In heavily loaded structural parts fibre reinforced plastics (FRP) are commonly applied as unidirectional layered composites. These laminates have to be designed for special load cases. Basis for the designing process is a stress and strength analysis in layers. Research activities at the IKV verify and extend existing dimensioning fundamentals.

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The manufacturing of composites with a high fibre orientation in load direction has great economic importance. To increase the efficiency a growing number of automated manufacturing processes are used. The “3D Fibre Spraying Process” as well as the Polyurethane “Spray Impregnation” has a high potential to become a completely automated manufacturing process.
Within the “3D Fibre Spraying Process” a hybrid yarn made of glass and polypropylene is chopped into defined fibre length and sprayed on a three-dimensional tool.

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For manufacturing of composite parts with a high content of oriented reinforcement fibres a lot of processes can be used. But the impregnation of a dry preform with a liquid matrix by liquid composite moulding processes offers a very high potential for economical manufacturing of high performance composite components.

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Nowadays thermoplastic composites (TPC) are getting more and more attractive. Not only the potentially short cycle times in comparison to thermosets but also the higher toughness and the recyclability make this material interesting for manifold applications. Hence this material is used in automotive, transport, protective and leisure industry. (More information in the PDF)

Both thermoset materials like sheet moulding compounds (SMC) and thermoplastic materials like LFT or GMT are processed by compression moulding. Even liquid impregnated net shaped semi finished products made of continuous fibres (preforms) can be processed. This processing procedure for fibre-reinforced plastics is used for low-cost and high-volume production. Typical applications for parts made of SMC are exterior parts in the automotive and truck industry as well as isolating parts in the electronic industry. Parts produced out of LFT also find different applications in modern cars. (More information in the PDF)

The roving based processes filament winding and pultrusion are established manufacturing processes for fibre reinforced plastics and are characterised by high laminate qualities, a high degree of automation and an eminent economic efficiency. The pultrusion process is a completely continuous manufacturing method for fibre reinforced profiles. By filament winding simple rotationally symmetric structures as well as complex hollow bodies can be manufactured. By processing variants and the application of alternative matrix materials it is possible to extend significantly the spectra of application of both manufacturing processes. (More information in the PDF)