Great Britain's first Engel v-duo press has been delivered to WMG's Automotive Composite Research Centre at the University of Warwick. "As a development partner with the automotive industry, flexibility is very important to us. The Engel v-duo enables us to research thermoset composites prepreg compression molding (PCM), sheet molding compound (SMC) compression molding, HP-RTM and stamp forming of thermoplastic composites," says Professor Ken Kendall, Professorial Fellow at WMG's Automotive Composite Research Centre. "The precise control provided by this equipment is an essential feature for us when researching these processes".

The tailgate consists of several components. The outer frame and inner part made of Borealis Fibremod GB416LF are glued together to meet design and load requirements. Painted exterior parts are glued to the tailgate structure, as well. As a loadbearing part, the tailgate must be extremely robust to withstand static and dynamic loads. Part of the tailgate also lies in the vehicle’s interior, meaning it must comply with emission, fogging, and odor requirements. Finally, to achieve overall weight reduction for the new Multivan — it weighs around 200 kg less than its immediate predecessor — the tailgate itself must also be lighter. Using Fibremod GB416LF enabled Magna to meet these challenges head on.

Great Britain's first Engel v-duo press has been delivered to WMG's Automotive Composite Research Centre at the University of Warwick. "As a development partner with the automotive industry, flexibility is very important to us. The Engel v-duo enables us to research thermoset composites prepreg compression molding (PCM), sheet molding compound (SMC) compression molding, HP‑RTM and stamp forming of thermoplastic composites," says Professor Ken Kendall, Professorial Fellow at WMG's Automotive Composite Research Centre.

Engel supplied the 1,700-tonne press with a mold and integrated HP-RTM equipment. With a mold mounting surface of 2.2 by 1.8 meters, the machine offers WMG the opportunity to produce a multitude of components and use different materials and manufacturing processes.

At its Center for Lightweight Composite Technologies in St. Valentin, Austria, the injection moulding machine manufacturer focuses on promoting the interdisciplinary development of fiber composite technologies with partner companies and universities. The aim is to speed up the launch of composite technologies in the automotive industry. The technology center is currently focusing on the processing of semi-finished thermoplastic products (thermoplastic fabrics and tapes) and on reactive technologies that use thermoset and thermoplastic material systems, such as HP-RTM and in situ caprolactam polymerization.

At Composites Europe 2015, which takes place from September 22nd to 24th in Stuttgart, Engel will be presenting the full potential of the Engel v-duo series and also guarantees visitors a look at many other current lightweight-design projects at its booth (stand D20, hall 7).

A long-glass fiber-reinforced polypropylene (PP) compound from Borealis is a core component of an all-plastic tailgate tagged to the new Volkswagen Multivan. Molded of Fibremod PP compound, the tailgate is said to be the largest ever all-thermoplastic tailgate.

The Engel v-duo is characterised by a very high degree of rigidity and excellent platen parallelism. Platen-parallelism control for injection compression moulding is included in the standard version of the machine. In addition, handling devices that move straight into the mould area can be integrated to save space. Using the sliding tables, insertion tasks and set-ups can be carried out flexibly and easily. The hydraulic accumulator has been done away with completely, and with the ecodrive servo-hydraulic system fitted on the standard version of the machine, the Engel v-duo is setting new standards in energy efficiency too.

PP fiber-reinforced compounds have a proven track record when it comes to lightweighting for interior, exterior, and under-the-bonnet automotive parts. The proprietary Fibremod long-glass-fiber-reinforced PP (PP-LGF) technology offers fiber impregnation, flexibility in the use of various PP matrices, and the production of grades in customized colors. Fibremod compounds are described as cost-effective alternatives to conventional metals and engineering plastics–based solutions, as they are highly suitable for injection molding processes. Moreover, Fibremod LGF compounds boast flowability for smooth processing and low warpage.

The Engel v-duo machine was designed specifically for fiber composite applications. Compared to conventional presses, the it is 50 per cent shorter in height and about 60 per cent lighter. The large vertical machine, which is available with clamping forces from 4,000 to 36,000 kN, therefore makes it possible to create compact production cells at low investment costs.

Engel's decades of experience in the automotive industry was another crucial factor in WMG's decision to invest in an Engel v-duo machine. It was also important to Professor Kendall to purchase an integrated solution where everything came from a single source. When Engel is used as a system supplier, the customer only communicates with one Engel contact, which can speed up the project planning and start-up of the plant significantly. A further advantage is that the HP-RTM unit, which Engel implemented in cooperation with its system partner Hennecke (in St. Augustin, Germany), has been integrated into the machine's control unit, meaning the entire manufacturing process can be managed via the machine's display.

Collaboration between materials supplier Borealis and Tier I Magna yielded the all-plastic tailgate, one of many firsts in the VW Multivan.

Fibremod GB416LF was specifically tailored for use in tailgate carriers and visible structural parts. As a high-flow, 40%-fiber-reinforced material, it fulfils stringent emission and mechanical performance requirements. Using Fibremod GB416LF also can eliminate the need for additional surface finishing steps such as painting.

WMG is a research and education group based at the University of Warwick and works collaboratively with global companies to develop innovative products, services and processes. Along with its UK base, the group operates education centers and partnerships in seven countries. The Centre's aim is to help the automotive sector tap into innovative technologies, using the industrial-scale machine to develop mass-production processes for the manufacture of fiber reinforced composite components

Great Britain's first Engel v-duo press has been housed at WMG's Automotive Composite Research Centre at the University of Warwick. Engel supplied the 1,700-tonne press with a mould and integrated HP-RTM equipment.

The revolutionary tailgate of the new VW Multivan demonstrates how customer-centric innovation and collaboration can produce high-performance parts that lower the overall carbon footprint of vehicles, said Borealis. The Fibremod portfolio of lighter-weight polypropylene (PP) compounds is giving Tier I suppliers and OEMs the freedom to design and manufacture more sustainable and lightweight solutions for leading automotive brands and their increasingly electric fleets, the company added.

The Engel v-duo machine was designed specifically for fibre composite applications. Compared to conventional presses, the Engel v-duo is 50 per cent shorter in terms of height.