INSTITUT FÜR KUNSTSTOFFVERARBEITUNG - AACHEN 3D Fibre spraying – Automated preforming for structural RTM parts Prof. Dr.-Ing. Christian Hopmann Dipl.-Ing. Marc Linus Fecher Dr.-Ing. Kai Fischer 8 th INTERNATIONAL CFK-VALLEY STADE CONVENTION, STADE 25 th of June 2014
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AACHEN 3D Fibre spraying Automated preforming for ... · INSTITUT FÜR KUNSTSTOFFVERARBEITUNG -AACHEN 3D Fibre spraying – Automated preforming for structural RTM parts Prof. Dr.-Ing.
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3D Fibre spraying – Automated preforming for
structural RTM parts
Prof. Dr.-Ing. Christian Hopmann
Dipl.-Ing. Marc Linus Fecher
Dr.-Ing. Kai Fischer
8th INTERNATIONAL CFK-VALLEY STADE CONVENTION, STADE
25th of June 2014
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Institute of Plastics Processing (IKV) in Industry and
Skilled Crafts at RWTH Aachen
Founded in 1950, supported by a Sponsors'
Society (currently > 240 members)
Associated with RWTH Aachen University
6 departments
Composites & PU
Extrusion & rubber processing
Injection Molding
Part Design / Materials Technology
Centre for analysis and testing of plastics
Training and further education
Staff
80 scientific employees
50 employees in laboratories, workshops
and administration
~220 student workers
Facilities Pontstr. 49
Facilities Seffenter Weg 201
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Outline
Institute of Plastics Processing (IKV) at RWTH Aachen University
Introduction and motivation
Advantages of the fibre spraying technology
Functional principle of the 3D Fibre spraying developed at IKV
Binder technologies used in the 3D Fibre spraying
Selected results
Conclusion and outlook
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General advantages of continuous fibre reinforced
composites
High fibre volume content > 50 %
High strength and stiffness
Defined fibre orientation
Reproducible manufacturing of
reinforcing fabrics
Good optical appearance
[BMW]
[Airbus]
[IKV Aachen]
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Cost distribution for the RTM-process
Post
processing RTM-process Preforming Textiles
Rovings /
Resin
50 % 20 % 25 % 5 %
[Cher13]
Preforming causes up to 50 % of the total part costs
Up to 30 % scrap during fibre cutting
Often high manual work effort necessary
Draping of single fibre layer
Integration of functional elements (e.g. cut-outs, inserts, stiffening profiles)
Automated preforming technologies for the manufacturing of complex and functional
integrated preforms often need a high machine employment
Challenges in manufacturing of thermoset composites
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Advantages of the fibre spraying technology for
thermoset structural parts
30 % less scrap
Automated process
No thermoforming & cutting
Part manufacturing Preforming Textile manufacturing