Upscaling of functional bio-based automotive components fabricated by 3D printing

{{ group }}
{{ object.name }}
{{ object.name }} {{ object.subheader }} {{ icon.replace(/^icon_/, '') }}

Develop nano-enabled bio-based recyclable car part prototypes (i.e. dashboard fascia) fabricated by 3D printing with antimicrobial and aesthetic properties and improved thermal and mechanical performance.

Microfibres form the material basis for the development of bio-based dashboards for the car interior. In this test case, the main aim is to develop biomaterials that meet the high mechanical and thermal requirements. The process includes the fabrication of biobased filaments with aligned fibres. The biomaterial is then used in the 3D printing process to produce the appropriate interior car part.

Facts & Figures

  • Design prototypes
  • Selection of biopolymers (PA10.10)
  • Treatement  and production of flax and hemp microfibres
  • Compounding PA10.10 with untreated flax fibers
  • 3D-printing and characterizations of the final pieces
  • The material developed for the project meets the specifications and technical requirements of the automotive sector
TestCases-factsheets_06_05Download

Related pilot lines

Increasing efficiency in processing of nano-enabled biobased materials by additive manufacturing technologies

A unique heading prototype will allow surface modification while printing in one step.

What we want to achieve: The main benefits from this pilot line for SMEs and companies will include competitive costs of dedicated processing equipment to produce complex3D printed parts and products at a very competitive cost, unlocking a change in their manufacturing processes and reducing manufacturing time by more than 50%. Download pilot line pdf

Quality improvement of biobased coatings and nanoparticle synthesis

Improving the production quality and - quantity of bio-based lacquers and machinability of bio-based materials in Roll2Roll processes for more efficient industrial use.

What we want to achieve:
  • The advantage for customers is the flexibility in synthesis. We can produce, process or modify almost all materials (bio-based or fossil-based). In addition to the technical equipment, the safety technology is also available.
  • Through our experience, we can also scale up laboratory synthesis, so that we can also increase the TRL that have run through third parties.
  • The coating facility is also very flexible and can even process rigid substrates.
  • The equipment (upgrade of the pilot facility) with the SiOX system is unique in the world and offers barrier coatings without the use of vacuum for polymer and fibre based substrates.
Download pilot line pdf

Compounding and processing of nano-enabled bio-materials

The Extensional Flow Mixer METEOR (patented by IPC) is used to develop new formulations with an efficient dispersion of additives while reducing the overheating, and so the thermal degradation of sensitive material, like PLA.

What we want to achieve:
  • A quality control will be integrated thanks to an inline capillary rheometer to be able to optimize compounding parameters. Control compounding parameters for zero material degradation and optimize distribution of the micro and nano-fillers.
  • Inline integration of 3D printing filament at 2 diameters 1.75 and 2.85 mm. Additionally, a flexible cooling system will be implemented with water or air for water-sensitive materials.
Download pilot line pdf

Increasing the production of bio-based nano composites

Melt blending processes as the key to efficient production of bio-based compounds of nano composites.

What we want to achieve:
  • We will be able to support SMEs and companies interested in the development of nanocomposites with no experience in nanomaterials handling at the industrial scale, from the materials fine-tuning (few kg) up to pilot scale (50 kg) for materials qualification, without any preliminary nanosafety investment in their plants.
  • Also, industrials interested in printed electronics from nano-enabled materials, will find a unique environment which will allow them to deal with the nano-safety issue during the development of new materials, up to development of 2D substrates for preliminary printing test, in coordination with the CEA-PICTIC pilot line.
Download pilot line pdf

Processing & modification of micro natural fibres

Optimisation natural microfibers flax or hemps as an important component of biocomposites.

What we want to achieve:
  • The fibers can show high adhesion to any polymer matrices and can be functionalised by different method to meet final requirements.
  • There is lack of such raw materials on the markets. Small fiber dimension allows to produce precise composite elements.
Download pilot line pdf