We will help our customers think in new ways that will release the full potential of these remarkable materials.
Three fundamental issues are being addressed. First, a range of specialist military grade materials is being developed, including fibres with a blend of strength and toughness optimised to each application and a range of new matrix materials based on proven compositions usually associated with traditional areas of high volume polymer forming.
The second is the manufacturing process, an area that Scott-Geddes describes as the most challenging. The solution is a forming technique adapted from another area of polymer engineering, but at this stage exactly what this comprises is remaining secret. A pilot system is currently producing prototype components for development programmes with vehicle manufacturers and progress is said to be excellent.
The third issue is the cost of the bulk materials. Fortunately this is an area where existing production techniques are scaleable and volume commitments should be rewarded with lower prices, says Scott-Geddes. “We will soon be in high volume production with our mainstream automotive customers in fact, the first company ever to manufacture high-volume carbon composites - so our military customers will benefit from the economies of scale that this generates.”
None of the technologies Caparo is using are radical or high risk and the new approach is sufficiently credible for several vehicle manufacturers to be working with Caparo on vehicle designs that are optimised to take advantage of carbon composite components. “Early applicationswill
complement traditional materials where the benefits are greatest,” concludes Scott-Geddes. “But the biggest benefits will come when new structures and systems are developed specifically to take advantage of the material's remarkable properties. For the first time, the ability to achieve this is available to suppliers of military vehicles and technologies.”
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