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On 12th February 2004, the Ford Motor Company signed an agreement
with Sotira s.a. regarding the Ford Programmable Preform Production
(F3P) process allowing for this innovative technology to be
offered to companies outside of the Ford Group.
This fully automated F3P process developed by Ford Motor Company
utilises a 6-axis robot, which provides a high degree of repeatability
for the manufacture of quality products. The combination of
computer-guided robot and state-of-the-art glass fibre delivery
system results in a preforming process that has obvious technological
and economic benefits.
F3P can significantly reduce the cost and improve the quality
of liquid composite moulded parts. It uses modern computer-controlled
technology to provide a high level of consistency and accuracy.
The process makes use of male and female perforated screens
to produce a preform to the same size and shape as the finished
part. F3P uses low-cost conventional fibre rovings, which are
fed to the machine via a glass handling system. A unique SMART
chopper gun mounted at the end of a seven-axis robot initially
sprays a glass fibre veil on to the lower screen and air is
sucked through it to hold the glass in place. The veil layer
both assists in de-moulding of the preform and is used to achieve
the required class-A surfaces. With the veil completed, chopped
or continuous glass fibres are sprayed onto the screen, either
randomly or oriented to allow efficient structural laminates
to be produced.
©
Aston Martin Lagonda Ltd
This new technology has been pioneered on the Aston Martin V12
Vanquish vehicle, where the bodysides and upper cargo deck are
produced using this process.
Other key F3P benefits include:
1. High-consistency preforms.
2. Excellent precision in the fibre
placing.
3. "Class A" surface.
4. Controlled thickness variation.
5. Superior control of glass distribution.
6. "Deep draw" geometry.
7. Easy demoulding.
One of the process's paramount economic benefits is the minimum
level of waste produced, which is considerably lower than for
other preforming processes. Other advantages include:
1. Lower raw material cost than with
some alternative processes such as mat-thermoforming.
2. Low energy consumption.
3. Net shape and net size preforms,
eliminating the need for trimming.
These features, particularly the use of low-cost raw materials,
make F3P extremely cost-effective compared to other preforming
processes. The end result is a net shape and net size preform.
© Aston Martin Lagonda Ltd
This technology is now also being exploited on the newly launched
DB9 vehicle where the manufacture of decklids, decklid surrounds,
door rings and sills all include F3P preforms. |
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