Title: Innovating Automotive Composites: ProxximaTM R3630 C32 DCPD Resin for Class-A Surface Parts

Authors: Jonathan M E. Hammel, Jacob Cartwright, David Morrissett

DOI: 10.33599/nasampe/c.25.211

Abstract: This study demonstrates the adaptability of ExxonMobil’s Proxxima™ R3630 C32 resin system in converting epoxy-based vacuum-assisted resin transfer molding (VARTM) process to polydicyclopentadiene (pDCPD) resin for scalable production of Class-A automotive parts. The Concept8 domed frunk, developed by Nowicki Autosport Design and fabricated by McCLARIN Composites, successfully transitioned form an OE-grade 3K twill carbon fiber and epoxy resin to a pDCPD-based solution using the same tooling and process. This resulted in the first commercially available Class-A reinforced automotive part for a passenger sports car using pDCPD resin system. The polyolefin thermoset resin system, with lower viscosity and density than conventional epoxy resins, enhances infusion efficiency, reduces cycle times, and lowers component weight for improved performance. Quantitative comparisons show reduced cycle times, improved infusion rates, and weight savings compared to incumbent materials. Future work will integrate pDCPD into high-speed transfer molding (RTM) process to enable highvolume production of structural composite components, further optimizing efficiency, performance, and scalability, positioning pDCPD as a key solution for next-generation automotive composites.

References: [1] Simulation-driven design optimization of reaction injection molding (RIM) process for polydicyclopentadiene (pDCPD): Minimizing cycle time, defects, and warpage, Komal Chawla et al, Journal of Manufacturing Processes, 2025 [2] Proxxima™ R3630 C32 Extended Technical Data Sheet [3] EPIKOTE™ Resin TRAC 06150, EPIKURE™ Curing Agent TRAC 06150, HELOXY™ Additive TRAC 06805 Technical Data Sheet Hexion, 2019 [4] JEC 2024: Proxxima™ Systems: Redefining Thermosets [5] ASTM D7136-07: Standard Test Method for Measuring Damage Resistance of Composites [6] ASTM D7137-07: Standard Test Method for Compressive Residual Strength of Composites [7] ASTM D5528: Standard Test Method for Mode I Fracture Toughness of Composites [8] ASTM 14067:2018: Greenhouse Gases - Carbon Footprint of Products [9] JEC 2024: Proxxima™ Systems: Innovating

Conference: CAMX 2025

Publication Date: 2025/09/08

SKU: 211

Pages: 8

Price: $16.00