Composite Panel Manufacturing with Disposable Moulds
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Solution Overview
Problem
The automotive industry faces high costs associated with metal stamping tooling and limited flexibility in producing composite vehicle parts, making it challenging to reduce tooling costs and facilitate the production of vehicles in lower volumes without economies of scale.
Innovation Solution
The Arrival system employs a method of manufacturing composite parts using a shared platform with autonomous robotic manufacturing, which includes preparing a yarn, forming a bespoke fabric, moulding the precursor material into shape, cutting it to size, bonding parts, and assembling vehicles, thereby reducing tooling costs and enabling flexible, cost-effective production of composite parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal stamping tooling is used to create exterior panels, then production speed and automation are improved, but tooling costs and capital investment increase significantly
Solution Approach 1:
The patent employs disposable or reusable moulds made from composite materials instead of expensive steel stamp tools. These moulds can be manufactured at a fraction of the cost of traditional metal stamping tools (US$5,000/m2 vs US$100,000+), enabling cost-effective production even at lower volumes while maintaining automated manufacturing processes
Solution Approach 2:
The invention changes the material parameters of the tooling itself by using composite materials for mould construction rather than traditional steel. This parameter change reduces the cost, weight, and complexity of the tooling while enabling the same high-speed automated production capabilities
2Productivity
If economies of scale are implemented through huge capital investment and vast factories, then cost per unit decreases, but flexibility and adaptability to market changes are reduced
Solution Approach 1:
The patent enables dynamic production capabilities where manufacturers can quickly adapt production volumes and product designs without the constraints of expensive fixed tooling. The reusable composite moulds allow for easier reconfiguration and adaptation to market changes, providing both cost efficiency and flexibility simultaneously
Solution Approach 2:
The invention creates a universal manufacturing approach that can serve multiple production scenarios - from high-volume to low-volume production - using the same composite mould technology. This multi-functional capability eliminates the need for separate tooling systems for different production scales, enhancing both cost efficiency and adaptability
3Ease of manufacture
If composite materials are used instead of metal stamping, then tooling costs are reduced, but manufacturing complexity and process development increase
Solution Approach 1:
The patent uses composite moulds that can be created as copies or replicas of the desired final part geometry, simplifying the manufacturing process. These moulds capture the complex shapes directly without requiring complex metal forming processes, reducing both tooling cost and process complexity while maintaining manufacturing capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies and automates the manufacturing of composite parts, reducing production costs and enabling the production of vehicles in lower volumes while maintaining quality and efficiency, allowing for bespoke designs and quick adaptation to market changes.
Implementation Method 1
heating means for heating the composite structure above a melting point of the thermoplastic polymer matrix
Implementation Method 2
cooling means for cooling the composite structure below the melting point to form the part
Data Source
AI summary
The disclosed composite structure provides a reinforced thermoplastic polymer composite part with a high-quality surface finish. This may be used as a vehicle part or body panel, such as an interior vehicle part or exterior body panel. Additionally, the surface finish may be coloured, such that the surface does not need to be painted or wrapped to achieve a desired surface colour, and the surface may protect inner layers from UV radiation, either by virtue of the material of the surface itself, or the incorporation of a UV-absorbing additive. Specifically, the disclosed composite structure comprises a structural layer comprising reinforcing fibres, such as glass or carbon fibres, and a thermoplastic body polymer. The structure further comprises a surface layer providing a surface finish to the composite structure, the surface layer comprising a thermoplastic surface polymer substantially free from reinforcing fibres.