COMPOSITES
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and designed according to the parts to be produced makes good sense. Such an approach allows the manufacture of high technological parts using endless fi bres with special features, including: ultralight, high geometric fl exibility; optimised bionic shape; and reduction of complexity. Force and tension can be optimised (fi bre strength/direction according to load) and there can be defi nable/adjustable strength and stiff ness. T is approach off ers multi-axial load capacity (tension/compression, bending, torsion). It is also material optimised and resources friendly Some designers, engineers and manufacturers are already developing new components and structures using the endless fi bres instead of metal/plastic approach for some applications. Parts with endless fi bres that have already been produced include lightweight brackets and sandwich panels.
WHAT ARE THE CHALLENGES? As in any materials and manufacturing process, technical and industrial challenges appear. Engineers and manufacturers must analyse the possibilities versus the product risk that new materials and technology demonstrates. T e main challenge that appears to determine the intense use of endless fi bres is to understand and know the manufacturing process from the start to the end. A well automated and calibrated manufacturing process will enable a continuous and repeatable quality of the manufactured products. As the use of endless fi bre material is considerably lower as the traditional way to manufacture parts, this
Structures such as springs are an ideal application for this process
approach brings signifi cant added value for the coming future where resources are getting more and more rare and costly. Moreover, a well-established supply chain of the endless fi bre material is a must. It is important to select a reliable and industrial endless fi bre material and manufacturer with industrial capacities.
Considering that, in the near future, it will be possible to manufacture 3D structural parts using natural fi bres combined with natural bio-based binders, which are 100% repairable (self-healing), recyclable and sustainable, the potential of endless fi bres as main structural material is clear. Sustainability is a mega-trend that
will infl uence our behaviour for the next decades, as humanity starts to understand that things must change. T e challenges are huge. Lightweight is the smallest common denominator for all mobility topics (street, water, air or even in space). Half of weight leads to half of energy, independent of what kind it is, needed for acceleration.
Assembly of wound hybrid structures
TECHNOLOGY WITH VAST POTENTIAL xFK in 3D is a process technology that will contribute considerably to this topic. OEMs have referred to it as a
“gamechanging technology”. T e reasons for this are obvious. It delivers from 50 to 70% of weight savings at the same stiff ness. Integration of functions leads to a reduction in complexity. Complex 3D structures of large size (dimensions of a car or even bigger) are possible. A simulation-driven digital process chain means topologic optimisation. Studying patterns found in nature, by thinking in ropes, leads to a bionic design. CAD-FEA-CAM is a fully automated robotised winding process. Finally, this approach off ers high fl exibility for using any fi bres in combination of any binder. By adding the use of natural fi bres today and in the near future, bio-based resins for circular economy aspects, by repairing structures and recycling the materials in an intelligent way, this process will be a breakthrough for sustainable systems. T e added value versus the relative quality of xFK in 3D solutions is compelling. OEMs and other industry experts confi rm that this technology will be unavoidable.
Claude Maack is managing director of Gradel.
www.gradel.lu
www.engineerlive.com 39
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