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A non-structural, horizontal, class A closure panel has been produced by the partners of a consortium development project “Recycle” for a Lotus Elise derivative, to reduce weight and improve recyclability over the current glass-reinforced polyester system.
Panels were moulded in 2.5mm thick self-reinforced polypropylene using a stamp forming process. Stiffening brackets for the front access panel were also moulded in 2.5mm self-reinforced polypropylene.
The parts were trimmed by water-jet cutting, painted and assembled with the stiffening bracket and location pins. Acrylic adhesive was used to bond the brackets to the panels using a single lap joint which performed well and in accordance with BS5350.
The self-reinforced polypropylene parts were painted by out-of-mould painting using standard low-bake paint systems (with prior surface treatment) and passed the full range of surface quality and environmental tests.
At end-of-life, self-reinforced polypropylene mouldings can be recycled using existing dismantling infrastructure and recycling technologies, and self-reinforced polypropylene has been shown to be sustainable from environmental, social and economic viewpoints.
The self-reinforced polypropylene gave a realistic alternative to the glass-reinforced polyester system. Significant weight savings were made, as the self-reinforced polypropylene part was 57% lighter than the original component and a detailed cost analysis showed that the self-reinforced polypropylene solution was cost-neutral.
Prototyping and testing of this case study component was the result of work carried out by the collaborative partners of the “Recycle” project;
Recycle Partners; NetComposites, Lotus, Propex Fabrics, BI Group, LTI, Traumalite and the Warrick University Manufacturing Group (WMG).
- Undertaken in collaboration with Lotus Engineering, Propex Fabrics and the University of Warwick as part of the ‘Recycle’ project
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