Composites – in a Complete PackageSimulation, processing and part testing for the new Ultracom™ semi-finished composite materials

Dr. Reinhard JakobiHead of Processing TechnologyEngineering Plastics Europe / BASF SE

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Ultracom™ – product and service package for continuous-fiber reinforced composite parts

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Ultracom™

Semi-finished product (Composites)

Overmolding material:Compounds

Service package

Tapes / Laminates

Ultramid® COMUltradur® COM

Ultralaminate™Ultratape™

Ultrasim®

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Processing

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Parts testing

Ultracom™ – part 3

Part 1 – Thermoplastic laminate and tapes

Part 2 – Thermoplastic compounds for overmolding

Part 3 – Service package

Design assistance with simulation: Ultrasim®

Composite part production at new manufacturing cell

Expanded part testing

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Ultracom™ – the new manufacturing cell

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Process: Inmold forming and overmolding

Forming of laminate in the mold (draping or in-mold forming)

Overmolding

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The CIFO part: Combination of Inmold-Forming and Overmolding

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Size: 40 cm x 40 cm

Height: 4.5 cm

Thickness of laminate: 1.5 mm

The CIFO part:20 individual functions

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Variety of different ribs / wall thickness transitions between the laminate and overmolded material

Overmolded edges

Stitch elements,i.e. locations in the laminate through which material is injected

Rib array for special crash investigations

Punched or formed holes for use as mounting elements

Carrier with ribbed U-profile

BASF manufacturing cell for Inmold-Forming & Overmolding

Injection molding machine

Magazine for laminates

Heating station

Clamping frame with inserted laminate

Six-axis robot

Automatic insertion of laminate into the clamping frame

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Design with simulation toolUltrasim®

Prediction of

Behavior of components incl. manufacturing process

Anisotropic fiber orientation at each location in the anisotropic molded part

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New, expanded numerical material description

Considering

Anisotropy, nonlinearity, shear rate dependence, tension-compression asymmetry

Temperature dependence, different kinds of failure

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Correct selection / placement of reinforcing fibers and semi-finished product

New: Ultrasim® for Ultracom™

Part testing with computer tomography

New at testing laboratory: computer tomography (CT) system

Observation of inner composite structure in a nondestructive way

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T-form welding und a CT video along the welding line

Part testing with computertomography

Additional testing capabilities:

Exposure to temperatures, climates and liquids

Quasi-static, dynamic or sudden forces and internal pressures

Tensile, compressive, flexural or torsional loads

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Ultracom™ –for development with the customer

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