Students in the Bachelor’s specialization in Plastics Engineering manufacture a vehicle entirely by hand. As part of their studies, they independently produce all the components for the chassis. From the carbon floor plate to injection-moulded steering components, 3D-printed frame parts, and impact elements made from polyurethane – even real rubber tyres are produced. Through various exercises, the students learn a wide range of manufacturing processes and, in the end, hold another self-made component for their model car in their hands.
© IKV
© IKV
© IKV
© IKV
© IKV
© IKVCar body – Thermoforming
The body you may be holding in your hands right now is manufactured using the thermoforming process . In this case, a polystyrene film 0.8 mm thick is heated under a ceramic radiator and formed around a mould, supported by a vacuum. The panes for the body are also produced using the thermoforming process. Before that, you will have the opportunity to accompany the production of the film in the flat film extrusion process.
Steering components – Injection molding
The steering components are manufactured using the injection moulding process, a fully automated primary moulding process for plastics. Plastic melt is injected into the appropriate mould under high pressure and solidifies in the cooled mould. The components are automatically ejected by the machine and are ready for immediate use.
Frame – Additive manufacturing
For complex components or components that are only to be produced in small series, additive manufacturing offers a way to produce components without molds. In the simplest case, a filament strand is heated and plasticised and then deposited by a fine according to a previously defined path. There are virtually no limits to creativity in this process. In the IKV workshop “3D printer driver’s license” you can learn guidelines and practical tricks for a correctly designed component.
Base plate – vacuum infusion for carbon fibers
If particularly high rigidity and low weight are required, parts made of carbon fiber-reinforced plastic are the material of choice. These can be produced automatically in series processes, but also by hand. Carbon fiber fabrics are stacked according to load direction and infused with a synthetic resin system under a film using a vacuum. Once the resin has cured, the component can be removed and reworked before being used as a high-performance component in the model car.
Impact elements – polyurethane processing
Polyurethanes are extremely versatile and can be adjusted as thermoplastics, elastomers and thermosets. Polyurethanes are very popular for the production of foam. This is also used for the impact elements of the model car. For this purpose, water is added to one of the two components of the PUR system, which reacts with the other component to formCO2, among other things, and thus forms a foam. The foam for the impact elements is also adjusted elastically by selecting the appropriate components.
Tires – Rubber production
Many steps are necessary before rubber, the starting product of rubber, can be turned into tires. First, the rubber is mixed with other ingredients to improve its properties. The rubber compound is then formed into tread strips through the extrusion process, which can then be wrapped around a tire mold. The final shaping of the tire takes place in a pressing process under pressure and temperature, the rubber vulcanises into rubber. In the tire exercise as part of the rubber technology lecture, you can put together your own tire compound and produce the tires for your model car at the end.
And the drive?
Special bonus: At the end of your bachelor’s degree in plastics technology, you will receive a battery, drive, remote control and steering servo from us to complete the model car.
About the “Plastics and Textile Technology” specialization for mechanical and industrial engineering students
With a wide range of topics – from macromolecular chemistry and materials science to plastics processing methods and the plastic-compatible design of components – plastics technology is a very comprehensive but also clearly defined specialist area in the field of mechanical engineering.
Students studying plastics technology learn how the special and variable properties of plastics can be used specifically to manufacture economical, resource-saving and innovative products.