Porsche develops TABASKO method for lightweight vehicle series production
Patented carbon fiber-reinforced polypropylene tape-based process supports cost reduction, light weight and thinner walls without sacrificing rigidity.
Share
Read Next
To test the properties of TABASKO, Porsche used the material to build a luggage tray. The tapes are placed in the component as upper and lower belts in alternation, meaning that they form a virtual sandwich. The spacing in the peripheral positions enables high flexural rigidity with minimal use of tape. Source (All Images) | © Porsche Engineering
Close cooperation between Porsche Engineering (Weissach, Germany) and Porsche AG’s (Stuttgart) material experts has resulted in the development of TABASKO, a patented tape-based carbon fiber construction method that can create composite components that combine maximum strength and minimum weight while also making use of post-consumer recycled materials, all in a series production process — thus supporting more sustainable automotive construction.
The goal behind TABASKO (coming from German for “tape-based carbon-fiber lightweight construction”) was to achieve better material properties at a reduced weight and cost. Currently, many Porsche vehicle components are made of glass fiber-reinforced polypropylene (PP) called PP-GFx. Porsche wanted to consider the use of carbon fiber — however, carbon fiber is still a considerably expensive material. Therefore, they had the idea of reinforcing PP with strategically placed carbon fiber tapes, using less material (and thus reduced cost) and achieving thinner walls, all without sacrificing rigidity.
Porsche’s work with a supplier also supported TABASKO’s use in series production. “The question was: How can you produce up to 80,000 parts a year — in a fully automated way and cost-neutral compared to today’s process?” explains Frank Häusler, materials expert at Porsche AG.
Top view of the strips of tape, which are only 0.2 millimeter thick. The carbon fiber filaments run lengthwise without interruption, which increases the rigidity compared to PP-GFx by a factor of 20.
TABASKO is fully automated and uses conventional equipment. It involves “inserting tapes into forming tools by means of a handling device and attached to either the top or the bottom of the component using vacuum channels,” so they can be easily attached to the component, an additional advantage for production costs. Successful prototype tests involving luggage trays has proven its ability to increase rigidity, reduce weight by up to 20% and that recycled plastics are suitable for component production.
Six patents have been filed for TABASKO, for the material structure, the production method, the tool technology and the process sequence in series production.
.
Related Content
-
JEC World 2024 highlights: Thermoplastic composites, CMC and novel processes
CW senior technical editor Ginger Gardiner discusses some of the developments and demonstrators shown at the industry’s largest composites exhibition and conference.
-
The potential for thermoplastic composite nacelles
Collins Aerospace draws on global team, decades of experience to demonstrate large, curved AFP and welded structures for the next generation of aircraft.
-
Welding is not bonding
Discussion of the issues in our understanding of thermoplastic composite welded structures and certification of the latest materials and welding technologies for future airframes.