• Matrix

    Cycle time: 125 sec; Low viscosity until snap cure; Tunable reaction kick-off

  • Preform

    Prefrom weight: 98 g; Preform cycle time: 120 sec; Near net-shape braiding

  • High-pressure injection

    Shot time: approx. 5 sec; Curing time: 120 sec; Mould pressure sensor; Post-injection capability through position encoder

  • Sand Core

    Sand core weight: 1.870 g; Self separating core-components; Reuse of up to 98 % core material

  • Performance Part

    Weight of final part: 226g; 62% weight reduction; Visible and structural hollow part; Functional integration

  • KTM 1290 Super Duke R

    Power: 127 KW / 173 HP; Displacement: 1300 ccm; Engine: 2 cylinder/4 stroke; Transmission: 6-speed

8 Partners – 1 Vision – 28 Weeks

Serial Production of a structural hollow lightweight component by using the innovative CAVUS technology. The Process was transferred to a licenseplate holder for the KTM 1290 Super Duke R.

On the K-Trade Fair 2016 a fully automated process of licenseplate holder production has been presented in support by the company Hennecke. The process was shown 5 times a day for 8 days nonstop. The R.A.C.E. project (Reaction Application for

Composite Evolution) now made an important development step in the industrialization of the CAVUS technology from our company, which will allow even complex fibre composite hollow parts to be produced with the automated hich-pressure RTM process.

Setting up a reliable process within 28 weeks requires thorough preliminary considerations and a close cooperation of all disciplines involved.

The project begins with an intense collaboration of design & construction. The success and feasibility are ensured by an inside-out design. For the best performance strong cooperation with filling, structural and braiding simulations are included too.

The design & concept are implemented in the part which begins with the sand core. The pressure-resistant core can be manufactured by rapid prototyping or core shooting in any complex geometry. The core will withstand an enormous injection pressure of up to 500 bar. The binder used is water-soluble. At the end of the process, it can be flushed out easily in an eco-friendly manner with regular water and without any use of solvents and can be reused up to 98%.

Presentation at the exhibition

Construction and analysis

The whole process

Foto: Hennecke

Afterwards the carbon fibers are woven around the sand core in a fully automated braiding process. The angle and orientation of each individual fibre is extremely important in order to properly absorb forces that are acting on the part.

The whole preform is infused in a high-pressure RTM tool with high quality class A surfaces. The injection process is ensured by a specified seal with high elasticity and lifetime. At the end a new cost efficient, lightweight part with new design is produced.

For us, competitive lightweight construction is a central focus in the development of high-performance products. With an innovative team, we realize parts in new technologies where we are constantly pushing the limits of what is possible for our customers. We at KTM Technologies also rely on powerful partners for our development projects in order to retain our leading position in lightweight construction in the future.






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