The process, called Powderbond – part of an Innovate UK funded project called SOLMAC – requires no surface preparation for the polymer, no activation period and is single stage, placing powder coated aluminium into a mould together with polypropylene and using the standard composite curing cycle.
Simon Saunders, founder of Ariel Motor Company, said: “The process is clean and quick, and the bond strength achieved far surpasses current adhesive-based methods.”
A typical chassis is made up of several hundred separate parts, welded and rivetted together. By creating the aluminium-composite bonds within a mould, the number of parts in the Hipercar chassis has been reduced by over 75%.
“Bonding metals and composites in a single stage gives tremendous freedom in design,” explained Powdertech director, James Grant. “Complex and intricate shapes can be moulded into the composite structure whilst also incorporating high strength metal features.”
