UK manufacturer awarded JEC Prize for composite tech in Hyundai Car

Hyundai and its design partner, UK-based Axon Automotive, have been awarded the Jury Prize at The JEC 2015 for the composite technology in the chassis of the ‘Intardo’ hydrogen-powered crossover car.

The super-lightweight carbon fibre-reinforced plastic (CFRP) car chassis is manufactured using two advanced composite materials developed by Scott Bader.

Firstly, the vacuum infused chassis components for this new Intrado concept vehicle use Axon Automotive’s innovative ‘Axontex TM’ structural beam technology, which has Scott Bader’s Crestapol 1250LV as the specified high performance acrylic thermoset resin.  

Secondly, all of the chassis and frame CFRP components are robotically bonded together by Axon using Crestabond M1-20 primer-less structural adhesive, with no mechanical fixings needed resulting in an automotive chassis with the strength and stiffness of a similar steel structure, but with a 70 percent saving in the overall chassis weight.   

First unveiled in 2014 at the Geneva Motor Show, the Intrado car is still at the concept stage and therefore the chassis is manufactured for Hyundai in the UK by Axon at its factory in Northamptonshire, where it moulds and assembles the CFRP chassis to Hyundai agreed specifications.

For more than two years, the Axon team has worked in close collaboration with Hyundai’s European Technical Centre, Scott Bader’s technical teams, and the two key carbon fibre supplier partners, Hyosung Corporation and Lotte Chemicals, to develop the exact design specifications needed for the chassis and frame of the crossover vehicle. 

A key objective set by Hyundai was to achieve the lightest weight possible for the final assembled chassis and frame of the Intrado to maximise the range and performance of this zero emissions, hydrogen-powered vehicle.

Dr Kevin Lindsey, Technical Director for Axon Automotive, commented: “Significant additional weight savings were achieved in the final assembled chassis by being able to bond all the sections together.

“The Crestabond structural adhesive has an ideal combination of high load bearing adhesion strength, with flexibility, toughness and high impact resistance, even at low ambient temperatures.”