OF LIGHTWEIGHT ADVANCED · PDF fileof advanced composites while overcoming traditional ... INSERTS, CORES AND JOINING Advanced composites similar to the ones

FIBERFORGE® sells custom composite sheet goods, finished parts, and manufacturing solutions to customers in the rapidly

expanding, thermoplastic advanced-composites market. Our patented automated layup and thermoforming system enables the

AFFORDABLE PRODUCTION OF LIGHTWEIGHT ADVANCED-COMPOSITE STRUCTURES.

FIBERFORGE ADVANTAGES:

• Lightweight

• Low scrap

• Recyclable

• One-minute cycle times

• High structural performance

• Low cost

Fiberforge works closely with

customers to develop and

implement solutions that readily

scale-up and meet high-volume

production requirements.

L i g h t w e i g h t : Weight is a critical factor in many products designed and produced today.

Fiberforge composites are superior to injection molded thermoplastics, sheet molding compounds, glass

mat thermoplastics, stamped steel, stamped aluminum, and carbon-fiber reinforced textile sheets for

lightweighting—as illustrated by the specific properties in the above charts.

Injection Molded

Glass/Nylon

Sheet Molding Compound/Glass Mat

Thermoplastic

StampedSteel

StampedAluminum

Carbon/Nylon Reinforced

Textile Sheets

FiberforgeCarbon/Nylon

Specific Tensile StiffnessSpecific Tensile Strength

0 2 0 0 4 0 0 6 0 0 8 0 0

MPa/ρ

0 2 0 4 0 6 0 8 0

GPa/ρ

The Fiberforge solution embodies all of the best features

of advanced composites while overcoming traditional

processing limitations. This solution uses automated,

high-speed machinery to obtain:

� LONG FIBER LENGTH

� HIGH FIBER ALIGNMENT

� HIGH FIBER FRACTION

Fiberforge’s results speak for themselves:

� 200% TOUGHER than epoxy-based composites

� 500% STIFFER than injection molding materials

� 60% LESS SCRAP than textile sheets

� 60-SECOND cycle times for forming

� 60% LIGHTER than steel

T H E F I B E R F O R G E P R O C E S SThe Fiberforge process uses automated machinery to layup flat tailored blanks that approximate the outline of the final

part. The machinery precisely orients each strip of material to give the final part its intended mechanical properties with

the least total amount of material. Following layup, the tailored blank passes through an optional consolidation step.

Next, the tailored blank is thermoformed, where the blank is heated and then transferred into a press where it is

stamped into its final shape. Lastly, the part is trimmed of any extra material.

LENGTHOF FIBERS

S H O R T L O N G

ALIGNMENTOF FIBERS

FIBERFRACTION

Loads are passed from fiber to fiber through the matrix—matrix

properties dominate thepart properties

Loads are carried mainly by the fibers—part properties

benefit greatly

Loads are carried along the fiber direction—partproperties benefit greatly

High fiber fraction dramatically improves part

stiffness and strength

Loads flow between and throughfibers with which they are

aligned—many fibers go “unused”,wasting fibers and hurting

performance

More matrix, less fiber—partproperties are weighted

toward the matrix properties

R A N D O M C O N T R O L L E D

L O W H I G H

GOOD BEST

GETTING THE MOST OUT OF HIGH PERFORMANCE FIBERS

EXAMPLE: FIBERFORGE SEAT FRAME FOR JOHNSON CONTROLS’ GENUS SEAT CONCEPT

SHOWN AT THE 2005 NORTH AMERICAN INTERNATIONAL AUTOMOTIVE SHOW

Johnson Controls (JCI) is a leading automotive Tier-one supplier of vehicle interiors, seating systems,

and batteries. The Genus prototype offers leading-edge features and technologies and embodies

JCI’s vision for the future of automotive seating. It incorporates new materials designed to improve

comfort and it features an innovative design: a thin, lightweight structure; a cantilevered base; and

TT AA II LL OO RR EE DD BB LL AA NN KK SSFiberforge has invented and patenteda novel approach to producing high-performance composites in highvolume. The process createsstampable advanced-compositeTAILORED BLANKS without costlyintermediate materials forms. Thestarting materials range from large-tow continuous or long-discontinuoustechnical fibers and neatthermoplastic resin to pre-impregnated thermoplastic tapes.Fibers include carbon, glass, andaramid, while resins include PA, PEEK,PEKK, PC, PP, PPS, PE, and PBT.

Frame

IR-Heating

Tailored Blank

CONSOLIDATEDTAILORED BLANK

TAILORED BLANKLAMINATION

0

0

90

-45

+45

90

90

90

90

-45

+45

90

FIBERFORGE’S AUTOMATEDTAILORED BLANK SYSTEM

“active” comfort features. Its design provides more cabin space and reduces overall system mass.

The Genus is the first concept to feature a thin overall profile and an exposed composite structure.

This cantilevered structure enables the seat to be raised, suspended on its base unit, and integrated

into the vehicle’s floor pan. Fiberforge supported JCI’s design, analyzed the seat frame for structural

performance, and manufactured several prototype frames.

Pressure

Mold

FinishedPart

Automatic Transfer

THERMOFORMINGOF TAILORED BLANK T H E R M O F O R M I N G

Thermoforming tailored blanks is the

best way for designers to capture the

potential of advanced composites.

Parts can be rapidly formed with low

scrap using TAILORED BLANKS made

from pre-preg tapes or “raw”

materials all while maintaining

length, alignment, and fiber fraction.

Thermoformed composite parts can

be post-processed in many ways to

integrate them into structural

applications.

THERMAL ANALYSIS

FINISHED PART

D E S I G N A N D D E V E L O P M E N T C A P A B I L I T I E S

Fiberforge maintains a design and development capability to assist you with your application of the Fiberforge manufacturing process. Up-front

we can assist with part design, matrix and fiber selection, lamina orientation, and analysis. Fiberforge can design and acquire prototype, short-

run, and production molds. Within the Company’s pilot manufacturing cell, we can produce prototype and short run production parts under

1-meter square and 200-millimeter depth of draw. Once you have adopted the Fiberforge process, a production and supply plan for tailored

blanks will be customized to suit your needs. Contact us for more details—our contact information is on the rear cover.

B E N E F I T S O F F I B E R F O R G EHIGH STRUCTURAL PERFORMANCETo justify the use of advanced composites, applications should be highly stressedstructures where stiffness and/or strength are critical properties. Primary orsecondary structures are good examples. Fiberforge’s specific performance isgreater than stamped metals’ and woven composite textiles’ commonly used inthese applications (see chart on first page).

MANUFACTURING VOLUMEBecause the Fiberforge process uses thermoforming to translate a two-dimensional tailored blank into a three-dimensional finished part, the cost ofpress molds must be factored into the fully-burdened part cost. Whilethermoforming molds cost significantly less than steel stamping tools, their costcan constrain the lower bounds of economic production. However, there aremany practical and emerging low-cost mold options that can be used forprototype and/or short-run production.

SECONDARY FORMINGThermoplastics can be post-processed and have tremendous design flexibilitywhen combined with additional thermoplastic forming processes like injectionovermolding.

INSERTS, CORES AND JOININGAdvanced composites similar to the ones made with the Fiberforge process havebeen produced for many years and many solutions exist for inserts, cores, meltwelding, and joining.

COSTCost is very dependent on fiber and polymer resin selection, production volumes,tooling requirements, and post-processing. Therefore, we ask that you contactus to discuss your application. You will find that compared to the competition,Fiberforge delivers significantly higher value.

Tailored Blank

Formed Part

Overmolded Part (source: EPFL)

Fiberforge delivers thermoplastic composite solutions. Our vision is toenable the growth of thermoplastic advanced composites into newmarkets. Together, Fiberforge and our customers will realize this vision ofhigh performance and low cost.

TTOO AACCHHIIEEVVEE HHIIGGHH PPEERRFFOORRMMAANNCCEE:: � SPECIFY long technical fibers� ALIGN the fibers� ENSURE a high fiber fraction

T H E F I B E R F O R G E S O L U T I O N

TTOO AACCHHIIEEVVEE LLOOWW CCOOSSTT:: � MINIMIZE scrap� USE engineering thermoplastics� EMPLOY high-speed processing� AUTOMATE blank layup� TAILOR fiber orientation

FIBERFORGE®

3768 Highway 82

Suite 204

Glenwood Springs, CO 81601

USA

Phone: +1 (970) 945-9377

Fax: +1 (877) 232-0292

Email: [email protected]

Web: www.fiberforge.com

©2005 Fiberforge

Fiberforge is looking for development partners and

tailored blank customers. If you are a designer,

materials supplier, molder, or manufacturer looking to

create breakthrough products, capture new markets,

and increase margins, we invite you to contact us to

learn more about Fiberforge.