1. The project 3D-LightTrans aims to provide a ground-breaking, highly flexible, efficient and adaptable manufacturing chain for the production of integral large scale 3D textile reinforced plastic composites (TRPC). This will enable to shift them from its current position in cost intensive, small series niche markets, to broadly extended mass product applications in transportation and other key sectors, like health and leisure. Project Coordinator Dr. Marianne Hörlesberger (AIT) marianne.hoerlesberger@ait.ac.at Exploitation & Dissemination Manager Dr. Ana Almansa (Xedera) aam@xedera.eu www.3d-lighttrans.com Copyright © 2012 3D-LightTrans – All rights reserved Abstract Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites Project data3D-LightTrans Concept Objectives 1.Substantial increase of achievable complexity and flexibility in the realization of 3D fabrics 2.New procedure for highly efficient production of TRPC parts (up to 70% shorter processing time, less than 0,5 mm. fibre displacement) 3.Establishment of the complete manufacturing chain 4.Enabling mass manufacturing of products with short production times and high customization To demonstrate this, a spare wheel well, an air vent part and a tailgate will be produced, featuring: -Different specific functions (structural, aesthetic, storage…) -Size up to 1,37 m. x 0,87 m. x 0,71m. 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. Project title Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites Acronym 3D-LightTrans Grant agreement no. 263223 FP7-NMP-2010-LARGE-4 Project duration From April 2011 to March 2015 Consortium 1. Austrian Institute of Technology GmbH 2. Xedera e.U. 3. Centro Ricerche Fiat SCPA 4. Coatema Coating Machinery GmbH 5. Federal-Mogul Systems Protection 6. Universiteit Gent 7. Grado Zero Espace srl 8. Technische Universität Dresden 9. LEITAT Technological Center 10. Lindauer Dornier GmbH 11. Northwest Textiles Network Limited 12. P-D Glasseiden GmbH Oschatz 13. Michel Van de Wiele 14.Onera - The French Aerospace Lab 15.Bentley Motors Ltd 16. SVUM A.S. 17. PROMAUT S.L. 18. Universite dOrleans In the 3D-LightTrans manufacturing chain, multimaterial semifinished fabrics will be processed to deep draped pre-fixed multilayered and multifunctional 3D-textile pre-forms. The fixed pre-forms can be easily stored and transported (if needed) without special temperature requirements. A project co-funded by the European Commission within the 7th Framework Programme Fig. 1- 3D-LightTrans 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 3D geometry and the thermoplastic matrix integrated in the hybrid yarn before weaving. -Multilayered and 3D-shaped fabrics with different weave architecture realised -Modified machines available in TU-Dresden (rapier looms with heddle frames and jacquard, adapted for weaving hollow structures); specific developments on loom for full automation on-going (Michel Van de Wiele) -Micro-CT results available, 3D-Finite Elements simulation of the unit cell on-going -On-going work on local reinforcement, pre-fixation and draping (with simulation of in-plane draping behaviour showing good correlation with experimental results) -First thermoformed test parts available; process simulation and part characterization on-going First project results For more information please contact: Contact -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) Fig. 4- Micro-CT picture of multilayer (UGent) Fig. 3- Different weave architechtures (TU-D) -Modelling, simulation and tests on Glass-PP fibre done -Running work to decrease/improve abrasion, ageing and adhesion Fig. 5-GP/PP Hybrd yarn 17 layered weave (left) and composite (right): Compression approx. 57% (TU-D) Fig.2- Different hybrid yarns and test results