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Workgroup Complex Structural Components

Members of the Workgroup

Dr. Axel SpickenheuerHead of workgroup
Dr. Annette BreierHead of biomedical textiles
Dr. Lars BittrichScientific staff member
Dr. Cindy ElschnerScientific staff member
Dr. Kai UhligScientific staff member
Judith HahnPhD candidate
Emanuel RichterPhD candidate
Simon KonzePhD candidate
Nicole SchneiderTechnician 
Dr. José Humberto Santos Almeida JúniorPost Doc, Humboldt fellow, Brasil 
Kyoichi SugaharaGuest student, Japan

Tailored composite design for complex structures

To be able to realize fibre arrangements that meet the calculated requirements concerning direction and accumulation of fibres, we developed the Tailored Fibre Placement (TFP)-Technology, numerical design methods and process software for computable complex fiber reinforced parts.     

TFP-Principle

The reinforcement structure is produced by the lay up of a single roving. This roving is fixed by stitching to the base material. The base material can be a 2D-textile such as a woven fabric or for thermoplastic composites a matrix-compatible foil material. During the process, the stitching unit is stationary and the base material is moved using numerical control. more

Fields of work

  • Development of new design and optimization methods for variable-axial composite
  • Optimization of variable-axial composite parts for strength and stiffness 
  • Manufacturing of stress adapted textile preforms by Tailored Fiber Placement (TFP) process
  • Manufacturing of composite prototype parts with thermoset and thermoplastic matrix materials

Projects

Current running projects:

  • AIF Cornet "TailComp"
  • ZIM "FlexOr"
  • AIF IGF "LoVarMed"
  • ZIM "Hotflex"

Completed projects:

  • ZIM "Holz-FKV-Verbund"
  • DFG "OptiTex"
  • ZIM "WintFlap"
  • BMBF "highSTICK+"
  • ZIM "10k-Tool"
  • EU "EMBROIDERY"
  • ZIM "Development of a highly centrifugal force loaded rotor"
  • AIF "Kleinquerschnitte" (Small cross-sections)
  • BMBF "EMIR"
  • BMBF "BIOTEX"
  • DFG priority program 1123 (''Schüttgutbecher'')

Sample applications: preforms, parts and textile implants

(click to enlarge)

Equipment

Composite manufacturing

  • TFP machine (Tajima): 2 heads, processing frame area: 1700 mm x 1500 mm (usable for one preform pattern)
  • TFP machine (Tajima): 1 head, processing frame area: 500 mm x 500 mm 
  • Vacuum infusion technique (ovens, pumps, presses)
  • RTM injection machine 
  • RTM tool for plain specimens (350 mm x 350 mm)


Software

  • FEA software: ANSYS
  • FEA pre- / post-processor for variable-axial composite parts: AOPS (in-house development)
  • CAD software: SolidWorks, Inventor, AutoCAD
  • Punch software: EDOpath (in-house development), BasePack
  • Software for topology, shape and bed optimization: TOSCA Structure

 

 

Spin-Offs

Hightex Verstärkungsstrukturen GmbH
www.hightex-dresden.de

The  Hightex Verstärkungsstrukturen GmbH, the first IPF spin-off since 1998, develops and produces tailor-made, stress-adjusted, reinforcement structures (preforms) for very light, strong, and highly stiff fibre composite components.

Qpoint Composite GmbH
www.qpoint-composite.de

Qpoint Composite GmbH is a technology spin-off of the Leibniz-Institute für Polymerforschung Dresden since 2009. Based on former inventions at the IPF a young  professional team develops and produces innovative heatable composite products. Next to anti- and de-icing application core products are complete solutions for self heating composite tools.

Complex Fiber Structures GmbH
www.complex-fiber-structures.com

Since March 2013 the company Complex Fiber Structures GmbH develops software solutions for the simulation and process optimisation of variable-axial composite structures as can be manufactured e.g. with help of the Tailored Fiber Placement technology.