Slide 1

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 2

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 3

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 4

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 5

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 6

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 7

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 8

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 9

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 10

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 11

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 12

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 13

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 14

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 15

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 16

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 17

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 18

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 19

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 20

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 21

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 22

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 23

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 24

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 25

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 26

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 27

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 28

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 29

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 30

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 31

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 32

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 33

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 34

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years


Slide 35

Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.

Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference

Advanced GMT Applications
 Content:
 Cost Saving in the Automotive Industry
 Benefits of Advanced GMT Applications (GMT and GMTex)
 Definition and Material Basics of GMTex
 Product and Process Information
 Impact Performance
 Current Applications
 Future Developments
 Summary

Advanced GMT Applications
 Cost Saving - which costs are we talking about?
 Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
 Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
 Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
 Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)

Advanced GMT Applications
 Cost Savings for OEM`s with Advanced GMT Applications:
 Weight saving (improved fuel economy)
 High degree of function integration (less parts, reduced
logistics)
 Reduced assemly effort (belt length) and costs
 High productivity of part production (cycle times: 20s @
2 mm wall thickness)
 Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)

Advanced GMT Applications
 Benefits of Advanced GMT Applications:
 Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)

Advanced GMT Applications
 Material Basics: Definition of GMTex
 GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers

Twintex

Glass fabric

PET special weave

Glass-Aramide
non-crimped

Advanced GMT Applications
 Material Basics: Single Ply Design of GMTex
 The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°

E-Modulus of PP-GM40

0°

15000

15000

315°

270°

45°

0

225°

315°

90°

135°
180°

270°

45°

0

225°

135°
180°

E-Modulus of GMTex

90°

Advanced GMT Applications
 Material Basics: Laminate Design of GMTex
 Tailoring of properties by variation of type and number of
reinforcing textile layers:

Tensile stiffness (MPa)

50000

40000

30000

20000

10000

0
GMT
40% GF

UD-GMT
40% GF

UD-GMTex
60% GF

UD-GMCTex
30% GF-20%
CF

Advanced GMT Applications
Advanced GMT
GMTex

 Production of GMTex:
Glass mats

Extruded PP-films

Middle-layer
Textile
reinforcements
Surface-layer

Double Belt Press

Advanced GMT Applications
 Molding of GMTex:

GMTex blanks

Hot air oven

Position of fabrics
in the molded part
Preheated blank

Preheated blanks in the mold
Molded part

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module



Excellent crash resistance and stiffness



Integrated hip protection



Multiple fixation devices, snap fits for wiring



Door and window opening system guidance



High productivity ( > 1000 parts/day)



Recyclability



Tier 1: Lames



Molder: Rangerplast Italy



Part weight: 1,5 kg

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module

Tested materials:



PP-GM40 (serial material), PP-GM30



DLFT 40% glass content



LFT pellets (Stamax) 40% glass content



GMTex and PP-GM30

 Blank layout for GMTex:
GMTex stripes Middle-Layer

GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)

GMT 30%

Advanced GMT Applications
 Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials



Side impact test (pole test) with
clamped parts, fixations can
rotate



Hip protection pad impact, flat
impactor on barrier behind

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

D-LFT 40% @400J - Absorption 250 J

Crash-Video

Crash-Video

GMT 40% @ 400J - Max. Absorption 800 J

Crash-Video

GMTex ML @1000J - Absorption 1000 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J

GMT 40% @ 400J - Max. Absorption 800 J

D-LFT 40% @400J - Absorption 250 J

GMTex ML @1000J - Absorption 1000 J

Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000

J

800
600

Side impact

400
200
0
Stamax 40% D-LFT 40%

GMT 30%

GMT 40%

GMTex ML

GMTex performance is limited by weak fixation points !

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

Crash-Video

GMT 40% @ 1200 J - max. absorption 900 J

Crash-Video

D-LFT 40% @ 900 J - max. absorption 500 J

Crash-Video

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Crash-Video

Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J

GMT 40% @ 1200 J - max. absorption 900 J

D-LFT 40% @ 900 J - max. absorption 500 J

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000

J

800
Hip pad impact

600
400
200
0
Stamax
40%

D-LFT 40%

GMT 30%

Brittle failure !

GMT 40%

GMTex ML

Advanced GMT Applications
 Current Advanced GMT Applications
 Structural Instrument Panels
 Seat Structures
 Battery Boxes
 Bad Road Engine Noise Shields
 Spare Wheel Wells
 Hatchback Doors
 Bumper Beams
 Rear Axle Supports

Advanced GMT Applications
 Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Excellent crash resistance and
stiffness



In-molded cross-car beam



Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning



LL / RL utilisation same part



Weight reduction (2 to 3 kg per
component)



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability



Part weight: 3,2 - 3,5 kg



Tier 1: Faurecia



Molders:
Nishikawa (Mazda)



Faurecia (Ford)



FPK (Volvo)



Advanced GMT Applications
 Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)





Excellent crash resistance and
stiffness



Cost savings compared to steel and
aluminum tooling due to low car
production numbers



Weight reduction compared to steel



High productivity ( > 1000 parts/day)



Recyclability

Molder: Polynorm UK



Part weights: 1,1 / 1,3 kg

Advanced GMT Applications
 Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)


Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage



Weight reduction



High productivity ( > 1000 parts/day)
and low cost tooling



Recyclability





Part weight: 2,1 kg

Molder: Rangerplast Italy

Advanced GMT Applications
 Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

GMTex with polyester weave
gives extreme wear and
impact resistance

Engine Protection Shield Audi C5

Advanced GMT Applications
 Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)


Excellent crash resistance,
stiffness and fatigue strength



Bonded into BIW with PUR
adhesive used for glazing



Weight reduction



Better acoustics compared to
steel



No additional corrosion
protection



High productivity ( > 1000
parts/day) and low cost tooling



Recyclability


Molder: Aksys



Part weight (C-Class): 4,2 kg

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Murano)

Advanced GMT Applications
 Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano
and Infinity hatchback
doors in steel not feasible

Advanced GMT Applications
 Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking

History 2: 806 with integrated brackets

History 1: 805 with additional metal brackets

Advanced GMT Applications
 Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top

Side

Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations can be disclosed):
 Motor Supports
 Lower Leg Beams for Pedestrian Protection
 Rear Seat Backs with integrated seating belt

Advanced GMT Applications
 Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests

Advanced GMT Applications
 Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM

Advanced GMT Applications
 Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
 Structural Front Ends
 Rear (Wall) Modules
 Parts for a „3rd Crash Level“
 Airbag Containers
 Airbag Covers
 Fire Walls
 Floor Modules

Advanced GMT Applications
 Summary:
 Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
 Cost and weight savings are the key benefits for the
automotive industry using these materials
 Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
 High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
 New and challenging applications are under development
and will be in the market in the coming years