Successful Teamwork – RAMPF Tooling contributes to the development of the Gumpert apollo racing car

The apollo: a potent, exclusive and unique racing car with uncompromising functionality and maximum driving dynamics. In successful collaboration with its long-time partner Esterhammer and the companies A. Erglis GmbH and CrossLink, RAMPF Tooling contributed to the development of the apollo racing car. The specialist for model, mold and tool building materials supplied the board material and the paste models for the side panels to produce the carbon fiber lay-up tools for the stunning sports car. Esterhammer delivered the HexPly Prepregs M49 from Hexcel.

RAMPF Tooling supplied the board material and the paste models for the side panels to produce the carbon fiber lay-up tools for the stunning sports car.

The apollo sports car can be viewed at the Reinforced Plastics stand.

The apollo is a stunning car because of its puristic but still aestheticly clean design. The racing car was produced in close collaboration between RAMPF Tooling, long-time partner Esterhammer and the companies A. Erglis GmbH and CrossLink.
The models, into which the Tooling prepregs (semi-finished product made from car-bon fibers) for the production of the lay-up tools were inserted, were made with RA-KU-TOOL® epoxy working board WB-0690 and RAKU-TOOL epoxy close contour paste CP-6100. Since the lay-up tools had to be seamless the board material was used to make the smaller models and for the larger models, like side panels, the close contour paste was used.
The model for the side panel made out of CP-6100 was produced as a self-supporting shell without any additional ribbing. This was possible because of the excellent mechanical properties, despite the model’s net weight of approx. 300 kg. Significant cost and time savings were made through the use of this technology.

For the production of the models made out of paste, an oversized negative was produced from EPS and afterwards the close contour paste CP-6100 was applied using the shell structure technique.
The close contour paste offers a highly efficient solution to produce large models quickly as the components are mixed and applied by machine without slumping on vertical surfaces. This is possible up to a layer thickness of 40 mm which enables a quick application. After a 24 h room temperature cure the paste can already be ma-chined. Through the very fine and seamless surface, the finishing time is consider-ably reduced. In addition the paste application can be considered an environmental friendly solution as it produces less wastage. But that is not all as by using an inex-pensive material for producing the negative, costs can be further reduced since virtually any type of material can be taken, from EPS to board material with low density.
After demolding the paste models, they were machined to the final shape by Erglis using a CNC machine. The surface finish of the machined models and further processing took place at the company CrossLink. Once the surface had been sealed and the release agent applied, the tooling prepregs were inserted into the mold. The pre-treatment with sealant and release agent is necessary to enable easy demolding after cure. The lay-up tool made with tooling prepregs was cured on the paste model in the autoclave at a temperature of 50°C.
Through the use of prepregs for the production of carbon fiber lay-up tools, high quality molds can be produced (controlled resin content, consistent high mechanical resistance, light and very stiff). Another advantage of the prepreg technology is clean and environmental friendly working (no liquid materials).
The HexPly Prepreg in combination with the resin system M 49 exhibits a perfect surface finish and an excellent UV resistance. Painted surfaces with minimal finish-ing work as well as high gloss carbon surfaces with unique durability can be pro-duced.

Advantages of the close contour paste CP-6100 at a glance:
» The material allows for a fast application. The components are mixed and applied by machine.

» The paste does not slump on vertical surfaces (up to a layer thickness of 40 mm).

» Easy and quick to process since the applied paste can be machined after a 24 h room temperature cure (= fast cure cycle).

» Minimal finishing work due to the very fine, seamless and homogeneous sur-face

» Fast and easy machining with CNC equipment since the model is already a close contour shape. Therefore less wastage is generated.

RAMPF Tooling - apollo car