Development and manufacturing of heavily loaded suspension link based on one shot RTM, highly integrated and lightweight CF concept

Abstract

Fibre-reinforced polymer composite materials are leading candidates as component materials to improve the efficiency and sustainability of many transport modes and specially in new vehicles based on electric mobility where weight is also an important requirement. The advantages of high-performance composites are numerous: they include lighter weight and reduced assembly costs due to high level of integration potential. This translates into greater weight savings resulting in improved performance, greater payloads, fuel or battery energy savings and emissions reductions. However, the manufacturing processes to provide high level of integration are still a challenge as the process becomes more complex in terms of materials preparation (cutting, stacking, etc), 3D preforming and toolings involved. In this context, Tecnalia, Gestamp and other partners have recently developed a suspension link, with the following features:

Lightweight CFRP concept despite of the very high demanding mechanical loads requirements Fast stacking, cutting and 3D net shape preforming including also the corresponding advanced toolings and equipment One shot RTM and highly integrated concept to optimize the mechanical performance and reduce the process steps and joining operations

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