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FMC for the KTM carbon skid plate

News International-French

18 Feb 2019

The first structural composite skid plate produced using an FMC/NCF/elastomer hybrid.

FMC for the KTM carbon skid plate

Light as a standard CFRP solution but 50% cheaper.

This direct production line with a one-shot process enables the best product-market fit in series production in terms of properties and costs.

A new hybridized carbon skid plate for motorcycles was successfully developed for serial production by KTM-Technologies, Mitsubishi Chemical and KTM in a short time and produced in a one-shot serial production process (cycle times <4 minutes). The composite look was created using a carbon-forged moulding compound (FMC) for the main part, non-crimp fibres (NCF) for local reinforcements and elastomers for local damping.

This new engineering process is pushing the boundaries within the composite market. Combining the materials in a single, fully-automated process step enables a new generation of sustainable composite structures offering huge design freedom. Joining is achieved by a direct chemical bond between different thermosets and elastomers without additional joining processes. This easy production also allows the manufacturing of most materials and parts in one location, thus saving transportation costs, emissions and time. This hybridized part with a refreshing carbon look leads to the best product-market fit compared to current skid plates made of aluminium, CFRP-fabrics or plastic materials. It is as light as a standard CFRP solution (lighter than plastic and aluminium) but 50% cheaper.

FMC for the KTM carbon skid plate

Key Benefits:
> New look with the best product-market fit in terms of properties and costs compared to current parts
> Creation of material cards for new hybrid material mixes
> Complex hybrid part manufactured with a time-saving one-shot process (< 4min)
> Reduced CO2 emissions due to direct production with less transport effort
> Reliable because calculated, tested, and proven in a real-life use case

Testing and real-life operation showed that the mechanical properties are also better for this application. Based on this new material, data was created for the simulation and development of other structural parts on the market. The result is a structural, complex part that meets market needs by saving time, costs and efforts. This new circle of sustainability leads to structural components with new material cards, where the reduced use of unidirectional carbon fibre helps save energy drastically, e.g. no exact pattern needed. The carbon fibre used will be recycled into fleece or short fibre reinforcement for thermoplastic materials. This innovation combines new composite design, efficient solution package and breakthrough serial production technology.

FMC for the KTM carbon skid plate

This FMC for the KTM carbon skid plate has been selected as a finalist for the JEC Innovation Awards 2019 in the Sport & Healthcare category.

The JEC Innovation Awards - organized by the JEC Group - are recognized as the industry’s most prestigious awards that identify, promote and reward the most innovative composite projects worldwide. The award winners will be announced during JEC World 2019 on 13 March at 4.30pm.

Their associated partners are: KTM-Technologies GmbH (Austria), Mitsubishi Chemical Carbon Fiber and Composites GmbH (Germany)