Design & Development
Material Development
Special applications require special materials.
Whether extreme environmental conditions, multi-axis loads or other complex requirements, we work with our network partners to design the ideal material for you that is precisely adapted to the requirements of your product.
Depending on the selected fibers, the layer structure and the wall thickness of the product, lightweight structures with almost any required property can be achieved. In contrast to conventional manufacturing processes and materials, complex geometries with undercuts are comparatively easy to achieve using fiber composite technology. Composites made of carbon fibers thus increase the scope for construction and design and therefore the power of innovation.
A special kind of surfaces
By selecting the appropriate material, different surfaces with the required fiber structure and surface quality can be produced, depending on whether the component is used in the interior or exterior.
Our Services:
- Development of materials to implement customer requirements
- Testing new materials and their combinations
- Carrying out material tests, for example determining mechanical properties under different climatic conditions or testing fatigue strength
- Improving the surface quality for Class A applications by using the latest in-mold coating technology.
Product Development
We design using state-of-the-art software and work closely with design and development departments. We work with the following CAD interfaces: UG, ProE, I-DEAS, STEP, IGES, VDA.
We use our many years of expertise to model and simulate designs and material composites and we check their suitability for the required application. Naturally, we always use the latest development methods. This often results in completely new advantageous design options for our customers, for example by using fillers or improving the design.
The focus is on short development times and few optimisation loops as well as on an economical production process.
Our Services:
- Production-oriented design
- Component design / FEA simulation (Finite Element Method)
- Functional testing at part or component level
Carrying out tensile and compression tests, DMA, DSC or FVC tests - Development in accordance with IATF16949
- Testing and development of recyclability
- Evaluation of life cycle assessment / carbon footprint
Re-thinking design – weight saving with higher stability
Double-shell SMC construction
Part consists of an upper and lower shell, which are bonded together
Sandwich SMC construction
Part consists of a circumferential shell which is filled with a plastic core
Bench Test
A prototype is produced based on the new design
Computation
CAX tools are used to calculate and visualize load simulations such as reaction to stress and displacement on the part
Integrated Functionality
For special requirements, functional elements and reinforcements, damping, but also complex electrical wiring or sensors can be integrated into the semi-finished product before final production in the preforming process.
By using TFP (Tailored Fiber Placement) technology, the semi-finished product is also provided with reinforcing structures through technical embroidery.
Example of AMG GT wheel arches
Local TFP reinforcement, for example for impact protection in the wheel arch of a car
Example of AMG GT wheel arches
Multi-material composite with glass fiber preform, cork and metal inserts
Example of AMG GT wheel arches
Finished component
Process Development
Efficient production that meets the highest standards of quality and functionality is our goal from the very first step of process development. One of the decisive criteria when selecting the production process is therefore the quantity to be produced. We plan the tool design in line with this and develop and simulate production scenarios that are suitable for your product.
Our services:
- Further development of existing processes
- Development of automation options for larger quantities without compromising quality
Contact
eacc HQ
Fritz-Müller-Straße 11-27
73730 Esslingen am Neckar
Tel.: +49 711 185 678 0
E-Mail: info.eacc.ug@mail.toray