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efcient injection, and Koschkar notes that BMW is keeping a close eye on thermoplastic material options as well. Wackersdorf produces 39 diferent stacked kits for the i3 Life Module, and from these, BMW in Leipzig and Landshut produces 49 preforms (some stacks produce more than one preform). Tese preforms are then combined to mold, ultimately, 16 carbon fber parts for the i3. Te largest and most complex carbon fber struc- tures made for the Life Module are the lef hand and right hand side frames. Each comprises nine preforms that are placed in one mold. Te dimensional stability and strength of this structure are both critical parameters, because, as will be shown, much of the i3's subsequent form and assembly process is oriented around these parts. Afer cure, parts are robotically de- molded and transferred to one of two sandblasting stations for removal of mold release and other contaminants. Clean components are then moved to one of four KMT Waterjet Systems Inc. (Baxter Springs, Kan.) waterjet cutting machines for trimming and hole drilling. Koschkar pointed out that process control at the plant is such that discovery of fatal faws in fnished parts is rare. Quality assur- ance, therefore, is performed on a ran- domized basis only, using a nuclear mag- netic resonance technology that reveals dry spots and delamination problems. Afer trimming, drilling and (if neces- sary) quality assurance is complete, the carbon fber composite parts are deemed ready for assembly, loaded into special- ized racking systems, and then trans- ferred to the Body Shop. LIFE MODULE ASSEMBLY Housed in a separate building on the Leipzig campus, the Body Shop supports some of the most technically complex aspects of i3 manufacture — assembly of the Life Module's 16 RTM'd parts. Te job is complex for two reasons: First, no mechanical fasteners are used to attach one part to another — the Life Module is completely adhesively bonded. Second, no touch labor is involved in Life Module assembly — adhesive application and part manipulation are automated. Body Shop head Ralf Brüggemann, like Koschkar, manages most of the op- erations in the facility from a mezzanine that overlooks the plant foor. At frst glance, the Body Shop visitor confronts a sea of orange robots (173 in all, supplied by ABB Robotics, Zurich, Switzerland), constantly turning, rotating, lifing and placing black carbon fber parts and structures in an array of discrete, enclosed assembly cells. Only occasionally does one see shop personnel move components from one cell to another. With Brüggemann's guidance, it becomes clear how the facility functions. Life Module assembly starts with the addition to each side frame of other parts, including door-hinge reinforcements and a door latch (both metal), an injection molded thermoplastic honeycomb crash-protection system (mounted along the frame bottom) and a 2-inch/51-mm diameter braided carbon fber roll with a foam core, which provides support in case the car rolls during an accident. Surface Engineering for Composites TFP's advanced nonwovens provide efective lightweight solutions for: • High Quality Surface Finish • EMI Shielding • Electrical Conductivity • Static Dissipation • Abrasion Resistance • Fire Protection E: inquiries@tfp-americas.com • T: 1 518 280 8500 TFP is part of James Cropper plc, a specialist paper & advanced materials group www.tfp-americas.com Visit TFP at SAMPE Seattle on booth L24 Technical Fibre Products are a leading manufacturer of advanced nonwovens, ofering both a diverse range of high quality nonwovens and the expertise to develop materials to meet specifc performance, process or aesthetic requirements. TFP's nonwovens are compatible with all common composite manufacturing techniques and resin systems and provide an improved surface fnish with additional functionality such as conductivity, EMI shielding or corrosion resistance. Technical Fibre Products Inc. C T J U N E 2 0 1 4 2 9 0614CT IM-OK.indd 29 5/20/2014 8:37:30 AM