Shape Group (Witney, UK) has successfully applied short fiber sheet molding composites (SMC) to optimized continuous carbon fiber ShapeTex preforms and compression-molded the first batch of parts. This process is often called overmolding. Normally, an overmolded composite material is used for overmolding, but in this case, ShapeTex uses compression-molded SMC.
ShapeTex preforms use continuous carbon fiber bundles, which significantly improve the radial and axial strength of the finished product. The short-fiber SMC is made of epoxy resin with a finished thickness of 4.5 mm.
The company cannot specifically notify customers for this demonstration. "But this is an exciting development. We can use continuous fibers from ShapeTex preforms as a structural support and reinforce a short fiber laminate on it to make it easier to flow and fill the mold cavity." General Manager of Shape (Peter McCool) said.
McCool continued, "This technology has great application prospects. We have spent a long time exploring how to achieve the connection between the two, and now it is time to bring it to market. Some of our customers like SMC's The aesthetic appearance, and its ability to press and repair parts using channels, ribs, and fixed rollers, means that we can combine these different features into one composite part, avoiding too complicated operations and multiple parts. The process is thermoset Developed with epoxy resins, using an approved resin system to ensure optimal strength for closed molded parts. "
Although these tests were performed in flat molds, the process is equally applicable to complex double-curvature parts. Shape will use this process to target high volume applications in the automotive and sports equipment markets.