61 aeronáuticos de grande porte e geometria complexa, que integra critérios económicos e ambientais. O projeto permite transferir a tecnologia RTM para a produção de grandes estruturas para asas de aviões de nova geração, apoiando-se em ferramentas digitais, novos conceitos de pré-moldação e uma gestão otimizada dos fluxos de material e energia. AUTOMÓVEL E RODOVIÁRIO – COMPONENTES BMW M natural fiber composites • BMW Group, M GmbH (Alemanha) • Parceiros: Bcomp, SGL Technologies, Cobra Advanced Composites e PPG Wörwag Coatings. A BMW introduziu compósitos de fibras naturais em modelos de produção em série, desenvolvidos a partir de linho e resinas específicas que melhoram a durabilidade e o acabamento superficial. O material reduz em cerca de 40% as emissões de CO2e durante a produção e cumpre os exigentes padrões do setor, com aplicações já testadas em veículos BMW M Motorsport. AUTOMÓVEL E RODOVIÁRIO – PROCESSO Caixa de bateria de plástico para veículos elétricos e produção em massa • Universidade de Tecnologia de Chemnitz (Alemanha) • Parceiros: Mahle Filtersysteme, Formenbau GF, In2p, Gerlinger Industries, Wickert Maschinenbau e Fraunhofer ICT. O projeto apresenta uma caixa de bateria para veículos elétricos fabricada em termoplástico reforçado com fibra de vidro, concebida para produção em grande escala através de moldação por compressão. A solução reduz o peso e as emissões do ciclo de vida em cerca de 25% em comparação com uma referência em alumínio, com tempos de ciclo inferiores a dois minutos. CIRCULARIDADE E RECICLAGEM Reciclagem da estrutura secundária do A380 para o A320 neo • Toray Advanced Composites (Países Baixos) since 1994 to produce nearly 10,000 small CFRP parts annually for A320 and A330 aircraft. SAUBER4.0 enables RTM’s transition to large, complex, high-volume structural components for next-generation single-aisle wings. The project delivered key technologies, including inductively heated invar RTM tooling, TFP/DFP preform production with 3D-printed molds, and a knowledge model linking process data and energy use. A holistic material- and energy-flow methodology was validated through five fully reproducible Wing Tip demonstrators. Key benefits: ● RTM Technology for large, complex integral parts ● Energy savings compared to today's a/c production ● Fully digitalized E2E CFRP production ● Successful validation of multi physic simulation ● Enabling AIRBUS next generation single aisle A/C BMW M NATURAL FIBER COMPOSITES BMW Group, M GMBH (Germany) www.bmw-m.com Partners: Bcomp Ltd (Switzerland) SGL Technologies GmbH (Germany) Cobra Advanced Composites CO., LTD (Thailand) PPG Wörwag Coatings GmbH & Co. KG (Germany) The BMW Group harnesses natural fiber composites for series production models through cross-industry collaboration with partners, thereby reducing CO2e footprint and overall weight. The BMW Group introduces series-ready natural fiber composites from renewable flax-based raw materials. Developed through cross-industry collaboration, a new resin and prepreg system improves durability, visual quality, and processing by overcoming moisture sensitivity. Extensive testing confirms UV, climate, and mechanical performance, supported by diffusion barriers and coatings. This material reduces CO₂e emissions by about 40% during production and addresses end-of-life impacts. Meeting strict automotive standards, the components have proven performance in BMW M Motorsport cars, demonstrating BMW’s commitment to sustainable, lightweight solutions for future models. Key benefits: • 40% CO₂e cut in production plus end-of-life vs. carbon • Highly suitable for visible exterior and interior parts • Several years of development and in-depth research • Natural fiber composites confirmed for future series cars • Applied in BMW M Motorsport racing cars Plastic EV battery housing for mass production University of Technology Chemnitz (Germany) www.leichtbau.tu-chemnitz.de Partners: Mahle Filtersysteme GmbH (Germany) Formenbau GF GmbH (Germany) In2p GmbH (Germany) Gerlinger Industries GmbH (Germany) Wickert Maschinenbau GmbH (Germany) Fraunhofer ICT (Germany) A thermoplastic, glass-fiber-reinforced traction-battery housing was developed. Using commercially available long- and continuous-fiber semi-finished products and fewer semi-finished variants enables automated large-scale compression molding. Lifecycle emissions are ≈25% lower than aluminum diecast. A load-bearing battery housing made from long and continuous fiber-reinforced thermoplastic was developed to reduce weight and increase structural rigidity. Commercial semi-finished materials were combined into a multilayer system and processed via compression molding, enabling manufacture of a flawless component from a single organo sheet. New lightweight grippers were engineered to handle lofted, preheated blanks. Waste-free production was achieved using rectangular blanks and a controlled pre-draping mechanism. With cycle times under two minutes, the process supports large-scale manufacturing and delivers about 25% lower lifecycle emissions compared to an aluminum reference design. Key benefits: • Large-scale FRP production of a EV battery housing • Less than 2 minutes cycle time • Around 25% CO2 reduction over the life cycle • 15% weight reduction of the equipped battery box Aeronáutica – Processo. Automóvel e rodoviário – Componentes. Automóvel e rodoviário – Processo.
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