{"id":46615,"date":"2025-04-22T11:23:56","date_gmt":"2025-04-22T09:23:56","guid":{"rendered":"https:\/\/composites-united.com\/sandwich-ganz-oben\/"},"modified":"2025-04-22T12:06:03","modified_gmt":"2025-04-22T10:06:03","slug":"over-the-top","status":"publish","type":"post","link":"https:\/\/composites-united.com\/en\/over-the-top\/","title":{"rendered":"Over the top"},"content":{"rendered":"\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

High-volume lightweight construction with thermoplastic sandwich structures<\/h3>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Thermoplastic sandwich moulding technology enables the fully automated production of 3D moulded components in material-efficient lightweight sandwich construction, which are additionally functionalised by injection moulding. The potential of this innovative hybrid technology was demonstrated on a storage compartment flap of a truck driver’s cab.<\/strong><\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

The fiber composite sandwich construction method enables enormous weight savings in the implementation of structural components. However, component manufacture is still associated with labour-intensive, manual processes and long cycle times.<\/p>

The use of thermoplastic fibre composite sandwich semi-finished products represents an innovative development approach for use in large-scale production. In contrast to thermoset fibre composite systems, these can be produced particularly efficiently in ThermHex’s continuous processes and processed into components in fast, automated manufacturing processes.<\/p>

With thermoplastic sandwich moulding technology (TS moulding), the Fraunhofer Institute for Microstructure of Materials and Systems IMWS has developed a process that enables the further processing of pre-consolidated, thermoplastic sandwich semi-finished products. The shaping step takes place by thermoforming in a closed mould, which also enables additional functionalisation by injection moulding.<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Mould for thermoplastic sandwich storage compartment flap in ENGEL v duo700 injection moulding machine at the Fraunhofer IMWS<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Successful demonstration of feasability <\/strong><\/p>

A research and development project now examined the thermoplastic sandwich moulding technology\u2019s applicability for efficiently and reliably producing vehicle interior components. To this end, a storage compartment flap from a truck driver’s cab was selected as a demonstrator structure and prototypically implemented in thermoplastic sandwich construction \u2013 for the first time on a real component structure.\u00a0<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

\n\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Storage compartment flap in a truck driver’s cab \/ \u00a9 Daimler Truck<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

This required a process-appropriate mould design using numerical process simulation tools and experimental research of the feasibility of component-relevant design features. Geometric features such as a visible edge running across the entire width of the component, a circumferentially closed edge and the injection moulding of a recessed grip were demonstrated. Furthermore, the injection moulding functionalisation was successfully implemented on the component. Hinge and fastening elements as well as a holder for the handle mechanism were injection moulded onto the thermoformed sandwich component.<\/p>

This successfully demonstrated the largescale production of functionalised, 3D-moulded lightweight sandwich components.<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
<\/div>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Process diagram of thermoplastic sandwich moulding technology<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Honored with the JEC Innovation Award <\/strong><\/p>

Compared to the reference component (paper honeycomb, PU-GF, SRIM process), a weight saving of approx. 15 % (without decor and functional elements) was achieved with the thermoplastic-based material structure. Its use also has a positive effect on the recyclability of the component. This also convinced the jury of the JEC Innovation Award 2025, which declared the thermoplastic sandwich moulding technology winner in the \u201cAutomotive and Road Transportation \u2013 Process\u201d category.<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

\n\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Project partner: Fraunhofer IMWS, Daimler Truck AG, ElringKlinger AG, ThermHex Waben GmbH, ENGEL Austria GmbH, Edevis GmbH<\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t
\n\t\t\t\t

Contact:<\/strong><\/p>

Fraunhofer Institute for Microstructure of Materials and Systems, Halle (Saale)
Dr.-Ing. Ralf Schlimper
Group leader Evaluation and Design of Fiber Composite Systems
+49 345 55 89-263 | +49 173 529 37 57
ralf.schlimper@imws.fraunhofer.de<\/a>
www.imws.fraunhofer.de<\/a><\/p>\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

High-volume lightweight construction with thermoplastic sandwich structures Thermoplastic sandwich moulding technology enables the fully automated production of 3D moulded components in material-efficient lightweight sandwich construction, which are additionally functionalised by injection moulding. The potential of this innovative hybrid technology was demonstrated on a storage compartment flap of a truck driver’s cab. The fiber composite sandwich […]<\/p>\n","protected":false},"author":5,"featured_media":46600,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[30,171],"tags":[],"main-cat":[144,34],"bildung":[],"forschungs-cat":[],"acf":[],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/posts\/46615"}],"collection":[{"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/users\/5"}],"replies":[{"embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/comments?post=46615"}],"version-history":[{"count":5,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/posts\/46615\/revisions"}],"predecessor-version":[{"id":46620,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/posts\/46615\/revisions\/46620"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/media\/46600"}],"wp:attachment":[{"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/media?parent=46615"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/categories?post=46615"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/tags?post=46615"},{"taxonomy":"maincategory","embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/main-cat?post=46615"},{"taxonomy":"bildung","embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/bildung?post=46615"},{"taxonomy":"forschung","embeddable":true,"href":"https:\/\/composites-united.com\/en\/wp-json\/wp\/v2\/forschungs-cat?post=46615"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}