High-Volume Aerodynamic Panels Through RTM/SMC Processes

A major European commercial vehicle manufacturer faced a critical production challenge. Their conventional metal front panels were too heavy, contributing to excessive fuel consumption and fleet emissions. The company needed lightweight, aerodynamic components that could be produced in volumes exceeding 15,000 units annually. Traditional hand lay-up methods using composite materials simply couldn't meet these volume demands while ensuring the precision and repeatability necessary for series production.

BV PLAST proposed an innovative dual-process approach, utilizing both Resin Transfer Molding (RTM) and Sheet Molding Compound (SMC) technologies. These advanced manufacturing methods combine the exceptional benefits of composite materials with true industrial-scale production capabilities.

The RTM process proved ideal for complex main components. Dry fiber reinforcements are precisely positioned in a closed mold before resin is injected under controlled pressure. This creates complete fiber saturation and produces dimensionally accurate parts with exceptional Class-A surface finish on both sides. The process is particularly well-suited for large, complex geometries like aerodynamic fairings, maintaining tolerances within ±0.5mm.

For higher-volume components with simpler geometries, BV PLAST implemented the SMC manufacturing process. Pre-impregnated fiber-resin sheets are placed in heated compression molds and cured under high pressure. With cycle times of just 3-5 minutes, this process enables exceptional throughput while maintaining consistent quality across thousands of parts.

 

The Implementation

BV PLAST developed a complete front panel system that strategically leveraged both processes. The main aerodynamic fairing, measuring 180cm × 140cm with complex integrated air deflection elements, was produced using RTM to achieve optimal geometry and surface quality. Side panels with mounting brackets and reinforcement elements were manufactured through SMC, ensuring cost-effective high-volume production.

The Results

The results exceeded expectations across all key metrics. The new composite components achieved a remarkable 45% weight reduction compared to steel construction, translating to 85kg weight savings per vehicle. The optimized aerodynamic geometry reduced the drag coefficient by 12%, resulting in 3-5% fuel consumption reduction and annual CO₂ savings of 2.8 tons per vehicle.

The RTM process delivered a 45-minute cycle time with Class-A surface finish and production capacity of 8,000 units per year. The SMC process achieved even greater efficiency with 4-minute cycle times, 25,000 units per year capacity, and a scrap rate below 2%. Components passed rigorous testing for impact resistance, UV stability, and temperature extremes from -40°C to +80°C.

Most importantly, the return on investment was achieved within just 18 months through reduced material and labor costs, minimal finishing requirements, and lower warranty claims.

 

"BV PLAST's expertise in both RTM and SMC processes gave us the perfect combination of quality and volume production. The RTM parts deliver the complex geometries we need, while SMC components provide cost-effective high-volume manufacturing. This has transformed our efficiency."
- Head of Procurement, Commercial Vehicle Manufacturer

 

Advanced Manufacturing for Modern Demands: BV PLAST's RTM and SMC processes combine the superior properties of composite materials with industrial-scale production efficiency.

Contact us to explore how advanced composite manufacturing can optimize your production.