Research and development and delivery of innovative materials and processes has been key for Stalcom Automotive Technologies.

SECRET TO LIGHTWEIGHTING SUCCESS

For the past 20 years Stalcom has been developing new ways of combining light metals, including higher strength Aluminium and Magnesium with a variety of Thermoset and Thermoplastic composites to optimize strength and rigidity, while keeping costs to a minimum and whilst striving to deliver sustainable circular economy solutions. Extensive R & D has developed solutions with the best material types for particular applications and recommended forming and fabrication processes, surface treatments and joining techniques.

KEY STRUCTURAL TECHNOLOGIES

Stalcom Automotive Technologies develops its own solutions and has particularly interesting IP in several key structural technologies. These are initially focused on the requirements of the niche volume sectors but Stalcom’sexperience can equally be applied to higher volume vehicles.

Flex-tech is a system of extrusions developed with a unique interlocking feature developed and patented by Stalcom.

  • Interlocking thin-wall extrusion system
  • Creates a bonded and riveted spaceframe structure with extruded joining ‘nodes’
  • Eliminates the need for expensive tooling
  • Allows rapid and low-cost delivery of lightweight aluminium spaceframe structures.
  • When combined with aluminium or thermoplastic-composite in-fill panels, the assembly is ideal for primary chassis and body structures.

See Case Study

Flex-tech is a system of extrusions developed with a unique interlocking feature developed and patented by Stalcom.

  • Interlocking thin-wall extrusion system
  • Creates a bonded and riveted spaceframe structure with extruded joining ‘nodes’
  • Eliminates the need for expensive tooling
  • Allows rapid and low-cost delivery of lightweight aluminium spaceframe structures.
  • When combined with aluminium or thermoplastic-composite in-fill panels, the assembly is ideal for primary chassis and body structures.

See Case Study

PowderbondPP is a breakthrough process for joining metal to polypropylene (PP) with unrivalled bond strength and is quick, clean and cost effective.The Powderbond product is a specially formulated powdercoat applied to metal parts that allows structural joints to be made to polypropylene based composites using heat and pressure – these joints are stronger than adhesive based joining systems. Stalcom is a development partner in the creation of Powderbond and lead development of automotive applications, developing IP in the use of this joining technique.

PowderbondPP is a breakthrough process for joining metal to polypropylene (PP) with unrivalled bond strength and is quick, clean and cost effective.The Powderbond product is a specially formulated powdercoat applied to metal parts that allows structural joints to be made to polypropylene based composites using heat and pressure – these joints are stronger than adhesive based joining systems. Stalcom is a development partner in the creation of Powderbond and lead development of automotive applications, developing IP in the use of this joining technique.

No Adhesive Needed

Lean Process - Fast Cycle Time

Repeatable Joint Performance Ideal for Automated Application

No Pre-Treatment of PP Required

STALCOM LIGHTWEIGHT LAMINATE (SLL)

Stalcom Lightweight Laminate is a tough, lightweight, hydrid material (patent applied for).
  • Created by sandwiching aluminium between layers of pierce resistant composite (pp/glass)
  • The layers are joined using Powderbond™ joining process
  • The scaleable manufacturing process allows specific desirable characteristics to be combined in a single assembly
  • Developed with EV battery applications in mind but with many potential applications.

Watch the Video

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STALCOM LIGHTWEIGHT LAMINATE (SLL)

Stalcom Lightweight Laminate is a tough, lightweight, hydrid material (patent applied for).
  • Created by sandwiching aluminium between layers of pierce resistant composite (pp/glass)
  • The layers are joined using Powderbond™ joining process
  • The scaleable manufacturing process allows specific desirable characteristics to be combined in a single assembly
  • Developed with EV battery applications in mind but with many potential applications.

Watch the Video

THERMOPLASTIC COMPOSITES

Underlying these innovations is a deep understanding of the use of composites for niche volume structural applications and acknowledging the importance of developing solutions that use affordable, sustainable new high strength composite materials. Working with composites offers the ability to produce, lighter, tougher parts at low cost. These have mainly been thermoplastic long fibre reinforced materials where extensive development is ongoing in many markets. Stalcom has application development relationships with a number of materials suppliers globally, including with Huesker for their W8SVR composite, and we leverage these to deliver class leading solutions.

COMBINING FUNCTION WITH AESTHETICS

  • W8SVR neolaminate composite, when moulded with appropriate techniques, can give excellent decorative “technical surface appearance”.
  • In some applications it can offer better absolute performance than other composite materials or even steel.
  • The internal material bond between the fibers and the polymer matrix is also particularly high and enables optimal absorption of the acting forces.
  • With the W8SVR X-Ply scrims, the required strengths can be integrated in the component to meet the load.

W9SVR Website

INDIVIDUAL BESPOKE SOLUTIONS

We pride ourselves on being skilled in establishing and developing individual bespoke solutions which meet the specific economic and functional requirements of our customers. The right solution for each customer may differ and is considered separately with the best solutions recommended to save weight, reduce costs, increase performance and improve designs in as sustainable a manner as possible.

Project Specific Selection of Different Materials

Design for manufacturing focus with products designed for manufacturing processes appropriate for their production volumes.

Optimisation for appropriate safety, stiffness and strength requirements and mass optimisation using FEA.

Sustainability principles inform development of engineering solutions.