Shape Group (Witney, UK) successfully compressed the first parts that combined short fiberboard molding compound (SMC) with optimized continuous carbon fiber ShapeTex preforms. This process is commonly referred to as overmolding. Typically, overmolded articles are injection molded composites, but in this case, ShapeTex uses compression molded SMC.
The ShapeTex preforms use continuous strands of carbon fiber to impart significant strength to the finished part, including radial and axial reinforcement. Short fiber SMC uses epoxy resin. The finished part is 4.5 mm thick.
The company was unable to announce the customer of the demo. “But this is an exciting development,” said Peter McCool, general manager of Shape. “We use ShapeTex preform continuous fibers as the structural backing, and we have fixed the short fiber laminates together to make it easier to flow and fill the cavity.”
“The potential of this technology is very large,” McCool continued. “We have been working on this portfolio for a long time and feel that it is time to bring it to market. We have several customers who like the aesthetics of SMC and have channels, ribs and fixed bosses for pressing and curing parts. The ability means that we can combine features into a single composite part that would otherwise require multiple operations and parts. The process was developed using an epoxy thermoset resin that provides an approved molded part with optimized strength using an approved resin system."
Although these tests were performed in a flat mold, the process is equally applicable to complex double curvature components. Shape uses this process to target high-volume applications in the automotive and sports equipment markets.
