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Lola use innovative DForm

Lola Composites Ltd, based in Huntingdon, Cambridgeshire - United Kingdom, has made extensive use of an innovative DForm® Deformable Composite System (DCS) carbon prepreg tooling system from Advanced Composites Group Ltd (ACG), part of the Composites Division of Umeco plc.

Over the last twelve months Lola Composites, a member of the Lola Group of companies, and a globally recognised supplier of advanced composites to the aerospace, defence, communications, automotive and marine sectors, has used ACG’s DForm DCS for tools in a number of programs. As Rob Hewison, Lola’s Technical Manager, said: “It has performed exactly as ACG predicted, giving us improved surface finish and a reduction in laminating time over the more traditional woven systems.” He continues: “We are often very sceptical of claims regarding improvements in quality with the ability to manufacture tooling more quickly but, in both respects, DForm has delivered!”

Importantly for Lola, the revised system was quickly adopted and implemented by the tooling shop with no problems being discovered, which is unusual as this is often the stumbling block in a department where you, more often than not, only get one chance to get the job right. The surface finish from a unidirectional based reinforcement is significantly better than that from a heavier woven reinforcement, although Lola still uses a lightweight woven first ply, the system can be used with the unidirectional material on the surface. Rob Hewison states: “We keep the first ply as woven to guarantee durability, but we have tools in production with a unidirectional face that has been proven to be perfectly durable, producing hundreds of phenolic aerospace interior parts with no apparent degradation. He continues: “In particular, we are looking at the system as a step forward in the drive for ‘A Class’ automotive composite tools as the tool has a significantly flatter finish than a traditionally manufactured prepreg tool.” Rob Hewison concludes: “We like the system, and even on our complex race-car tooling, we find it to be easier to lay up than the more traditional all woven systems.”

Due to its clients’ preferences, Lola continues to use the entire suite of tooling materials which ACG offers. However, where possible, Lola promotes DForm as a completely viable alternative on the basis that it will allow the client to reap the benefits of the system. Lola is keen to look at future developments in ACG’s tooling system for production of components.

Due to the increased uptake of ACG DForm, the Group recently installed new, custom-built processing equipment at its Heanor manufacturing facility to further enhance and accelerate the productivity rates of this ground-breaking tooling and mass production component prepreg.

Originally previewed in 2008, DForm is a labour and cost-saving prepreg technology and advanced DCS that combines the conformability of a short fibre moulding compound with the directional characteristics of a high performance, long fibre composite. This unique combination of characteristics is achieved through selective fibre slitting of a unidirectional prepreg precursor. DForm does not require detailed laminating or extensive vacuum debulking. On the contrary, it readily flows under press or autoclave pressure to replicate the precise details of a complex mould tool or components.

DForm for Tooling:
When compared to standard fabric-based tooling systems, DForm offers considerable savings in lay-up times (typically in the region of 20 to 30% reduction) through operational de-skilling, brought about through ease of application, as well as a readily achievable, superior surface finish. Furthermore, the directional nature of DForm’s structure helps to maintain dimensional accuracy and performance predictability, thereby presenting a major advantage over random short fibre and resin infusion tooling systems. An added advantage is DForm’s ability to create an extremely flat, print-through free surface profile with no local thinning or loss of fibre orientation.

DForm for Components:
Like all of ACG’s prepregs, DForm can be customised to suit customers’ specific requirements, and is particularly suited to high volume semi-structural applications.

Dr. John Nixon, ACG’s Technical Marketing Manager, said: “This new, market leading technology is an exciting addition to our extensive product range. DForm will allow customers to save money and improve efficiency whilst maintaining the high standard expected of our products. We look forward to working with customers to find and develop new and exciting applications for such a versatile technology.”

For more information on DForm and Advanced Composites Group please click on to http://www.advanced-composites.co.uk/general_archived_news_index_2009.html