Tailored Fiber Placement in Thermoplastic Composites

Abstract

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.

Recent developments in manufacturing, mechanics, and design optimization of variable stiffness composites

“…While most of the studies use thermoset composites in TFP, applications of thermoplastics are also investigated. 49,50 The TFP process has a relatively faster rate of tow deposition, but smaller width of the tows takes longer to manufacture complex geometries.…”

“…While most of the studies use thermoset composites in TFP, applications of thermoplastics are also investigated. 49,50 The TFP process has a relatively faster rate of tow deposition, but smaller width of the tows takes longer to manufacture complex geometries. Some works also present on the embroidery-based approach with electrodeposition resin molding 51,52 for uniform impregnation of resin.…”

TFP Technology As Theadvanced Method Of Manufacture Of 3D Reinforced Preforms Frompolymer Composite Materials

“…Speckenheuer et al presented the first results of research on the possibility of using hybrid threads for the manufacture of tfp-preforms, allowing to obtain high-quality composites. The commingled yarns are made by simultaneous spinning of E-glass fibers (GF) and Polybutylenterephthalat (PBT) filaments with different sizings and have increased adhesion to the matrix [31]. Thus, it should be noted that currently TFP technology applies standard threads used in the textile and chemical industries.…”

“…No significant increase in the impact strength was observed. In paper [31], SpinCom hybrid threads [33] consisting of glass and polybutylene terephthalate fibers were used to produceTFP preforms of thermoplastic composite samples. The possible use of hybrid threads to produce thermoplastic composites based on TFP preformswas demonstratedon the example of a bicycle saddle.The test results showed that the combination of the size-adapted SpinCom combination yarn and the Tailored Fiber Placement technology allows to obtain high-quality thermoplastic composites with the precise location and efficient use of the material.…”

“…Furthermore, the TFP technologyenables the creation of integrated structures without auxiliary operations andthe use of the material's propertyto the full. The highly automated manufacturing process involving several embroidery heads makes the technology attractive for the serial production of 3D reinforced blanks.TFP preforms are widely used abroad -certain companies have mastered the process and introduce it into production [14][15][16][17]. However, despite the clear advantages of directional patching, composites and products based on the TFP technology are not available in the Russian market.…”