Center for Composites Manufacturing

The objective of this project was to develop thermoplastic composite materials and product forms and to develop and demonstrate fabrication methods for molding these materials into components for use in buses and other mass transit applications. The specific purpose is to demonstrate that these technologies can provide lower cost, lighter weight, improved performance structures for mass transit applications. During the four quarters of this effort the authors have formulated several thermoplastic prepregs, fabricated test panels, and tested the panels. A compression molding flow tool was manufactured, delivered and used to mold plaques for test specimens. Test panels were made with flame retardants and successfully tested for both flame spread and smoke density. Based upon cost and weight analysis a bus seat was selected as a component for fabrication and testing. An all-composite 2-person bus seat was designed and analyzed. Tooling was designed to prototype the bus seat design and then fabricated for compression molding trials in a production facility. The successful molding of the bus seat was accomplished resulting in the production of 20 full-scale bus seats to be used for testing and validation of design criteria. The molding operation was also simulated using unique long-fiber thermoplastic analysis software. Comparisons of the molded parts with the flow simulation was successful and excellent press tonnage predictions were made.

Language

  • English

Media Info

  • Media Type: Digital/other
  • Edition: Final Report
  • Features: Appendices; Figures; Glossary; Photos; Tables;
  • Pagination: 94p

Subject/Index Terms

Filing Info

  • Accession Number: 01847980
  • Record Type: Publication
  • Report/Paper Numbers: FTA-AL-26-7001.1
  • Files: TRIS, ATRI, USDOT
  • Created Date: Jun 5 2022 5:00PM