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Honeycomb technology to reduce 20% weight of Hyundai Creta’s trunk floor
Source:Adsale Plastics Network    Editor:JK    Date:29.May.2020

EconCore, a specialist in lightweight thermoplastic honeycomb core technology, and DPA Moldados, a tier 1 automotive supplier, have developed innovative technology which has reduced the weight of the Hyundai Creta’s trunk floor by 20%. The thermoplastic composite, combining a sandwich panel of PP honeycomb and GMT composite skin.


The technology developed and patented by EconCore is unique in design. The thermoplastic honeycomb is produced continuously while direct lamination of the sandwich skin layers is most often in-line integrated in the highly automated process.


José Carlos Ricciardi, managing director of DPA Moldados, a Brazilian Tier 1 supplier that has partnered with Econcore to develop this lightweight solution, said: “We had been seeking a way to address weight reduction, and on that journey we combined forces with EconCore and their German daughter company ThermHex Waben.”


Hyundai Creta.

EconCore’s solution is effective because sandwich panels are the most suitable structure when it comes to delivering rigidity at low weight, indeed, trunk floor assemblies of many cars are made of a combination of paper honeycomb and polyurethane / glass fibre composites.


Given the high performance of the honeycomb structure, the use of material is very limited. A low-density honeycomb, when combined with skin layers, delivers a performing sandwich panel. Within Econcore’s technology, the application of skin layers takes place directly as the honeycomb core is made, all within an integrated production process delivering maximum of cost-efficiency.


Additionally, EconCore also recognise that sustainability within manufacturing processes is currently at a forefront of its consumers’ minds. The company’s process uses thermoplastic honeycomb core and thermoplastic skin layers that comprise partly or sometimes fully recycled materials and at the end of product’s life, the part can be easily recycled.


Tomasz Czarnecki, COO of EconCore, explains: “With regards to recyclability, our process is using thermoplastic honeycomb core and thermoplastic skin layers that on their own can be already based on partly or even fully recycled materials. At the end-of-life our product, and the thermoplastic finishing carpets that automotive parts require for decorations, are recyclable.”



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