EXPERT'S DIGEST ATL/AFP Fig. 4: Stamp formed CFRTP structure with insert which has been integrated during the thermoforming process At Fraunhofer IPT, the thermoforming has been combined with a simultaneous functionalization process. Inserts and fasteners can be integrated during the thermoforming process (figure 4). As the thermoplastic matrix material is molten prior to the thermoforming process, inserts can be integrated into the structure by a local forming process. One main benefit of this process integration is that the conventional additional process step for the integration of the insert is redundant. Additionally, the mechanical properties of molded-in joints are superior in comparison to joints with drilled holes as the fibers are not damaged but squeezed to the boundary area of the joint area. In contrast to injection molding or thermoplastic welding the load is carried not only by the matrix material but by the fibers. The increase of the joint strength has been proven at Fraunhofer IPT for both fabric-based thermoplastic composites as well as for composite sheets made out of unidirectional tapes. After the integration of inserts is completed and the matrix material is cooled down under melting temperature, an in-mold trimming of the CFRTP structure can be performed. Hence the conventional process chain of forming, trimming and joining can be shortened to one integrated process step. Development and implementation of production processes and systems In addition to the research activities Fraunhofer IPT also develops and implements production processes and systems to realize automated manufacturing processes of lightweight fiber-reinforced themoset and thermoplastic components. A new laser-assisted fiber placement system developed by Fraunhofer IPT will be launched this summer (figure 5). The " hybridTLK " (hybridAFP) is a laser-assisted fiber placement system which can be added as an end effector to industrial jointed-arm and linear gantry robots in variable Fig. 4: Stamp formed CFRTP structure with insert which has been integrated during the thermoforming process Expert's digest jec composites magazine Additive Manufacturing 98