Development of New Resin Formulations and its Mixing/Distribution Prototype for SMC (Sheet Moulding Compound) in Automotive Industry

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The project development of new resin formulations and its mixing/distribution prototype for SMC in automotive industry will be conducted by the Centre Technologique en Aérospatiale (CTA) and Magna Exteriors Inc. (MEI), a world leader in automotive parts fabrication. The CTA is a College Centre for the Transfer of Technologies (CCTT) affiliated to Cégep Édouard-Montpetit and to École Nationale d'Aérotechnique (ÉNA). MEI has already proven the efficiency of fast-cure carbon SMC manufacturing to produce structural composite parts regarding mechanical properties, weight reduction and process costs. Those results were obtain through ARD project 488489-15, Development of manufacturing process for automotive hollow composite structures, in collaboration with CTA. In order to move toward the industrialisation of this process for automotive structural part, the realisation of this project is crucial and is divided in five (5) main subprojects steps: resin in-line mixing and distribution prototype, resin formulations development, automated SMC prepreg development, composite parts manufacturing and optimisation and technology transfer. Each steps are interrelated and essential to achieve the industrialisation objectives. The new resin formulation developed by MEI for SMC compression moulding process is still in the early stage, where several avenues shall be explored to optimise its performances. More precisely, characteristics such as chemical cohesion, homogeneity, glass transition temperature (Tg), tensile and flexural modulus and strength, coefficient of thermal expansion (CTE), shrinkage, specific gravity and fiber and void content can be influences and modified through the use of various additives. These additives will be individually evaluated to measure their effects on resin performances. However, to implement this resin into carbon SMC prepreg fabrication, a mixing and distribution prototype shall be developed and specifically adapted to MEI in-house resin. The output SMC prepreg will be available for automotive composite structural demonstrators manufacturing. The expected success of this R&D project, along with the knowledge gained by MEI, shall lead toward the fabrication of a production resin mixing and distribution system and prepreg line used to manufacture SMC prepreg. Moreover, the optimal resin formulation for carbon SMC prepreg will be developed. These expected achievements will allow MEI to rise its worldwide leading edge on automotive part manufacturing. This technology will be implement in MEI Canadian facilities and its local suppliers resulting in Canadian job creation. The final targeted product resulting from this project, carbon SMC structural composite parts, has the potential to reduce vehicle weight by up to 34% and help the worldwide objective to reduce greenhouse gases emissions.