Thermoforming and welding processes for sports applications

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The sports industry has been utilizing high-performance composite materials for several years. These materials are typically composed of carbon fibers embedded in a thermosetting resin matrix, such as epoxy. While they exhibit excellent specific mechanical properties, their fabrication often relies on labor-intensive manual processes, including hand lay-up followed by curing through the application of heat and pressure using heated presses, ovens, inflatable bladders, and similar equipment. This high degree of manual labor contributes to the offshoring of component manufacturing to regions with lower production costs. Additionally, the handling of pre-impregnated thermosetting composites presents several challenges: they have a limited shelf life, require frozen storage conditions, and offer limited options for recycling production waste or end-of-life components.

Argon 18 is a company founded in Montréal in 1989, specializing in the design and manufacturing of high-performance bicycles. The company aims to automate the forming processes of bicycle components to improve part quality, reduce production costs, and retain or bring back manufacturing jobs to Quebec. To achieve this, the developed processes must be adapted to alternative composite materials, as those currently in use require slower, more manual manufacturing methods. This project is being carried out in this context, led by Professor Martine Dubé at ÉTS in collaboration with Professor Louis Laberge-Lebel from Polytechnique Montréal and the company Argon 18. The objective is to develop automated forming and assembly processes for thermoplastic composites to manufacture bicycle components with enhanced mechanical properties and reduced weight, while enabling local production. Additionally, the project will support the training of three master’s students and one postdoctoral fellow.

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