Current running projects:

AIF Cornet "SIQ4TFP"

Self Improving Quality for Tailored Fiber Placement Composite Production

AIF/CORNET

• Design of a comprehensive training track to analyze the influence of TFP parameters on process accuracy.
  
  
• Development of a machine learning algorithm to predict and correct path deviations in the TFP process.
  
  
• Introduction of a real-time training strategy enabling adaptation to local variations and new materials.
  
  
  

DAAD "ENUHVA"

Experimental and numerical characterization methods for variable-axial reinforced elastomers

DAAD PPP/Probral

• Experimental campaign for fiber-reinforced elastomers (FRE) to deliver a robust testing protocol for FRE calibration of anisotropic hyperelastic models.
  
  
• Implementation, calibration, and validation of these models in commercial FEM software by means of virtual evaluation and manufacture of technology demonstrators.

 

 

DFG Transfer "Tiefbohren"

VIBRATION-DAMPING COMPOSITE DRILL TUBES with integrated sensors for deep hole drilling processes

DFG

The BTA deep drilling process enables drilling with high length-to-diameter ratios. However, long tools lead to strong vibrations, especially when drilling high-alloy materials. This increases tool wear and, due to reduced drill quality, results in higher scrap rates for typically very expensive components. The DFG research project developed a vibration-damping composite drill tube with a hybrid connection concept for joining fiber-reinforced plastic (FRP) and metal via a plastic intermediate layer and the integration of fiber optic sensors for process and tool contion monitoring. Part of the hybrid connection concept is an innovative fiber winding pattern that creates form-fit connections with specific thickness changes and thus creates a high-strength connection.

Project partners:

• Institut für Spanende Fertigung (Technische Universität Dortmund)
• Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP
• BGTB GmbH – Beratende Gesellschaft für Tiefbohr- und Zerspanungstechnik
• KAISER Maschinenbau und Zerspanungstechnik GmbH & Co. KG
• carbovation gmbh 

 

 

BMWK LuFo VI-2 "LaST"

Combination of Tailored Fiber Placement (TFP) & Filament Winding (FW) for pressure tanks

BMWK LuFo VI-2

Software development:

• Thickness estimation with higher accuracy (esp. in turning regions) compared to conventional software tools
• Winding pattern generation (geodesic & non-geodesic) and process simulation
  
  

Development of draping concepts, experimental validation.

M-era.net "MBrace"

Multi-Matrix Composites for Fashionable, Customized and Evolvable Braces

M-era.net Call 2021

Every year, 22 million Europeans are treated for scoliosis, a spine curvature. The brace treatment is the most effective therapy, but a strain for every child that must undergo it. A brace is worn for years for 23 hours a day and significantly restricts upper body movement. It all happens in a time of self-discovery when opinions of teenage friends count. This project aims to significantly improve the well-being of patients. It combines innovative materials research of functional multi-matrix composites and the development of cost-effective manufacturing technologies with new therapy methods such as machine learning for gait analysis with fashionable design. Flexible elements intend to give the body more range of motion and significantly increase patient compliance. The aim is to transform braces from an uncomfortable fixation device into a supportive aid with high wearing comfort and to change their perception from a medical necessity to a fashionable accessory.

Goals: 

• Composite structural parts to transmit required forces and allow open structure
• Lightweight brace design with a modular construction principle
• Manufacturing of a final demonstration brace for communicating project achievements
  
  

Project partners: 

• Institute of Biomedical Engineering (TU Dresden)
• HTW Dresden
• Jan Kochanowski University in Kielce
• Sirris
• Isomatex S.A.
  
  
  
  

Find out more Project video

M-era.net "Gradient"

Graded Interphases for Enhanced Dielectric and Mechanical Strength of Fiber Reinforced Composites

M-era.net Call 2021

High-performance composites, composed of reinforcement (fiber, particles, fillers,...) and a matrix, have a large usage in many fields. Particular in power transformers and switchgear its application is responsible for many advantages. In this specific case, the dielectric and mechanical strength is influenced by the fiber-matrix interphase. Since the composite failure, generally, occurs in the fiber-matrix zone, it is critical to develop approaches to reduce stress concentrations in this region. 

• Development of approaches to reduce stress concentrations in the interphase; 
• Fiber surface modification; 
• Graded Interphases (interphase engineering); 
• New methodologies, validation tools and multi-scale simulation for interphase characterization and optimization.
  
  

Project Partners:

• Luleå University of Technology (LTU)
• University of Latvia (LU)
• Hitachi Energy Sweden AB, Composites (Hitachi)
  
  
  
  

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ZIM "CFKadapt"

ZIM "Basaltfunier"

ZIM "ProLaMas"

EFFICIENT LIGHTWEIGHT CONSTRUCTION: Fiber Composite Machine Tool Sledge with TFP

ZIM

By reducing the mass of the machine sledge in a milling machine while maintaining structural rigidity, it is possible to increase process speed while reducing drive power. Carbon fiber-reinforced plastics (CFRP) with a variable-axial fiber design are to be used, allowing a significant reduction in mass (50 %) with the same or improved structural rigidity compared to the most commonly used grey cast iron or steel designs, and also compared to the multi-axial CFRP designs used in the state of the art.

Project Partners: 

• Hightex Verstärkungsstrukturen GmbH
• Schmuhl Faserverbundtechnik GmbH & Co KG.
• Zentrum für angewandte Forschung und Technologie e.V. (ZAFT)
• Schwäbische Werkzeugmaschinen GmbH
  
  
  

Industrial Project "ConThiCo"

Consolidation of thick thermoplastic composite parts made by Tailored Fiber Placement

Industrial Project

• Successful hot pressing of C-Frame part made out of 16 CF-LEXTER-Preforms (530 g) 
• Multi-stage structural failure with increasing load maxima in tensile test 
• Maximum peak force levels similar to CF-epoxy C-Frame with approx. 70% of comparable stiffness

IGF "CoTherMu"

Development of locally flexible 3D composites from thermoplasticelastomer- multi-matrix systems in complex textile preforms

IGF

• Hybrid yarn online-spinning 
• Short consolidation times 
• Better recyclability

DAAD-PPP/CAPES "FiBraCo"

Fiber Bragg Grating Sensors For The Monitoring Of The Response Of FW+TFP Composite Pressure Vessels

DAAD-PPP/CAPES

• Methodology for inserting FBGs inside composite parts
• Interlayer strain measurements
• Evaluation of stress concentrations in FW/TFP processes

Completed projects:

AIF Cornet "TailComp"

AIF IGF "LoVarMed"

AIF "Kleinquerschnitte"

BMBF "BIOTEX"

BMBF "highSTICK+"

Project partners: 

• Dietrich Wetzel KG 
• Sächsisches Textilforschungsinstitut e.V. 
• IFC-Composite GmbH

BMBF "EMIR"

Engineering of Multifunctional Integrated CFRP Structures

The CFRP Fuselage Project

Focal point of the EMIR (Engineering of Multifunctional Integrated CFRP Structures) project is the development of a CFRP double-shell aircraft fuselage. Within the aviation research program III promoted project 'EMIR' the Leibniz-Institut für Polymerforschung Dresden e.V. elaborated in co-operation with airbus Germany production methods and processes for frame structures. Over 20 german research establishments as well as the aviation companies airbus Germany GmbH and EADS compiles together solutions for weight and cost-optimized fuselage, how it could already be used in some years.

Use of the TFP-Technology for the Low-Cost production of adapted fiber frame structures for the employment in double-shelled fuselage structures within the aviation.

Project partners: 

• Airbus
• Hightex-Verstärkungsstrukturen GmbH
  
  
  

Find out more

DAAD "PROBRAL"

DFG priority program 1123 (''Schüttgutbecher'')

Development of strength-optimized biaxial knitted preforms for complex geometries: Design, manufacturing, and testing of a biaxially reinforced glass fiber-reinforced plastic (GFRP) bulk material hopper.

The project is part of the Priority Programme (SPP) 1123 titled "Textile Composite Materials and Manufacturing Technologies for Lightweight Structures in Mechanical and Automotive Engineering". The research project aims to systematically develop the fundamental engineering principles for the load-path-optimized design of textile preforms and components. Additionally, it focuses on creating textile-adapted manufacturing technologies, consolidation processes, assembly techniques, and tooling systems. Using selected technology demonstrators from mechanical and automotive engineering, the project exemplifies innovative approaches for the load-appropriate development of textile-reinforced composite structures in lightweight design.

Purpose 

• Design and construction of a double-shell tool for the injection of a 3D preform made from biaxial knitted fabric with variable wall thicknesses.
• Development and manufacturing of an electrically heatable injection mold made from fiber composite materials.
• Development of a manufacturing technology for producing the bulk material hopper.
• Production of bulk material hoppers using different versions of the biaxial knitted fabric.
  
  
  

DFG "MerVa"

DFG "OptiTex"

DFG "Kreuzbandersatz"

EU "EMBROIDERY"

The approach to be investigated in EMBROIDERY is the development of a resistive self heated layer able to be embedded within either rigid composite laminates of elastomeric materials for membranes manufacturing. This heating layer will by manufactured by means of the Tailored Fibre Placement (TFP) technology. This will bring the following benefits: 

• The development of a reusable self heating membrane for infusion and preforming operations which will dramatically increase the productivity and the quality of the components.
• In RTM composite tooling, the integration of a heating layer close to the cavity, allowing much faster heating/cooling ramps and, overall, decreasing the energy demand compared to the current techniques.
  
  

In addition, TFP provides an outstanding capability to the composites industry, the fibre steering potential. That means that in the preform, the fibre orientation at each point can be oriented according to the stress field of the component, exploiting the full capabilities of the reinforcing fibre and optimising the material usage. However, in practice this potential is not exploited yet due to the lack of a computer commercial software package which takes into account the fibre steering feature. Therefore, a second focus of this project will be put on developing computer algorithms which account for steering potential. The final objective is the implementation of such algorithms into a commercial software for composites analysis. 

A third focus of the research will be put on the automation of the Tailored Fibre Placement technology itself. TFP has been developed in the mid 90s and is based on embroidery machinery used in the garment textile industry. The machines have been adapted to deposit and stitch fibre rovings onto a base material. However, being a relatively new technology and coming from the conventional textile industry, it is necessary to improve and adapt the process and equipment to the specific requirements of the advanced composites industry manufacturing.

Project partner: 

• Tajima GmbH

FNR "HoBaCo"

SAB/EFRE "Carbonstickgrund"

SAB "NGScope"

SMWK "Orbita"

ZIM "AniDo"

ZIM "TFPprint"

ZIM "FlexOr"

ZIM "Hotflex"

ZIM "Holz-FKV-Verbund"

ZIM "Membranpresse"

ZIM "WintFlap"

ZIM "10k-Tool"

A new kind of CFRP moulding tools 
with long service life

Objectives: 

The subject of research and development are complex designed and directly electrically heated infiltration tools made of fiber reinforced plastics (FRP). Carbon fibers are supposed to be used as the heating structure material. These new kind of tool technology is designed for FRP manufacturing, including preforming and resin transfer molding. 

The usage of directly heated tools made of FRP reduces significantly the tools mass, the required process time, and in consequence the energy consumption, compared to conventional metal tools. Another benefit is the matching thermal expansion of the tool and the casted part, also regarding anisotropic structure behavior. Furthermore a homogenous surface temperature can be accomplished due to specific design of the electro-thermal heating structure. 

The objective of the IPF sub-project is to define suitable coatings for these novel FRP tools. On the basis of various material tests and finite element analysis required process time and process parameters are supposed to be established and to be validated with the help of demonstrators.

ZIM "Development of a highly centrifugal force loaded rotor"