JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 71

The use of automated laser-assisted processing of thermoplastics instead of thermosetting prepregs (tapes) can solve the disadvantages of the state-of-the-art approach. Because of the possible in-situ consolidation without post-consolidation steps during part production, all the resources needed for autoclaving are saved. Shape complexity is enhanced by the flexibility provided in terms of fusibility (e.g. placement of local reinforcements, joining with other components), reshaping ability (e.g. thermoforming) and further processability (e.g. overmoulding). In addition, thermoplastic composites enable higher temperature loads (e.g. PEEK, PEKK, PES), excellent chemical properties (e.g. PPS) and a significantly improved damping behaviour [GAO01], [BAI05]. The huge variety of thermoplastic matrix systems (e.g. PA, PP, HDPE, PEI) and fibre reinforcements (e.g. carbon, glass fibres) enables other industrial sectors (such as automotive, oil & gas, wind energy, chemistry, civil and mechanical engineering) to reach optimal solutions with respect to the required performance-to-cost ratio and cost-effective exploitation of thermoplastic composites. Over the past decades, laser systems have proved to be the most energy-efficient, precise and cost-effective method for tape placement in a lot of benchmarks [ESC01], [SCH09]. The challenge in laser-assisted tape placement is the choice of the proper laser source, laser optics, temperature control strategy, consolidation system and their suitable combination within the individual application. Based on the high variety of possible part geometries, different materials and sizes, there is no particular system which fits every application best. Flexibility often comes with inefficiency with respect to a certain task and reduced cost effectiveness because of high investment costs. Therefore, the Fraunhofer Institute for Production Technology (IPT) has been developing customized laser-assisted systems for more than 15 years to enable the best solution for every particular challenge (Figure 2).

Fig. 3: 3D demonstrator (up) and structural parts with open and closed geometry (down) manufactured at Fraunhofer IPT

Fig. 2: Customized laser-assisted tape placement solutions developed by Fraunhofer IPT

Outcomes
Some of the already performed approaches and challenges are highlighted and discussed below. As laser optics in the simplest way, static systems with a fixed laser position, fixed laser spot size and fixed radiation distribution between placed tape and substrate can be applied. These

systems, however, are mainly used as test rigs by university laboratories for preliminary investigations. The more complex the part geometry (change of radiation geometry), the more adaptable the system has to be in order to achieve constant temperature along the lay-up path. For the flexible production of a varying 3D lay-up path with different materials and an adjustable number of tapes, Fraunhofer IPT and its partners developed highly sophisticated optic solutions that allow automated online adjustment of the laser spot size (height and width) and the vertical and horizontal positions along the layup path to achieve the most favourable radiation distribution and constant processing temperature. For verification of the 3D lay-up, Fraunhofer IPT laid up a doubled-curved demonstrator geometry, which can be described by two “Gaussian” functions in the x and y directions (500x500x50mm) (Figure 3). Different methods and measurement devices (such as IR cameras, pyrometers and multi-point radiometers) can be used for temperature control strategies. IR cameras generate a lot of data concerning heat distribution in the nip-point and are suitable for process development purposes, especially if

No76 October - November 2012 /

jec composites magazine 71



JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012

Cover
Edito
Point of view: high-perfomance
Contents
COMPANY & BUSINESS In Brief
APPLICATIONS
- Bicycle
- Kayak
- Urban car
MARKET
- Human resources
- Aramid & basalt
SPECIAL JEC AMERICAS
- Floorplan
- 6th I.C.S.
- Academics posters area
- Awards
- Eductation & Skills
- Innovations Report & News
- Moulding
- Injection
- Defense
- CNC
- Land transportation
RESEARCH & DEVELOPMENT
- Thermoplastic
- Tape placement
- Cost effectiveness
TECHNOLOGY & INNOVATIONS
- Out-of-autoclave
- CFRC
- Software
Agenda of Events
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - Cover
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 2
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - Edito
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - Point of view: high-perfomance
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 5
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - Contents
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 7
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 8
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 9
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 11
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Bicycle
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 13
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 14
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Kayak
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Urban car
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 17
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 18
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 19
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Human resources
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 21
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Aramid & basalt
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 23
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 24
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 25
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 26
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - SPECIAL JEC AMERICAS
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Floorplan
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 29
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 30
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - 6th I.C.S.
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 32
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 33
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 34
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 35
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Academics posters area
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 37
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Awards
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 39
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 40
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 41
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Eductation & Skills
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 43
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Innovations Report & News
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 45
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 46
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 47
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 48
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 49
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Moulding
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 51
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 52
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Injection
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 54
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 55
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Defense
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 57
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - CNC
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 59
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Land transportation
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 61
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 62
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Thermoplastic
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 64
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 65
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 66
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 67
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 68
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 69
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Tape placement
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 71
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 72
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 73
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Cost effectiveness
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 75
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 76
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 77
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 78
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 79
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 80
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Out-of-autoclave
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 82
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - CFRC
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 84
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 85
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - - Software
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 87
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - Index
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - In the world
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 91
JEC COMPOSITES MAGAZINE - Issue #76 - October/November 2012 - 92
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