Reducing component weight offers automotive engineers and designers a means to increase vehicle fuel economy while reducing carbon dioxide emissions. Camshaft module lightweighting has been achieved by Germany’s Fraunhofer Institute for Chemical Technology (ICT) and research partners by replacing die-cast aluminum The camshaft module features a monolithic design with integrated bearings. Source: Fraunhofer ICTwith a fiber-reinforced thermoset polymer.

Use of the thermosetting composite material lowers powertrain weight burden and also requires less energy to manufacture relative to aluminum as the molds used in its production are more durable. The polymer castings require less reworking and finishing work and offer superior absorption of noise-generating vibrations. The monolithic plastic camshaft module is manufactured as one piece, reducing assembly and installation time and attendant costs.

While the fiber-reinforced thermoset polymer is just one quarter as stiff as aluminum, the plastic-based camshaft was designed within maximum allowable deformation parameters. Functional prototype evaluation during 600 hours of testing demonstrated excellent performance in a state-of-the-art internal combustion engine.

Automotive parts manufacturer MAHLE Group, Daimler AG, Belgian plastics manufacturer SBHPP/Vyncolit, and French plastics company Georges Pernoud also contributed to the development of the fiber-reinforced thermoset polymer component.