GreenGrip: Crafting Sustainable Bio-Composite Rackets

Purpose and goal:

The project has developed a concept for manufacturing bio-based, tubular shaped hollow composite parts using PaperShell material. For this, a BIM-technology, (Bladder inflation Molding), has been utilized. The demonstrator consisted of a handlebar for mountain bikes.

This geometry has challenges such as varying diameters over the length, conical and double curved sections. Demonstrational parts have been manufactured and material properties have been investigated and characterized in relation to process window. Expected results and effects:

The results include both process set-up and demonstrational parts. The project has lifted the TRL- level for the concept from 1-2 up to 3-4. For industrialization further work is mainly recommended in the areas of “pre-forming” and “material formulation”. The concept shows a potential to be automated for high volume manufacturing.

Approach and implementation: 1.Technology development and process set-up.

A BIM-technology was developed for moulding bio-based PaperShell material in tubular shaped, double curved, hollow geometries. Chosen tooling geometry was a MTB handlebar. Several demonstrator parts were made and evaluated. 2.Design and Materials characterization.

The influence of process parameters on both mechanical performance and void content were studied. Process window was defined.