FastRTM Project Successfully Demonstrates Rapid Manufacturing of Complex, Net Shape, Structural Composites Using Hexion Fast-Cure Epoxy System

COLUMBUS, Ohio–(BUSINESS WIRE)–A unique, automated production platform developed by a French industry
consortium – and utilizing an epoxy resin system from Hexion Inc.
(“Hexion” or the “Company”) – has demonstrated the feasibility of
manufacturing large, net-shape composite parts at industrial scale. It
offers a model for automotive manufacturers seeking to integrate
weight-saving structural composites into their mass production vehicles.

The fully automated manufacturing platform, developed by the French
FastRTM consortium led by the Institut de Recherche Technologique –
Materiaux, Metallurgie et Procedes (IRT M2P), consists of a press,
modular tooling, high pressure injection machines,
temperature-controlled flow tube technology, two 6-axis robots, online
monitoring and control, and a fast-cure resin system from Hexion.
Together, the equipment and materials enable an innovative process
called compression resin transfer molding (C-RTM).

In this two-step process, Hexion’s resin system – EPIKOTE™ Resin TRAC
06170 / EPIKURE™ Curing Agent TRAC 06170 /HELOXY Additive TRAC 06805 –
is injected into a mold with a preform, a preliminary fiber shape, when
the press is slightly open, allowing for partial impregnation. Then, a
compression stroke presses the resin through the preform for complete
impregnation. This allows for very fast resin injection and curing –
from 15 seconds to one minute – and less than two-minute part-to-part
production.

“Hexion is proud of the contribution we have made to the success of the
FastRTM project, which closed in December,” says Ann Frederix, Senior
Vice President, Epoxy Specialties. “In its last year, the consortium
achieved some major milestones, including a final, successful mass
production session.”

This final manufacturing session demonstrated:

• Automated production of 100 large (1m²), complex, net shape glass
  fiber reinforced plastic structural parts in two-minute part-to-part
  cycle times
• Curing times as short as one minute per part
• No need for machining or trimming post-production
• Part perforation prepared at the preforming step and maintained during
  injection step (no need to drill holes for assembly following part
  production)
• Simulated “start and stop” with no adverse reactions in the process
• Consistently high-quality parts with excellent mechanical performance
  and uniform impregnation (no fiber distortion, dry spots or unfilled
  resin at ends)

The epoxy thermoset composite parts made with the Hexion resin system
can also be recycled or recovered at the end of their useful life via
mechanical recycling, thermal recycling, and chemical recycling.

The FastRTM project was led by the IRT M2P, a research center which
brings together industrial and public research entities to accelerate
innovation and develop key technologies, based on public-private
coinvestment and partnership. The FastRTM consortium members included:
Renault s.a.s., the Faurecia Group, the Hutchinson Group, Hexion, the
Chomarat Group, Arkema Inc., Composite Integrity by Institut de Soudure
Group, Pinette Emidecau Industries (PEI), Compose Tools, and the Societe
d’Industrie et de Service Electrique (SISE).

Hexion will continue to collaborate with industrial leaders on
automating, accelerating and improving the production of preforms with
Hexion binder systems, through another French-based consortium, the
FastFORM project.

The complex demonstrator part produced as part of the FastRTM project,
along with a real-life automotive inner deck lid demonstrator, will be
on display in Hall 6, Booth G52 at the JEC show in Paris, March 6 to 8.

About the Company

Based in Columbus, Ohio, Hexion Inc. is a global leader in thermoset
resins. Hexion Inc. serves the global wood and industrial markets
through a broad range of thermoset technologies, specialty products and
technical support for customers in a diverse range of applications and
industries. Hexion Inc. is controlled by investment funds affiliated
with Apollo Global Management, LLC. Additional information about Hexion
Inc. and its products is available at www.hexion.com.

Contacts

Hexion Inc.
John Kompa, 614-225-2223
[email protected]