Thermoplastic tapes are expected to shape the next generation of thermoplastic composites. This calls for highly accurate tape stacking. Engel contributes this technology to achieve a breakthrough by combining high-precision control software with camera technology in tape stacking.

For high production efficiency, a tape stacking unit is best equipped with two robots and one camera station

Software-Based Tape Stacking with the Aid of Camera Technology Paves the way for Thermoplastic Composites

Spritzgießen

Kunststoffverarbeitung: Verfahren

Anlagen zur Composite-Herstellung

Kunststoffverarbeitung: Maschinen und Komponenten

Verbundwerkstoffe / Werkstoffverbunde

Kunststoff Werkstoffe

UD-Tapes

Verstärkungsstoffe

Kameras

Fertigungsautomation

Bildverarbeitung

Faserverbundwerkstoffe

Andere Werkstoffe

Automatisierungstechnik

Optische Mess- und Prüfverfahren

Qualitätssicherung

Qualitätssicherung Kunststoff

An Eye for the Essential

Carbon fiber-reinforced plastics (CFRP) are being used in more and more components. Their production is also becoming more and more effective. In the event of damage, however, business continues to be carried out manually. For this reason, greater automation is desirable when repairing CFRP. Automated laser processes could be one way of doing this.

Stepped scarfing on slat demonstrator: scarfing is a challenging step in CFRP repair

Automated Repair of Carbon Fiber-Reinforced Plastics

Kohlenstofffasern / -matten

Laserschweißen

Verbindungstechnik Verfahren

Thermisches Fügeverfahren

Lasertechnik

Laser Substitute Manual Work

Threaded inserts ensure a secure connection of hybrid components. Under continuous load, effects can occur with thermoplastics due to pressure and temperature, which means that a durable screw connection is no longer guaranteed. Such effects can be prevented by thread inserts with a special surface structure.

Metal thread insert with surface structuring on both sides prevent settling behavior of thermoplastic polymers in multi-material components

Structuring of Surface Ensures Reliable Anchoring of Thread Inserts in Organic Sheets

Automotive

Elektronik

Kunststoffe

Photonik

Optik

Reduced Settling Behavior in Multi Material Components

A number of examination methods can be used to identify weaknesses caused by incorrect fiber orientation. In particular, the fiber volume content and fiber distribution permit conclusions to be drawn regarding the stiffness and tensile strength behavior. A new ultrasound method offers the flexibility to capture these parameters on the finished component.

Ultrasound coupling: a shear wave probe contacts a glass fiber-reinforced plastic test specimen via a viscous couplant

Methods for Determining the Fiber Orientation in Reinforced Plastics

Ultraschall-Sensoren

Messtechnik

Sensoren / Messwertaufnehmer

Computer-Tomografie-Systeme

Werkstoffprüfung

Optische Mess- und Prüftechnik

Ultraschallprüfgeräte

Kunststofffasern

Röntgenprüfgeräte

Software für Optische Messtechnik

Groundbreaking Ultrasound  Shear Waves

Many people have good ideas and intentions. Few have the courage and determination to put them into practice. The young rezemo entrepreneurs Julian Reitze and Stefan Zender are one successful example. In 2019, some three years after their start-up was founded, the company was already producing well over one million compostable coffee capsules per year.

Sawdust and wood shavings from the woodworking industry, PLA as a binding agent – the recipe for ecologically compatible coffee capsules

A Start-up Produces Organic Coffee Capsules Made of Wood and Plant Starch in Millions

Biokunststoffe

Holz

Successful with Wood

Thermoplastic injection molded parts can be reinforced with local continuous fibers in combination with metallic load application elements. This also makes them suitable for structural applications such as transverse control arms and transmission mountings. A 3D winding technology was tested for potential use in a large-scale production process.

Robot-based fiber winding of complex injection molding inserts. The complex contours cannot easily be draped with flat reinforcing semi-finished products

Local Continuous Fiber-Reinforcement through 3D Skeleton Winding Technology

Leichtbau

Industrieroboter

Montagetechnik

Thermoplaste

Three-Dimensional Fiber Skeleton

The traditional markets for glass fiber-reinforced thermoplastics remain stable. Thermoplastic composites are gaining fast with 3D-printing and hybrid processing techniques. The fiber composite industry is tackling the recycling issue with pragmatic ideas.

The Oechsler Drivematic drive actuator can be integrated into the 3D-printed CFRP monocoque frame of an Arevo „e-bike“

The Manifold New Collection of Reactive Systems and Thermoplastic Composites

Glasfasern / -matten

Reaktionsharze

Duroplaste

Sekundärfasern

Kunststoff-Rezyklat

Fasern

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Aramidfasern

Harzsysteme für Composite-Herstellung

Phenolharze

Harzwerkstoffe

Werkstoffe für additive Verfahren

Harze, Epoxid

Duroplastische Werkstoffe

Hochleistungskunststoffe

Fiber-Reinforced Plastics

In addition to excellent mechanical characteristics and suitability for recycling, the key feature of hybrid lightweight structures made of fiber-reinforced thermoplastics is that automated, large series production is possible. New mold and process technologies were successfully developed within the scope of the ReLei research project, enabling the production of complex shaped sandwich elements in an efficient combined process.

In the ReLei project, several research and industry partners developed a rear shelf based on a fiber-reinforced polyamide as an example for manufacturing a complex sandwich structure

Thermoplastic Sandwich Structures for Large Series Applications

Schaumspritzgießen

Faserverarbeitung

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Spritzgieß-Sonderverfahren

Making It Big with Small Bubbles

Composite materials are often the key to lightweight design for many applications. However, these hybrid materials face a major challenge where recycling is concerned.

The experimental components were manufactured in a fully automated SMC manufacturing cell, developed by Engel, with an Engel v-duo 700 machine and an easix KR35 articulated robot

A Research Project Highlights the Recycling Potential of Lightweight Composites

Composite-Halbzeuge

Spritzprägen

Bruchmechanische Prüfung

Presswerkzeuge, Kunststoff

Pressen von Kunststoffen

Kunststoff-Recycling

Kunststoff-Aufbereitung

Zero-Waste Concept for Carbon SMC

Currently, small wind turbines can hardly be operated profitably in landlocked regions. This drawback has now been overcome by the partners EAB Gebäudetechnik Luckau GmbH and the Chair of Polymer-based Lightweight Design at the BTU Cottbus-Senftenberg: passive smartblades made from 3D-printed molds adapt independently to wind conditions. This is achieved by an intelligent layer structure and its bending-torsion-coupling.

This newly developed rotor blade is especially suited for weak-wind regions and adapts independently to the wind load

Additive Manufacture of FRP Injection Molds for FRP Components of Small Wind Turbines

Simulation Produkt- / Formteildesign

Software

Simulation

Finite Methoden

Ingenieurwissenschaften

Technische Mechanik

Windkraft

Energieerzeugung

Erneuerbare Energie

Analysetools, FEM

Additive Fertigung

Highly Efficient Adaptive  Fiber-Composite Rotor Blades

AVK and SMC BMC Alliance launch SMCCreate 2022 Design Conference.

Verbände, Institutionen, Messen

Dienstleistungen

Design in SMC and BMC Composite Materials

Solvay has signed a long-term agreement with Avio to supply advanced composite and adhesive materials for demanding applications in aerospace.

Luigi Pellegrini and Sergio Colabucci, Avio, Gerald Perrin, Giuliano Russo and Salvatore De Nicola, Solvay, ( from left to right) at the signing of the agreement

Harze

Klebstoffe

Chemisches Fügeverfahren

Materials for Space Exploration

Internal pressure loads are typical for fiber-reinforced plastic components. To increase the burst strength of components, the fiber orientation can be modified in a targeted way during injection molding by means of a rotating mold core. A newly developed simulation method allows this modified fiber orientation to be taken into account at the design stage.

Practical implementation of a mold system with rotating core.

16:9

Mold System with Rotating Core Improves Mechanical Properties

Werkstoffprüfung, mechanisch

Spritzgießsimulation

Design Methodology for Parts Subject to Internal Pressure

Lanxess has expanded its composite range called Tepex flowcore. The product family is specially developed for various compression molding processes.

No additional injection-molded material was used to produce the ribbing on the demonstrator model. It is made entirely from compression-molded Tepex flowcore.

Ductile Composites for Compression Molding

JEC Composites Startup Booster: the 2022 winners have been announced

In a few years, JEC Composites Startup Booster has became a reference for entrepreuneurship in the composites industry worldwide.

Start up

Wirtschaft

Unternehmen und Unternehmer

Networking in the Composites Industry

More Mobility for Physically Disabled People

Students at the PFH Hansecampus Stade, Germany, develop seating system for electrically assisted handbike.

Independent mobility and participation in everyday life for both physically disabled children and adults: that is the aim of the “E-Handbikes” research project, which is being conducted under the line of Prof. Dr.-Ing. Marc Siebert at the PFH Hansecampus Stade, Germany. Students developed the seating system for the electrically powered, three-wheeled handbike.

Countless preliminary considerations on the right material thickness, load tests and the testing of various manufacturing methods: Students Maximilian Miller, Hannes Hartung, Jan Matti Tinnemeyer, Thalea Kröger and Dennis Beck developed a seating system for a three-wheeled vehicle known as a “handbike” during the 5th semester of their “Lightweight Engineering & Composites” bachelor’s degree program. The e-handbike will be equipped with an electric drive and is intended to provide children and adults with disabilities with a significant increase in independent mobility and participation in everyday life.

“For us, this was a completely new task, otherwise it’s primarily about lightweight construction. We first had to familiarize ourselves with the seating needs of people with disabilities. Hannes Hartung’s experience helped us here, because Hannes plays wheelchair basketball,” explains student Thalea Kröger. The students developed the seating system as part of the lecture “Manufacturing Processes for Fiber Reinforced Structures (FVT)” at Hansecampus Stade.

Seating System Successfully Implemented by Students

“With the project, the students were able to apply their theoretically acquired knowledge of the material CFRP (carbon fiber-reinforced plastics) and their design skills,” says Prof. Dr.-Ing. Marc Siebert. Not least due to Corona restrictions, the coordination and harmonization of team members and the planning of work opportunities in the Airbus training workshop became a particular challenge in addition to the technical aspects.

“The goal is to let the students take the decisive step from the conceptual phase to the real implementation and production of physical prototypes,” Siebert explains. “Furthermore, it was a test for me to see whether 5th semester students can already work successfully on research projects,” says the professor. To this end, the seating system was decoupled from the overall project and the test balloon was launched. With great success: “The result is impressive, the seating system was successfully implemented in lightweight construction and has all the necessary adjustments for individual adaptation.”

Vehicle Concept for Physically Disabled Children and Adults

Handbikes are comparable to a bicycle or recumbent bike, but are propelled by the arms alone. In a two-year research project “Emob-Reha” (Electromobility in Rehabilitation Technology), funded by the European Regional Development Fund, the research team led by Prof. Siebert at the PFH’s “Fiber Composites Technology” chair is developing the vehicle concept for physically disabled people.

The electrically assisted handbike allows simultaneous steering and propelling, and in addition to electric assistance also has a small turning circle and good traction, so that it can also be driven on loose surfaces. “Among the daily life companions for paraplegic people is the wheelchair. However, the range and scope of independent mobility in a wheelchair are clearly limited due to its design; just think of mulched areas on children’s playgrounds, paths covered with snow or even a beach,” says Siebert.

The students from Stade also benefited in their development from several partner companies at the university, such as PFH cooperation partner Airbus and the company Schill & Seilacher, which provided reactive resins free of charge.

PFH - Private Hochschule Göttingen  

https://www.pfh.de

Maximilian Miller, Hannes Hartung, Jan Matti Tinnemeyer, Thalea Kröger and Dennis Beck (from left) developed a seating system for a three-wheeled vehicle known as a “handbike” during the 5th semester of their “Lightweight Engineering & Composites” bachelor’s degree program