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Quality controlled UD-Tape Production for the individualised Production of load optimised Thermoplastic Composite Parts

Mittwoch (05.07.2017)
13:00 - 13:20 Uhr
Bestandteil von:

The manufacturing of functionalised thermoplastic composite (TPC) parts is most often done in a combined forming and back-injection moulding process. However, especially for the production of individualised parts or the production of different product variations with small lot sizes this production process is not cost-efficient due to the cost-intensive mould technology. The combination of the additive manufacturing of functional structures (ribs, fastening elements, mounting devices) and forming of continuous fibre reinforced TPC sheets, with load optimised properties made of unidirectional (UD) tapes offers an innovative economic solution. In the BMBF funded project LightFlex a flexible and individual component manufacturing is developed by using a quality-assured tape production line, which allows the processor to vary the fibre and matrix material as well as the crucial tape parameters such as tape width, thickness, and degree of impregnation in order to quickly adapt to changing part requirements and customer preferences. An innovative tape production line enables the variable production of tape widths between 25 and 75 mm and is optimised for the processing of glass fibres (> 2.400 tex) and carbon fibres (>24K) in combination with polypropylene or polyamide as matrix material. Typical tape thicknesses will be between 0.1 and 0.3 mm. In the presented paper the relationship between the tape parameters and the component quality is shown. Therefore a special attention is paid to the interaction between tape requirements (in particular the degree of impregnation) and the resulting component properties depending on the used subsequent process. To control the extrusion-based tape manufacturing process an optic quality assurance system is used, allowing the measurement of the characteristic tape parameters (width, thickness, identification of imperfections, spreading quality the fibres). Those data are used to adjust the spreading and impregnation process during tape production.

Christian Beste
RWTH Aachen University
Weitere Autoren/Referenten:
  • Prof. Dr. Christian Hopmann
    RWTH Aachen
  • Markus Hildebrandt
    RWTH Aachen
  • Daniel Werner
    Faunhofer-Institut für Produktionstechnologie
  • Henning Janssen
    Faunhofer-Institut für Produktionstechnologie