Large scale manufacturing technology for highperformance lightweight 3

Large scale manufacturing technology for high-performance lightweight 3 D multifunctional composites Abstract 3 D-Light. Trans Concept Project data The project 3 D-Light. Trans aims In the 3 D-Light. Trans manufacturing chain, multimaterial semifinished fabrics will be processed to Project title to provide a ground-breaking, highly deep draped pre-fixed multilayered and multifunctional 3 D-textile pre-forms. The fixed pre-forms Large scale manufacturing technology flexible, efficient and adaptable can be easily stored and transported (if needed) without special temperature requirements. for high-performance lightweight 3 D manufacturing chain for the production of multifunctional composites integral large scale 3 D textile reinforced plastic composites (TRPC). Acronym 3 D-Light. Trans This will enable to shift them from its current position in cost intensive, small Grant agreement no. series niche markets, to broadly 263223 FP 7 -NMP-2010 -LARGE-4 extended mass product applications in transportation and other key sectors, Project duration like health and leisure. From April 2011 to March 2015 Consortium Objectives 1. Austrian Institute of Technology Gmb. H 2. Xedera e. U. 3. Centro Ricerche Fiat SCPA 1. Substantial increase of achievable complexity and flexibility in the 4. Coatema Coating Machinery Gmb. H realization of 3 D fabrics 5. Federal-Mogul Systems Protection 6. Universiteit Gent 2. New procedure for highly efficient production of TRPC parts (up to 70% 7. Grado Zero Espace srl shorter processing time, less than 0, 5 8. Technische Universität Dresden mm. fibre displacement) 9. LEITAT Technological Center 3. Establishment of the complete manufacturing chain 4. Enabling mass manufacturing of products with short production times and high customization 10. Lindauer Dornier Gmb. H Fig. 1 - 3 D-Light. Trans manufacturing chain (all pictures -except battery case and truck- by TU-D) The final composite part is produced by thermoforming. Neither manual draping of the textile onto the forming tool nor infiltration/curing are required, since preforms are already fixed in the desired 3 D geometry and thermoplastic matrix integrated in the hybrid yarn before weaving. 12. P-D Glasseiden Gmb. H Oschatz 13. Michel Van de Wiele 14. Onera - The French Aerospace Lab 15. Bentley Motors Ltd First project results To demonstrate this, a spare wheel well, an air vent part and a tailgate will be produced, featuring: 11. Northwest Textiles Network Limited 16. SVUM A. S. 17. PROMAUT S. L. 18. Universite d‘Orleans - Hybrid air mingled yarns with different glass rovings and PP, PA, PET/PES as matrix material (tensile modulus of 30 to 36 GPA for a mixture ratio of 70: 30 with E-Glass) - Modelling, simulation and tests on Glass-PP - Different specific functions (structural, fibre done aesthetic, storage…) - Running work to decrease/improve abrasion, - Size up to 1, 37 m. x 0, 87 m. x 0, 71 m. and varying complexity - Mass and/or cost reduction (in comparison with e. g. cast aluminium and carbon-glass-epoxy composite) - Demanding mechanical properties and load requirements: -40°C to 120°C (typically), tolerance to stone impact, rigidity and torsional deformation… - Suitability for subsequent assembly and post-processing: mechanical fastening, integration of metallic inserts, addition of brightwork, etc. ageing and adhesion Fig. 2 - Different hybrid yarns and test results A project co-funded by the European Commission within the 7 th Framework Programme - Multilayered and 3 D-shaped fabrics with different weave architecture realised - Modified machines available in TU-Dresden (rapier looms with heddle frames and jacquard, adapted for Fig. 3 - Different weave architechtures (TU-D) weaving hollow structures); specific developments on For more information please contact: loom for full automation on-going (Michel Van de Wiele) - Micro-CT results available, 3 D-Finite Elements simulation of the unit cell on-going Contact Project Coordinator Fig. 4 - Micro-CT picture of multilayer (UGent) Dr. Marianne Hörlesberger (AIT) marianne. hoerlesberger@ait. ac. at - On-going work on local reinforcement, pre-fixation and draping (with simulation of in-plane draping behaviour Exploitation & Dissemination Manager showing good correlation with experimental results) Dr. Ana Almansa (Xedera) - First thermoformed test parts available; process simulation and part characterization on-going Fig. 5 -GP/PP Hybrd yarn 17 layered weave (left) and composite (right): Compression approx. 57% (TU-D) aam@xedera. eu www. 3 d-lighttrans. com Copyright © 2012 3 D-Light. Trans – All rights reserved