case studies

PRODUCT AND PROCESS DEVELOPMENT

HELMET:

The project envisaged the development of a new helmet made of composite material Carbon Mind studied the lamination of vain constructive solutions, through FEM Analysis, to develop a shell in composite material with reduced weight and fully homologable according to current regulations. Together with the product, it is stalo developed a dedicated production process, from machines to agl stamp The cure times and thermal homogeneity of the molds were designed with particular thermal analyzes and coupled CFD, in compliance with the specifications and production times imposed by the customer. Finally, the shell was approved, testing the finished product, first entirely and then externally

OPTIMIZATION OF THERMOPLASTIC COMPONENTS

The project, developed for a rental company, saw Carbon Mind as the main protagonist in the CAE design of mass-produced automotive components The components initially in metal material were designed in composite material using reinforced thermoplastic tapes in carbon fiber or glass fiber The aim was to reduce the weight and cost of the components without compromising the mechanical behaviour. A final optimization of the orientation of the nasins has led to a significant reduction in material scrap using ATL automatic lamination processes

DESIGN OF UREOL MODELS

CARBON MOLDS
AND VARIOUS EQUIPMENT

Starting from the mathematics of the piece supplied by the customer, solutions are studied to make the production process reliable, repeatable, safe. The study begins with the definition of the lines of decomposition of the piece (if foreseen, obtained with appropriate draft analyses) and as a strict consequence, the definition of the mold set-up. The activity then continues with the design of equipment for handling the mold and extracting the piece.

The service is extended to any type of mold (Ureol, Aluminium, Steel, Carbon, etc.), and for any composite product as well for the technology applied to it (Compression Moulding, RTM, Autoclave, etc)

THERMO-FLUID DYNAMIC ANALYSIS

AND THERMAL OPTIMIZATION

Downstream of a mold design for carbon products, targeted thermal analyzes are performed, in order to minimize the mass of the mold (subsequently validated with the support of structural analyses) and optimize the thermal flow at the interior of the mold itself thus ensuring heating times compatible with the resin systems and temperature uniformity along the mold and the curing processes can be used again and one of the most influential constraints is precisely the cooling. The molds often and willingly need a quick restoration of the operating conditions in order to be able to be useful again and one of the most influential bond is cooling. The thermo-fluid dynamic analyzes make it possible to find solutions hoc to accelerate cooling times and thus ensure greater efficiency and control over the production process

PRODUCT AND PROCESS DEVELOPMENT:
SADDLE

The product was developed starting from a co-design, starting from the customer’s geometry, followed by an analysis and fabrication of a composite saddle.

Through the vain FEM simulations, we have reached a definition of the surveyor such that maximum mechanical performance could be obtained. The project ended with the creation of prototypes starting from the customer’s moulds.

PRODUCT DEVELOPMENT

FOR THE AEROSPACE SECTOR

The activity involved the creation of prototype sandwich panels for aerospace applications.

These panels, in addition to undergoing vibro-acoustic tests, are subjected to thermo-vacuum, which is why more detailed precautions had to be taken compared to conventional solutions for products not intended for field of aerospace. One of these is the use of 01 mm holes on each side of the core cell.

The frame, the constituent element of the panel, was obtained by breaking it down into 4 equal parts and sticking them on a suitable gluing mask, so as to keep the sharp edges at the corners of the frame on the piece, a design constraint.

PROCESS DEVELOPMENT AND PRODUCTION OF SMALL
CARBON LOOK LAMP SERIES

The development project of carbon components for a product of a well-known Italian lighting company involved a first step of brainstorming on the most suitable materials and technologies applicable to its production.

The design then moved on to the economic sustainability of the proposal, which has taken into consideration a functional equipment for the creation of a few prototypes or a small series, to reduce costs and streamline the production process.

The symmetrical components that make up the varnished Carbon Look lamp have been made in two versions with twill pattern and plain. In parallel with the approval of one of the two by the customer’s marketing department, they have been 3 adhesives were tested for the aluminum wing-lamp body interfaces, as well as their resistance.

APPROVAL TEST

Carbon Mind managed the pre-test phase and, subsequently, the test phase for the homologation of the internal safety equipment of the LMP3-2020 car. After the design of the homologation portal configurations according to the applicable standard, and the production of the equipment, Carbon Mind supported the staff of HP COMPOSITES, the company for which the project was carried out, within the FIA accredited test center, for the verification of compliance with the safety requirements of the 2020 regulation.

The 14 homologation tests, conducted by combining different configurations and equipment, were carried out in the record time of half a day for the 3 days initially foreseen.

For full scale testing, contact the lab here

CLASS A PACKAGE ANALYSIS

Automotive industry bodywork components made of composite material and intended to be painted in the same color are usually referred to as “Class A Packages”.

The work carried out by Carbon Mind was to analyze the resistance to hygrothermal aging of different packages as their constituents vary: surface film, barrier, body. Furthermore, each constituent was analyzed in order to understand which intrinsic characteristics determined the successful outcome of the tests. Final objective: find the best combination for the customer.

study of new adhesives

Finding the right adhesive for each application is more complex than it seems. Thanks to a vast range of equipment and tools in the internal laboratory and the know-how on composite materials, Carbon Mind was responsible for creating a selection matrix to guide the Technical Office of a well-known company in the automotive sector to find the right compromise between the nature of the adherents, the production process and the technical requirements (mechanical, thermal, aesthetic and other special ones, such as fume toxicity, resistance to chemical agents) of the glued joint.

For product testing, contact the laboratory here

NEW MEASURING PLATFORM

The company shows its latest project at the World Endurance Championship in Sebring (USA).

Ahead of the start of the FIA World Endurance Championship (WEC) season in Sebring (USA) on 17 March 2023, Carbon Mind in collaboration with the Automobile Club De L’Ouest (ACO), which organizes the 24 Hours of Le Mans, has designed a new measuring platform that will be used to verify the compliance of the cars of competitors to the technical regulations of the discipline.

Discover the project