JEC COMPOSITES MAGAZINE - 2020 1st Quarter - Innovation report - 31

Multi-sector

NEW MULTI-MATERIAL
PROCESS FOR LARGE SERIES
As part of the FuPro project, TU Dresden developed a novel large-scale production process for multi-component structures
made of thermoplastic composites and metal inserts. The new process enables integrative composite design with hollow profiles,
curved organosheets and complex rib structures for high-volume lightweight applications. A highly-automated process chain
was set up for this project, ranging from braiding and preforming of the hybrid yarn over the consolidation of the hollow profile
up to its overmoulding and combination with the organosheet.
Under the leadership of Brose and the Institute of Lightweight Engineering and Polymer
Technology (ILK), the design was implemented on an application scale and demonstrated
producing a seat backrest with an integrated seat belt.
The backrest demonstrator illustrates the substantial advantages of the new processing
method and its design possibilities compared to the state of the art (Fig. 2). Compared to
the conventional steel design, weight can be reduced by approximately 30%. Moreover,
ten stamped-bent parts and an additional plastic carrier are substituted by a single integral
component. A large number of additional assembly elements can also be eliminated due
to the possible integration of screw domes, snap-fits, etc. The part costs are somewhat
higher compared to the steel structure, but the high degree of functional integration leads to
significantly lower project investments.
When considering the total costs, there is currently a profitability in the range of small to
medium vehicle unit numbers.
https://tu-dresden.de/ing/mw/ilk

INNOVATION REPORT

Multi-sector

INNOVATION REPORT

HYVARC HYBRID TOOLING FOR PRODUCTION

Multi-sector

Ascent Aerospace, the world's largest provider of turnkey solutions for aerospace tooling and
integration, further developed its HyVarC® hybrid tooling solution for full production capability.
With a durable BMI composite working surface that is permanently bonded to an Invar face
sheet and structure, HyVarC moulds can handle full production runs of 500+ parts at a 190°C
cure cycle. By combining the stability and vacuum integrity of an Invar structure with the
flexibility of a composite surface, Ascent can offer production tooling with a shorter lead time and
lower cost compared to traditional mould offerings. The availability of production features such as
integral vacuum systems, drill bars, attached thermocouples, and fairing bars makes HyVarC an ideal solution for any programme.
Ascent also offers HyVarC tooling with a lower-cost epoxy working surface that can be utilized for lower-temperature or lower-rate
applications. With a working temperature of 175°C, this option is ideal for shorter run programmes that expect developmental
engineering changes during initial part fabrication. The composite working surface can be easily thickened or remachined to adjust
the contour for springback or other surface modifications.
www.ascentaerospace.com

INNOVATIVE RUGGED CARBON SPLICERS

Double Queen's Awards winners for Innovation, Airbond, based in Wales, introduces a range of
new, innovative rugged carbon splicers with a five-year guarantee (in normal usage). Companies
who manufacture composites or carbon fabric can make significant cost reductions through
saved time and significant waste reduction.
Yarn splicers produce a smooth joint between threads, significantly reducing costs in all textile
processes. It has been historically difficult to make spliced joints in brittle materials such as
carbon or glass fibres used by the composites industry. These also tend to be much heavier yarns
than the traditional textile industry. These new products come with a long, five-year warranty and are
tougher than anything else on the market, worldwide.
The splicing process is complex and involves moving air at high speed, to interweave fibres without
breaking them. The ability to successfully splice carbon and glass fibres with this method has eluded
many experts for decades as the fibres tend to be brittle and turn to dust. Airbond, who understand the
science of airflow, have learned how to operate splicing chambers at lower pressures to successfully
splice fragile and large yarns.
Airbond's research led to the invention of new and better forms of pneumatic yarn splicers that, for the
first time, can splice modern composite materials efficiently and effectively.
www.airbondsplicer.com

January-February-March 2020 /

jec composites magazine

https://www.tu-dresden.de/ing/mw/ilk http://www.ascentaerospace.com http://www.airbondsplicer.com

JEC COMPOSITES MAGAZINE - 2020 1st Quarter - Innovation report

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - 2020 1st Quarter - Innovation report