The CMACFER project – Center for Innovation in High-Performance Cementitious Matrix Composites for Strengthening the Mechanical Chain of the Automotive Parts Industry, coordinated by GEMASC in partnership with the Hercílio Randon Institute and UFRGS – aims to formulate new innovative solutions for the automotive industry. The project is disruptive, with a technological spillover of cementitious matrix composite materials within the metalworking industry for the manufacture of stamping molds for automotive parts, and is configured at a technological maturity level ranging from TRL2 to TRL4. Partial advances in the project have allowed the obtaining of materials with strengths close to those required in the process (~200 MPa in compression at a temperature of 200ºC). The project aims to develop an ultra-high-performance cementitious matrix composite material for the manufacture of stamping tools for polymeric components.

This project is already exploring different types of applications, including the application of this material concept (fiber-reinforced cementitious/geopolymer composite) to other categories of forming tools and dies. Another possibility for this composite material concept is its application in other types of products, particularly as a replacement for steel.

Based on preliminary results and other material performance optimization routes, it is also possible to explore the improvement of these fiber-reinforced cementitious composites for high-temperature applications, which could be applied in different areas of industry. It is also possible to work on the development and improvement of other specific properties of such composites, such as thermal conductivity, electrical conductivity, abrasion resistance, chemical resistance, among others.

The satisfactory results obtained throughout this project have allowed us to identify a real and innovative advantage in the manufacture of temporary or prototyping molds for new components. The technology developed within this project validated and proved that this type of tool makes prototyping processes economically viable, which were previously often rendered unfeasible due to the high costs associated with the production of traditional tools. In many cases, prototyping and testing components in real-world environments is economically unviable due to the high cost of conventional molds/tools. These molds, besides being expensive, are often discarded after use or fail to meet expectations, representing a significant financial risk for companies. The development achieved in this project brought an innovative solution: the possibility of producing press molds that are even much more economical compared to traditional methods.

This cost reduction allows for testing new components with dimensions and characteristics very close to those of the products that would be commercialized, without compromising the project budget. Furthermore, the technology developed here opens new possibilities for rapid and efficient prototyping, allowing changes and optimizations in form and concept to be implemented quickly and economically. This not only accelerates the product development cycle but also increases the flexibility and innovation capacity of the industrial partner. Therefore, the impact of this project goes beyond technical validation: it represents a strategic enabler for prototyping, reducing economic barriers and allowing the company to explore new ideas and designs with greater freedom and less risk. This ability to innovate quickly and efficiently positions the industrial partner competitively in the market, opening doors for the development of more advanced products aligned with industry demands.