Genesis of your product. why and for whom?

The objective of this demonstrator was to replace traditional C-groove metallic wall inserts used for anchoring car body train elements such as passenger seats by additive manufacturing polymer inserts integrated in a CFRP wall panel by one-shot and multimaterial advanced process manufacturing.

Benefits for the final customers?

Important weight and manufacturing steps reduction, both contributing to decrease the manufacturing cost. 3Dprinting allows modularity and quick design changes. One-shot manufacturing achieved 50% savings in energy consumption and operation, 30% in labor costs and 7% in material.

The product : materials and processes

This demonstrator is an Integrated C-groove multi-material sandwich composite side wall for a car body shell application, manufactured by 3Dprinting and automated one-shot processes. All the materials are fire resistant. Sandwich: Urethane Acrylate Resin, PET foam, dry CF applied by automated placement. Insert: PPE-PS by FFF. Process: Out-of-autoclave one-shot infusion.