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Advanced Thermoplastic Composites (ATC)At DSM Engineering Plastics

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What Are Advanced ThermoplasticComposites (ATC)?

v Thermoplastics reinforced with:• Continuous fibers (UD Tapes)• UD Tapes woven into sheets/fabrics

v Why ATC?• Step change in mechanical properties

over regular compounds• Tensile Strength increased from nominal

300 MPa to > 2100 MPa• Tensile Modulus increased from nominal

35 GPa up to 125 GPa

Structuralmetals

SFT(Short fibercompounds)

CostPe

rfor

man

ce

ATC

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Why ATC: Weight loss is the most effective technology forlowered emissions

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What changed: the significance of light-weight

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UDT Physical Characteristics

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DSM UD Tape: Complete Data Package available

§ Material models and CAE Input Decks (LS Dyna)§ Thermo-forming and draping simulation§ Overmolding and insert-molding simulation (Filling and Temperature

end of filling)§ In Situ Consolidation Winding & Tape placement processing guidelines§ Hot-pressing, Autoclave and laminating processing guidelines

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DSM UD Tape: Technology and Support

q Design and CAE• Thermo-forming and simulation• Over-molding and Mold-Flow• Winding• Structural analysis

q In-House macro & micro structural analysis of UD Tape• Off-Line Quality Control• Material modeling• Micro-mechanics

q Circularity• ≥ 90% retain of performances

q Adhesion - Bonding• Plastic to Plastic• Plastic to Metal• With and without adhesives

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Examples of applications and achieved weightreductions

Weight targets for each module met

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Examples of applications

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Motivation Results Database Further steps

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omcFRTP for Application in Automobile Structural Parts

© Institute for Composite Materials | 12/6/2018 | 11

cFRTP branche Automobile branche

Support forstructural parts

Aluminumbranche

Steelbranche

Stro

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ppor

t• Focused Standardization of cFRTPàrobustness, efficiency, transparency

• Improvement of data quality andavailability for simulation

• Robust and efficient quality control Stro

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Working groupestab. 2015

The „opponent“ is not the cFRTPcompetitor but the metal branche

The only chancefor cFRTP is towork together

OEM steering committee, links to …

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Manufacturing with ATC

The UD tapes are used in a variety ofapplications:

q UDT can be woven and/or stacked intoplates (0.2 mm to 5 mm thick) andrepeatedly shaped by thermoforming(heating & pressing), analogous to hot,sheet-metal stamping

q The UD Tapes can be used as inserts ininjection molding

q The UD Tape can be wound (filament-winding) into pipes of varying cross-section profiles

UD Tape

UDT WindingUDT Insert MoldingUDT Thermoforming(Tailored Blanks)

CONFIDENTIAL ConfidentialDSM Approachü The ambition is to create:

“DSM Automotive Weight-Loss Center”

a product development process that can drive the metal-composite conversionwith a high degree of acceptance & success

ü The strategy consists of creating key nodes in the value chain:

1. Manufacturing & supply of UD Tapes with DSM engineering polymers

2. Manufacturing Demonstration Facility that captures manufacturingtechnologies for UD Tape Winding, Tape-placement & Thermoforming andCAE simulations of UD Tape based composites behavior in customerapplications

3. Key OEM/TIERs collaboration for PTO opportunities

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DSM Approach: Fill gaps in the composites sectorwhich lacks intermediate-goods suppliers

Polymer

Fiber

UDTape

Slitting

Winding

TapePlacement

Thermo-Forming

OverMolding

MetalJoining

Tier 1

OEM

CAE CAE CAE

PartDesign

CFD

+

Intermediate Goods

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Visual Presentation of Gaps In Supply Chain

UD Tape Tape Lay Up Consolidation Thermoforming

Gaps: Fragmented/Opportunistic

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Circularity - Recycle ‘Close-the-loop’

Following Injection Molding:

q Grinded material sieved over 3 mm mesh.q Not so much issue with feeding material to the feed-throatq Some low variation in shot weight

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Circularity - Comparison against commercial gradeRegrind Q-HG10* Retention (%)

Modulus (GPa) 15 15 100Tensile strength (MPa) 200.2 215 93Elongation at break (%) 2.4 2.9 83

* Average value calculated from >15 production batches

Pretty consistentand reproducibletensile result

Contact persons

Raj Mathur Tel.: +31652590614. Email: raj.mathur@dsm.comGiacomo Perfetti Tel.: +31683649747. Email: giacomo.perfetti@dsm.com