Curved Foldable Tailored Fiber Reinforcements for Moldless Customized Bio-Composite Structures. Proof of Concept: Biomimetic NFRP Stools

Abstract

Fiber Reinforced Polymers (FRPs) are increasingly popular building materials, mainly because of their high strength to weight ratio. Despite these beneficial properties, these composites are often fabricated in standardized mass production. This research aims to eliminate costly molds in order to simplify the fabrication and allow for a higher degree of customization. Complex three-dimensional shapes were instead achieved by a flat reinforcement, which was resin infused and curved folded into a spatial object before hardening. Structural stability was gained through geometries with closed cross-sections. To enable this, the resource-saving additive fabrication technique of tailored fiber placement (TFP) was chosen. This method allowed for precise fibers’ deposition, making a programmed anisotropic behavior of the material possible. Principles regarding the fiber placement were transferred from a biological role-model. Five functional stools were produced as demonstrators to prove the functionality and advantages of the explained system. Partially bio-based materials were applied to fabricate the stool models of natural fiber-reinforced polymer composites (NFRP). A parametric design tool for the global design and fiber layout generation was developed. As a result, varieties of customized components can be produced without increasing the design and manufacturing effort.

Tailored Lace: Moldless Fabrication of 3D Bio-Composite Structures through an Integrative Design and Fabrication Process

“…TFP was developed for fabrication of complex preforms from carbon fibre rovings for applications in aircraft and automotive industry. However, the potential of adapting the technology to fabrication of building elements from natural fibres is currently being researched [8,16,23]. In the considered scenario, TFP would be used for fabrication of preforms from nontwisted TEX1000 flax rovings, attached to a glass fibre membrane with a cotton thread.…”

“…Prior to the invention of synthetic fibres and their prolific use in contemporary FRP production, natural fibres were the material of choice for most textile-based products with many societies using them for hundreds of years [3,8]. Since the industrial revolution, advances in manufacturing have focused on mass production and automation therefore choosing synthetic fibres over natural fibres for their predictable and controllable properties.…”

Mycomerge: Fabrication of Mycelium-Based Natural Fiber Reinforced Composites on a Rattan Framework

“…Two mycelium composite prototypes were developed during the Material Matter Lab IV at the BioMat Department in the ITKE Institute of the University of Stuttgart. This is a seminar practicing validation through small-scale structural demonstrators in the form of chairs and stools [ 16 ]. A timber veneer mold ( Figure 1 a) and a soft cotton fabric mold ( Figure 1 b) were used to develop the two alternatives.…”

Structural Optimization through Biomimetic-Inspired Material-Specific Application of Plant-Based Natural Fiber-Reinforced Polymer Composites (NFRP) for Future Sustainable Lightweight Architecture

“…The combination of innovative materials, bio-based engineering principles and new fabrication techniques is a promising way to ensure more sustainable construction methods. The architectural use of polymer composites has a great potential for optimizing lightweight, structural and non-structural applications such as canopies, pavilions, or facade elements (Figure 2) [7][8][9][10][11][12][13][14][15][16]. The resulting change in global climatic conditions is forcing architects to develop new approaches of design thinking.…”