What is Ex-Core
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Unique Solutions
The EX-CORE® technical revolution can deliver a production-cost saving of up to 81% compared to conventional carbon-fibre reinforced plastic (CFRP) processes used in the car industry today.
It delivers stronger components that liberate designers to create carbon-fibre shapes and angles that could only be dreamed of before, thanks to the syntactic foam core that squeezes the carbon-fibre material out against the mould.
It adds strength, with that foam setting into a solid that reinforces the core of the component, and it reduces cost, with its low-energy, low-wastage, one-shot manufacturing process.
And the more complex the production design is, the more Ex-Core saves compared to traditional methods.
5 Key Benefits of Ex-Core
Our revolutionary technology is changing the way industries operate, and we're here to show you how. Whether you're a business leader seeking a competitive edge or a curious mind eager to explore the latest breakthroughs, you're in the right place.
Join us on this journey as we unveil the five key benefits that make Ex-Core a transformative force in today's ever-evolving landscape. Explore, learn, and envision a future where Ex-Core plays a pivotal role in your success.
A unique self-contained tooling
With integrated heating elements and pressure sensors, Ex-Core can regulate the temperature of the foam in real time to force the carbon-fibre sheets out against the shaped inner surface of the tooling.
The internal pressure generated by the expanding foam can deliver components with intricate shapes and function integration that are unattainable with existing carbon-fibre production.
Ex-Core also produces cleaner production pieces, because it pushes the fibres outwards against the mould at between 2 and 8 bar of internal pressure, forcing the material precisely into every radii and eradicating the traditional need for redundant extra material to counter assumed defects.
By eradicating male and female tooling, the Ex-Core system is also less complex for its specialists to operate, generating a higher percentage of approved pieces.
UNRAVEL THE MAGIC
The size of the advantage the EX-CORE® process revolution can deliver will be greater in some applications than in others. The broad-brush scale of that advantage in any particularly application, and whether Ex-Core’s processes can be the best solution for a particular business, can be found in the Safety Data Sheet specifications.
Can Ex-Core Solve Your Problem?
While Ex-Core understands that no single carbon-fibre process is a universal silver bullet for every client, we are also confident that we have the versatility and technical brilliance to find the premium solution for most clients.
That includes costings, production volumes and even designs or surfacing that simply can’t be produced any other way.
Ex-Core Expectations
A full list of product specifications will streamline the process with an EX-CORE® expert. Ex-Core can give you the most accurate assessment of your needs only if we know volumes and cost expectations, design demands and wall thicknesses and required densities, and even whether you need a specific characteristic from your Ex-Core foam. That way you can know if you can maximise the Ex-Core advantage.
Ex-Core Essentials
The EX-CORE® system can deliver its benefits to a wide range of industries that demand greater strength in carbon-fibre components, lower cost and lighter weight.
Its Tg is between 90˚C - 100˚C, while its density ranges from 70 to 250 kg/m3, with a cure cycle of less than three hours, but usually less than one hour.
It is beneficial on components that are anywhere from 2mm to 100mm thick, and can even be adapted to include self-extinguishing or non-flammable foam formulations.