Japanese consortium bids to push advanced composites into automotive fast lane

Mitsubishi Rayon Co. Ltd. (MRC), a manufacturer of chemicals, plastics, textile fibers, and consumer products, including carbon fibers and methyl methacrylate (MMA) monomer and polymers, has paired with the the Japanese government organization, New Energy and Industrial Technology Development (NEDO), and the University of Tokyo to purchase the RELAY (rapid, efficient lay-up) unit from Fiberforge for R&D purposes.

The technology creates tailored, multi-ply preforms from unidirectional thermoplastic prepreg tape that can then be formed into a finished part. The effort is part of NEDO’s Development of Sustainable Hyper Composite Materials Technology initiative, which aims to reduce automobile weight through the use of lightweight and recyclable thermoplastic advanced composites.

With the Fiberforge technology (see our initial report here), the unidirectional tape can utilize a variety of reinforcements, including glass, carbon, or aramid fibers, as well as different resin matrices, like polypropylene, nylon, and polyetheretherketone (PEEK). The tailored blanks can vary in thickness and fiber orientation to maximize structural performance. Key to the technology, and its goal to replace heavier materials like steel in automobile construction, is that a high degree of automation reduces the labor intensity typically associated with advanced composite part manufacturing. Fiberforge feels this automated lay-up can expand the commercial reach of advanced thermoplastic composites into higher-volume markets and products. —[email protected]