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R.I.M. case study: It goes on wheels

 

 

The detailed technical advice that Materialise N.V. offers is very important for us, as we are dealing with the automotive business, a sector which is always demanding a high-quality service.

Patrick Temmerman - Plant Manager Röchling Automotive Belgium

Machining the R.I.M. mould core pieces

Röchling Automotive, a German-based subsidiary of the Röchling Group, is one of Europe’s leading manufacturers of systems and components made from polymer materials and natural fibre plastic composites for the automotive industry. The Röchling Group is a family-owned business, with more than 180 years of experience in industry.



The assembled mould core

Röchling Automotive Belgium, a tier one automotive supplier within the Röchling Group, was founded 15 years ago and for several years one of Materialise’s most loyal customers.

Whenever car manufacturers like Volvo contact us in the early design phase, Materialise is one of our preferred suppliers for prototypes. Materialise offers an excellent technical support service and advises on RP technology, in compliance with our needs, after a thorough analysis of the project. This detailed technical advice is very important for us as we are dealing with the automotive business which demands high-quality service.

One of the projects which Materialise and Röchling Automotive closely collaborated on, is a set of wheel arch liners for the new Volvo convertible C70 which was introduced to the market the end of 2005. For many years Röchling Automotive has developed and manufactured wheel arch liners (as a part of their technical plastic product range).



This project was a collaboration between 3 parties – Pininfarina (Italian design bureau), Volvo and Röchling Automotive as the first tier supplier who chose Materialise for prototype support

R.I.M. prototype of one of the wheel arch liners

Volvo needed a series of wheel arch liners to be assembled during the first building phase. In this early stage typically 25 cars are assembled on which to complete the first tests.

 

We have contacted Materialise to make the first functional prototypes of the 4 different wheel arch liners. Looking at the quantity our customer requested, the lead time they required and the expectations towards modifications, the Materialise team and I decided together to go for the Low Pressure Reaction Injection Moulding technology (R.I.M.). We at Röchling Automotive were very satisfied with the continued communication in the search process for the ideal solution.

Wheel arch liner: R.I.M. prototype and production part

Materialise moulded the wheel arch liners by means of the R.I.M. technology. Four R.I.M. tools were made using machined PU mould cores combined with hand lay up cavities. Materialise moulded the wheel arch liners in their RIM2 PU, which is ideally suited for this application.

 

We received the first off tools within 4 weeks, as requested and were very pleased with the quality. Volvo appreciated the functionality of the R.I.M. models which were immediately set into action for the first road tests.

Volvo C70

The prototype wheel arch liners were tested on several features: How does the wheel arch liner fit on the car? Noise factor? Do the cables fit behind the part? How is the reaction to extreme low/high temperatures?

 

 

 

Mr. Temmerman explains:

During the tests, design imperfections were discovered and Volvo has made important modifications on the various prototypes. Prototypes are indispensable – an essential phase in the product development process. It might imply a high cost but we at Röchling Automotive are convinced that it is necessary and it is part of our professional development. These prototypes ultimately reduce the cost for the customer, by eliminating expensive modifications to the moulds.

 

Materialise wishes to thank Patrick Temmerman and the Röchling Group for their co-operation in compiling this article.

 

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