Vacuum-assisted pultrusion of bio-composite injection molding precursors for the automotive industry

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The automotive industry is forced by regulations to constantly reduce the environmental footprint of their products. This drives the development of new materials and process with lower environmental footprint. One approach consists in adding natural fibers to thermoplastic polymers to reinforce vehicle interior components. Renewable fibers such as flax, or hemp, confer high mechanical properties to plastic components while also providing obvious environmental benefits. However, blending flax fibers to polymers is challenging. Few techniques are able to both achieve (i) intimate mixing of polymers and fibers as well as (ii) sustaining production volumes needed for the automotive industry. We have developed and patented a new technology, the multi-mold vacuum assisted pultrusion, that can potentially solve both aspects of the challenge. Using this technology, we have produced flax/PP rods with good reinforcement distribution and low porosity. These high-quality rods can be pelletized and used as injection molding precursors. Following interest from automotive OEMs such as Ford Motor Co., we intend to demonstrate the applicability our technology to the production of biocomposite injection precursors for the automotive industry. To achieve this goal in this one year, we will thoroughly characterize the constituents, flax and polypropylene. Then we will investigate pultrusion mold shapes and coating to accelerate our production speed to more than 1 m/min. The pultruded biocomposites will be pelletized and used as precursors for injection molding. This project will allow us to demonstrate to key automotive industry players the scalability of our technology for the production of greener vehicles.