Increasing production efficiency in the discontinuous processing of reactive plastics
In the “VarMischung” project, running until March 2026, IKV investigated how variable catalyst concentrations during the dosing of reactive resin systems can be used to mitigate the trade-off between long flow lengths and short cycle times in low-pressure RTM processes. To this end, the reaction kinetics and rheological behaviour of an epoxy resin system were characterised experimentally. The results reveal an almost linear relationship between catalyst content and reaction rate, enabling the curing behaviour to be actively controlled along the flow path.
Based on these material data, a time-resolved simulation model was developed that captures the coupled interaction of mould filling and local curing. From more than 300 simulated catalyst combinations, it was demonstrated that variable catalysis can reduce the overall process time, particularly for medium to long flow lengths, while offering no benefit for short flow paths. Complementary mechanical testing further showed no significant effect of catalyst content on the mechanical properties of the cured material. For experimental validation, a modular dosing concept was developed and a plate mould was upgraded with pressure, temperature, and DEA sensors.
© IKVProject data and funding
We would like to thank the BMWE for funding the IGF project (funding code 23299 N) and the project partners for their cooperation.
Project duration: 01.03.2024 – 28.02.2026
