Under the skin: Breakthrough creates faster, cheaper, greener carbonfibre
developed its own version of RTM, unsurprisingly called ‘RTM-Lambo’, back in 2011. The bottom half of the tubs are pre-formed by laying up into carbonfibre moulds and then combined with the top half of the body, which is made in an autoclave in the traditional way. However, RTM-Lambo is a lengthy process that requires the installation of dedicated production lines.
Retrac’s version of compression moulding starts with adding dry matting to the mould, followed by pre-mixed resin before the combination is compressed and heated. This method is cheaper than using pre-preg because it cuts out a manufacturing step and should help open up the use of bio- composites to a wider audience. Crucially, the whole process is completed in one step and takes minutes rather than hours.
Although compression moulding has already been adopted for components by some manufacturers and their leading suppliers, Retrac’s system differs in that the 60-tonne screw press is driven by electric servos rather than hydraulics for more precise control of the press. Unlike hydraulics, which consume energy through the whole compression cycle, the servos consume energy only as the press closes.
The press has its own built-in vacuum system, is controlled by the company’s own software and enables carbonfibre components to be made faster and to a high-quality standard or achieve acceptable quality using natural fibres and resins. The bio-resins used have the highest proportion of sustainable, bio-based ingredients on the market.
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