A NOVEL MANUFACTURING CELL FOR A NEW GENERATION OF COMPOSITE PROCESSING AND APPLICATIONS

Abstract

A novel manufacturing cell has been developed to open new perspectives in composite and polymer processing by combining intrinsic and geometrical stiffness in an integrated processing operation. Two concepts for combining aligned fibre structures and flow moulding materials have been demonstrated through processing trials. The first technique was demonstrated through a hook comprised of robotically placed UD carbon/PA12 tow overinjected with PA12, combining creep resistance and load introduction with a bulk flow process. Stamp forming of commingled fabrics followed by overinjection moulding formed the second variant, demonstrated with both polyamide and polypropylene based systems. The manufacturing cell, together with subsequent moulding trials and material tests, has scaled the concept and validated the integrated processing philosophy.