The refinement of the RTM process, Audi expects to use a new process to combine the various materials. In the end, Audi decided to hand over the work to a Tier 1 supplier, who was responsible for the relevant production work. Both sides have fine-tuned the injection molding pressure, compression force and mold gap in the RTM process to further optimize the molding process.
For the Audi R8 Spyder's sandwich structures, the injection pressure is no more than 40 bar, the maximum molding clearance is 0.6 mm, the maximum compression force is 500 MT, and the mold temperature must not exceed 123 °C. With this new process, the injection time can be shortened to 15 seconds, while the overall production cycle time can be controlled within 5 minutes.
The road to the promotion and application of new processes to manufacturers
When the independent research and development of Audi materials and processes achieved results and transferred the results to the two major European composite materials suppliers responsible for actual production, the other party also felt that there were uncertainties in the technologies and products involved in the cooperation. To this end, Audi provides suppliers with relevant technical presentations to inform them about the application of new technologies. In the end, Audi convinced the supplier that the latter was responsible for the production of such parts, and the supplier also took on many risks. As a supplier of a car company, it is really not easy to do this.
High cost constraints manufacturing Audi continues to explore new processes
In 2017, Audi introduced a four-seat luxury car, the Audi A8, which uses a carbon fiber composite back wall and an upper rear shelf. Both of these components are made of carbon fiber and are also super Fast RTM process. Today, the company is looking at all aspects of the product, not only the price of carbon fiber, but also the production speed of the RTM process. In addition, consider the price of the resin, the price of the adhesive, and the price of the entire material chain. To this end, we must adopt a new concept.
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