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3D-LightTrans Large scale manufacturing technology for high performance lightweight 3D multifunctional components Abstract3D-LightTrans Concept Project.

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Presentation on theme: "3D-LightTrans Large scale manufacturing technology for high performance lightweight 3D multifunctional components Abstract3D-LightTrans Concept Project."— Presentation transcript:

1 3D-LightTrans Large scale manufacturing technology for high performance lightweight 3D multifunctional components Abstract3D-LightTrans Concept Project data The project 3D-LightTrans aims to provide a groundbreaking, highly flexible, efficient and adaptable manufacturing chain for the production of integral large scale 3D textile reinforced plastic composites (TRP). 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. Background Project results TRP (textile reinforced plastic composites) combine light weight with excellent mechanical properties, while holding the potential for huge material cost savings in comparison with metal. Reinforced composites (often carbon on thermoset matrix) are used for aircraft and a few niche automotive applications, but are too expensive for the mass market in spite of the lower material costs, due to the long processing cycles and labour intensity. 3D-LightTrans will create a manu- facturing chain able to exploit TRPs inherent economic potential. 3D-LightTrans concept relies on individual processes and approaches, with suitability proven in experimental work performed at the TU-Dresden. To achieve 3D-LightTrans goals, the partners will develop know-how, processes and equipment to establish automated production chains for low cost, high quality and reproducible industrial manu- facturing of large scale parts featuring complex 3D geometry. For more information please contact: Dr. Erich Kny (AIT) Project Coordinator Dr. Ana Almansa (Xedera) Exploitation & Dissemination Manager Project title: Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites Acronym: 3D-LightTrans Grant agreement no.: 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.Acondicionamiento Tarrasense Associacion 10.Lindauer Dornier GmbH 11.Northwest Textiles Network Limited 12.P-D Glasseide GmbH Oschatz 13.Michel Van de Wiele 14.Office National dEtudes et de Recherches Aerospatiales 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 prefixed multilayered and multifunctional 3D- textile preforms. Storage and transport of the fixed preforms takes place without special temperature requirements. A project co-funded by the European Commission within the 7 th Framework Programme 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. Fig. 2. Spacer fabric and deep draped multilayer fabric with simple geometry (TU-D) Fig. 3. 3D-LightTrans manufacturing chain Fig.5. Cost improvement to be achieved with 3D-LightTrans Contact Hybrid yarn 3D-LightTrans weaving processes b) Spacer fabrics with hollow spaces manufactured in a single weaving step a) Multilayered fabrics Draping and fixation Storage and transport of 3D fixed pre-forms Thermoforming Consolidated compound parts (car door, battery case) Hybrid yarn production Thermoplastic Reinforcement * … durable investment costs Differential Integral Hull Rips 67 * 1 * 4 * ca. 100 Braiding Prepeg Weaving Auto- clave 3DLT Weaving 0 h Thermo- pressing Time consumption Infiltration Fabric Assembling Consolidation Component In tool Fig. 4. Project timeline and scheduled results Reliable/ repetitive production of different hybrid glass yarns Modeling & simulation toolbox Fixation process Integrated manufacturing chain incl. TRP thermoforming Scale-up for mass production Automation, handling processes & tools Weaving machines for complex multilayer & 3D-shaped geometries Specification of requirements D-TRP demonstrators Fig. 1. Comparison of material price


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