Sustainable rPET-based formulations for high quality Automotive components
AOC and BÜFA have helped Quantum Mouldings to make high quality pop-top roofs for camper vans, using AOC’s novel rPET-based Synolite™ 4600-G-1 products, and BÜFA’s Neogel® 3000 series gelcoats. Besides offering mechanical strength and great part aesthetics, the use of rPET-based formulations helps to reduce the environmental footprint, a feature highly valued by customers and consumers.
Quantum Mouldings is a well-established manufacturer of composite components used in automotive and transportation, industrial, marine, and leisure applications. The company is specialized in medium volume production, typically 1,500 to 5,000 parts per year.
Multiple composite transformation processes are deployed in the Quantum Mouldings’ factory in Kidderminster (UK), including RTM, Hand lay-up and Spray lay-up. The company has a reputation of manufacturing high quality parts, made with high accuracy and dimensional consistency.
Performance requirements
One of the products made by Quantum Mouldings is a “pop-top” elevating roof, used in the retrofit market for converting conventional vans of different brands into camper vans. The parts need to combine a premium colour and surface finish, with high mechanical integrity and durability.
“During hot summers, the parts can heat up to temperatures above 80 °C in service, particularly when they are in dark colours”, explains Mark Young, Managing Director of Quantum Mouldings. “Therefore, it is very important the parts do not deform and remain in shape when exposed to heat.” The gelcoat finish must also be colour fast and resistant to UV aging to ensure that the pop top stays looking good year after year.
Processing robustness
For this demanding application, the company is using a combination of AOC’s Synolite™ 4600-G-1, a formulation used in RTM and vacuum infusion based on recycled PET, and BÜFA’s Neogel® 3000 series gelcoats. Quantum Mouldings value that the resin features low shrinkage, resulting in low warpage and good dimensional predictability during processing.
“We have seen that the Synolite™ 4600-G-1 also has a lower exotherm compared to the products we were using in the past. This translates to less stress on the moulds and a longer tool life compared to using other resins”, adds Mark Young. “Compared to DCPD resins, the parts can also be demoulded more easily and faster, with less risk of sticking. The flexibility to cure the resin with different peroxide types and concentrations allows us to use this one product in a number of different parts with different size and complexity.”
Better performance in sustainability
The Synolite™ 4600 series products are based on recycled PET, coming mostly from post-consumer waste. For each single ton of product, approximately 4,000 scrapped PET bottles are consumed, ensuring the efficient reuse of a valuable raw material. The Synolite™ 4600 series products have also been certified by Lloyd’s.
“We are seeing big interest from our customers for applying these rPET-based formulations for their composite parts”, comments Fons Harbers, Vice President Marketing and Sales for AOC EMEA. “While it takes more effort and additional process steps in manufacturing rPET-based products, we believe it is worth it and helps in reducing the carbon footprint of our customers’ products.”
“We enjoy a lot working as one team with Quantum Mouldings and AOC, making parts with a good balance of performance and quality at competitive system cost’, concludes Eddie Putwain, General Manager of BÜFA Composites UK. “The demand for reliable products that simultaneously bring great environmental performance will only grow in the coming years. So we are ready to help our customers in taking big steps for improving sustainability performance.”
