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motorcycle seat base tape sandwich process

Enabler for sustainable products

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JEC World<br />

5 – 7 March 2024<br />

Join us<br />

at Hall 5,<br />

booth<br />

5L106<br />

Tape <strong>sandwich</strong> <strong>process</strong><br />

Enabler for sustainable products<br />

ENGEL and KTM Technologies developed a new <strong>process</strong> to produce a thermoplastic <strong>sandwich</strong> structure with<br />

endless fibres at the outer skins. A motorbike <strong>seat</strong> bench was manufactured as the first product using this<br />

technology. The <strong>process</strong> uses thermoplastic endless fibre <strong>tape</strong>s on top and bottom of a <strong>base</strong> material where<br />

the reinforcement has the highest impact on the structural properties. That’s why the amount of fibre <strong>tape</strong>s<br />

can be reduced to a minimum compared to a homogeneous reinforcement in the part. To keep the <strong>tape</strong>s on<br />

the mould surface a special mould technology was developed which fixates the <strong>tape</strong>s at the edge area and<br />

at the corners by using vacuum. Optimised <strong>process</strong> parameters during the injection moulding <strong>process</strong> ensure<br />

that the <strong>tape</strong>s are materially coherent joined to the injection moulded core.<br />

Bilder: KTM Technologies GmbH<br />

Due to the specific mechanical properties of the <strong>sandwich</strong> structure, the stiffness required for <strong>motorcycle</strong> <strong>seat</strong><br />

<strong>base</strong>s can be realized with a single-layer UD-<strong>tape</strong>. This means that the <strong>tape</strong> <strong>sandwich</strong> <strong>process</strong> requires significantly<br />

less energy and simpler production cell technology than conventional fibre-reinforced plastic composite<br />

<strong>process</strong>ing methods. With this new <strong>process</strong> it is possible to reduce the wall thickness (up to 75%), the design<br />

space needed (up to 66%) and the weight (23%) of the part with at least the same stiffness. This consequently<br />

leads to a reduction of the CO 2<br />

-Footprint (less material, less energy) and to a realistic recycling-scenario<br />

(single grade thermoplastic) at EOL. Do you have further questions concerning the <strong>tape</strong> <strong>sandwich</strong> <strong>process</strong> or<br />

would you like to discuss a specific project? We will be happy to advise you!<br />

Mr. Paul Zwicklhuber<br />

Composite Processing<br />

ENGEL Austria GmbH<br />

Mail: paul.zwicklhuber@engel.at<br />

Tel.: +43 50 620 74683<br />

Mr. Hans Lochner<br />

Material and Application<br />

KTM Technologies<br />

Mail: Hans.Lochner@ktm.com<br />

Tel.: +43 6246 77077 226<br />

ENGEL AUSTRIA GmbH | Ludwig-Engel-Straße 1 | 4311 Schwertberg, Österreich<br />

Tel. +43 50 620 0 | Fax +43 50 620 3009 | sales@engel.at | www.engelglobal.com<br />

The information, product features and pictures contained in this brochure are intended exclusively as a technical guide. ENGEL is not responsible for any<br />

technical changes or print/typographical errors. Reproduction in whole or in part is prohibited without the prior written consent of ENGEL AUSTRIA GmbH.

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