Fiber path optimization methods combined with the Tailor Fiber Placement (TFP) technology provide the optimum correlation between load case and fiber orientation and therefore lead to unmatched component performance with endless fiber composite materials. The aim of this work is the development of an innovative manufacturing technology for thermoplastic composites (TPC) including sizing-adapted commingled glass fiber (GF) / thermoplastic yarns (SpinCom yarns) to be processed by TFP to textile preforms with a variable-axial, load adapted fiber design. Furthermore, these preforms will be consolidated in a low energy and resource consuming process using novel light and low cost forming tools produced by incremental sheet metal forming technology. Finally, a low cost solution for thermal processing even for complex shaped TPC parts will be presented. Heading towards optimized resource and cost efficiency of the whole process chain, first results of SpinCom yarns, fiber path optimization, tool manufacturing and forming procedure are presented and demonstrated using GF/PBT (polybutylene therephthalate) SpinCom yarns and the geometry of a bicycle saddle.

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Lightweight design for automotive applications gains more and more importance for future products, independent from the powertrain concept. One of the key issues in lightweight design is to utilize the right material for the right application using the right value at the right place. This results irrevocably in a multi-material design. In order to increase the efficiency in manufacturing car components, the number of single parts in a component is decreased by increasing the complexity. Examples for the state of the art are tailored welded blanks in cold forming, tailored tempering in press hardening or metallic inlays in injection molding of polymers. The challenge for future production scenarios of multi-material components is to combine existing technologies for metal- and polymer-based applications in efficient hybrid process chains. This paper shows initial approaches of hybrid process chains for efficient manufacturing of hybrid metal-polymer components. These concepts are feasible for flat as well as for tubular applications. Beside the creation of the final geometric properties of the component by a forming process, integrated joining operations are increasingly required for the efficiency of the production process and the performance characteristics of the final component. Main target of this production philosophy is to create 100% ready-to-install components. This is shown in three examples for hybrid process combinations. The first example deals with the combination of metal forming and injection molding of polymers. Example number two is the application of hybrid metal-polymer blanks. Finally, example number three shows the advantages of process integrated forming and joining of single basic components.

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