This paper details about weaving of single-layer 3D ‘T’ profile with fillet for use as insert in composite ‘T’ joints and ‘T’ stiffeners. The ‘T’ insert with fillet was woven using 3 K carbon tows on a narrow width multi-beam automatic loom. Weaving was carried out based on the double-cloth weaving principle. Novelty of the work lied in the approach adopted for designing of the weave architecture in developing 3D ‘T’ profile with fillet portion, arriving at the pick cycle diagram for weave design development which has been detailed in this paper. Test results of composite ‘T’ joints fabricated incorporating the insert showed strength improvement as well as change in crack propagation mode as compared to conventional ‘T’ joint. The continuous insert with fillet acted as a bridging member among the three sections of the ‘T’ joint, thus contributing to performance improvement.

This paper details about the manufacturability of integrally woven ‘T’ stiffeners using orthogonal weaving technology based on the pleat formation concept. The development was carried out on a customized automatic take-up-at-will rapier weaving machine equipped with multi-beam warp let-off and electronic dobby. Bridging the gap between the base portions of the flange sections and locking the web sections together by using equally spaced intermittent extra warp yarns were the added innovations in the work apart from integral weaving of the ‘T’ stiffener. These innovations were achieved by suitably modifying the weave design. The development comprised a 5-part weave design for the ‘T’ stiffener and was carried out using 6K carbon tows. Calculations for X, Y, Z contents and overall fibre content by volume, from first principles of cloth construction approaches, for the flange and web sections of the ‘T’ profile, have also been included.

Now-a-days, safety is very important in various on-site industries likemanufacturing, construction & power generation industries. To escape the workerfrom head damage, wearing of industrial safety helmet in on-site industries hasbecome obligatory according to OHSAS 18001[Occupational Health and SafetyAssessment Series]. Hence the resisting possessions of safety helmet should be high tohold out against the fortuitous circumstances. This project focuses on scrutinizing andcomparing the fabricated industrial safety helmet using composite material which ismake by us, with existing industrial safety helmet. The fabricated safety helmet shallbe figure out in both practically and theoretically processes. In practical examiningthe fabricated helmet shall go through the component testing which was specified byBIS 2925 [Bureau of Indian Standards]. In theoretical the results of the practical testwill compared in FEA (Finite Element Analysis) using ANSYS 19 R3 software onprototype and existing models. This project talk about the outline of safety helmetconstructional attributes, definition, types and choosing of suitable compositematerial.

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