COMPOSITES
E
ndless fibre winding for 3D components is moving to the next level with a fully automated winding process. Te process is wet
winding of impregnated fibres around or on a winding mould. Various fibres can be used, including carbon (high strength or high E-modulus), glass or natural fibres such as basalt, hemp, flax, ramie or others, Te matrix used is a thermoset type.
Various resins can be used as well and these are mono-component or duo- component with some additives for meeting certain specific requirements depending on their application (e.g. fire smoke and toxicity in aerospace, outgassing and extreme temperature ranges in space applications). Furthermore, the traditional polymers with hardener could be replaced in the future with biobased polymers – an area where there is still some development in front of us. Applying all possible fibre materials with the huge amount of polymer materials now will open a large panel of possibilities and applications. As the impregnation is realised directly on the robot (wet winding), this system is giving maximum of flexibility for multiple business fields, such as aerospace, aeronautics, automotive and mobility in general, consumer goods, furniture, sporting products and much more. Once the components to manufacture
are wound, the winding mould is proceeded in a curing process that is not needing an autoclave process. Curing is typically conducted at atmospheric pressure at temperatures around 200°C.
The finished bracket tube holder
GAMECHANGER FOR LIGHTWEIGHT DESIGN
Claude Maack introduces fully automated industrial equipment using endless wet fibres for manufacturing 3D ultra-lightweight structures
Optimised fixation of a tank: the spring effect allows expansion of the tank by guaranteeing enough friction at all given load cases
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Nevertheless, depending on the specification of the application, all combinations of fibre/matrix must be qualified accordingly. Tis is an absolute must as the mechanical resistance and E-modulus are varying and depend on their manufacturing process. It is key to know these characteristics to have a reference for comparing the results of the FE analysis. As the process for design finding, topology optimisation is simulation driven and with this equipment, the gap for industrialised manufacturing process for highly demanding applications is now closed. Te result is a new game-changing process, which the German originator and innovator Automotive Management Consulting (AMC) named “xFK in 3D”.
Dimensions can be from 50 x 50 x 50mm up to the size of a car and above. Te process itself is not limited. It’s the handling, transport and curing of large components that are potentially limiting.
Te manufacturing process is in the qualification process for space applications with ESA and the three largest satellite Integrators of Europe. Te continuous fibre technology xFKin3D is suitable for non-rotationally symmetrical components such as brackets and other complex support elements. xFKin3D overhauls the endless winding process to a higher “D” level, i.e. with the xFKin3D technological process, it enables parts of 3D, 4D & even 5D to be produced, bringing intelligent functions to the structure if required.
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