Toho Tenax Europe GmbH has manufactured the assembly carrier for the Porsche GT3 Cup II race car. It is the first automotive part being produced in serial production with Tenax® Part via Preform (PvP) technology in Heinsberg, Germany, supplied directly to the OEM. The company explained that its decision to pursue collaboration with Porsche is a result of its parent company’s (Teijin) recent expansion of its composites businesses.

As Toho Tenax explains, the PvP technology allows the company to make carbon fiber reinforced plastic (CFRP) automotive parts. During the process of makes the parts with PvP, Tenax® carbon fiber is sprayed, consolidated and trimmed automatically into near net-shape preforms, helping to reduce carbon fiber waste and minimize intermediate processing. The injection uses a high-pressure resin transfer molding (HP-RTM) technology including an in-mold coating step providing easy surface painting.

The company claims that compared to current state of the art processes – which uses fabric based on carbon fiber being draped manually in the mold – the Tenax® PvP process produces preforms automatically without internal cuts and draping effects. Toho Tenax says the preform leads to a perfect load behavior of the part. Another benefit of using the PvP technology is that costs are significantly reduced due to the automation of the whole preforming process, providing a reduced number of intermediate steps.

In addition to the assembly carrier, the new Porsche vehicle features many other composite parts made with CFRP, including its doors, rear lid and rear wing. Polycarbonate is used for the vehicle’s rear side and rear screen.