issue 08/2021

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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.

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

Glasfasern / -matten

Faserverarbeitung

Simulation Produkt- / Formteildesign

Verbundwerkstoffe / Werkstoffverbunde

Finite Methoden

Harze, Epoxid

Windkraft

Analysetools, FEM

Additive Fertigung

Faserverbundwerkstoffe

Highly Efficient Adaptive  Fiber-Composite Rotor Blades

Diode lasers are often used for the production of lightweight components by means of thermoplastic tape laying. However, common tape laying systems are noticeably limited in their production capacity. With a flexible multi-head system, Laserline GmbH promises a cost-efficient system that should also pay off in large-scale production.

Multiple Processing Heads in a Row Optimize Processing Speed

Halbleiterlaser, Diodenlaser

Schnüre, Bänder, Tapes

The Hydra among Diode Lasers

In the iComposite 4.0 research project, it has been possible to cut the costs for a prototype component by more than 50 percent and throughput time by 40 percent.

Economic Production of Fiber-Reinforced Plastics in High Volumes

Schröder, Susanne

Pressen von Kunststoffen

Self-Regulating Production Plant

Short glass fiber-reinforced plastics are exposed to complex load cases during the operating time. Therefore, the influence of alternating load and frequency in the form of load spectra on material fatigue is investigated and an integrative computational method for structural design is presented. With this practical approach, a fast fatigue life estimation is possible.

The Influence of Varying Frequency and Load Level on the Fatigue Life of Short Glass  Fiber-Reinforced Technical Thermoplastics

Thermoplaste

Cumulative Failures Prevention

Climate change and the transport revolution are demanding smart fiber-reinforced composite solutions. In sectors such as the marine industry, infrastructure, and rail vehicle construction, many different fire protection concepts are competing. The composites industry is paying increased attention to recycling.

Fiber-Reinforced Composites Drive Innovation in the Transport and Construction Sectors

Composite-Halbzeuge

Kohlenstofffasern / -matten

Sekundärfasern

Fasern

Composites Are Trendsetters in Lightweight Design

Organo sheets have become established in several industrial sectors for the series production of highly stressed lightweight components. The utilization of waste material is a promising recycling approach.

Feeding Mechanically Recycled Fiber-Reinforced Thermoplastics Back to Production

Mahlgut

Recycling

Kunststoff-Recycling

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Mahlen

Organo Sheet Recycling

The company’s latest model in the blown film segment is a five-layer co-extrusion blown film line that enables the production of film with maximum lay-flat width of 1400 mm.

Kung Hsing Stands out in Multi-Layer Film Extrusion

Blasfolienextrusion

Wickelmaschinen

Kunststoffverarbeitung

Folien

High-Speed and Efficient Blown Film Line

Starting immediately, ips Intelligent Pelletizing Solutions GmbH & Co. KG, Niedernberg, is also supplying systems for the production of long fiber-reinforced thermoplastics (LFT). For this, the company is delivering complete systems from a single source ¿ from planning through construction to commissioning ¿ just as for strand and underwater pelletizing systems. 

Intelligent System Concept for the Production of LFT Pellets 

Kunststoffverarbeitung: Maschinen und Komponenten

Pultrusion

Granulieren

For Heavy-Duty Structural Components 

The introduction of fiber direct compounding at deller plastics Uwe Braselmann was driven by tangible economic advantages. The plastics processor uses the lightweight construction process for manufacturing cable drive housings for operating electric power windows in car doors.

deller plastics Uses Competitive Advantages of Fiber Direct Compounding

Spritzgießen

Linearroboter für die Kunststoffverarbeitung

Lightweight Components  from the Roll

Carbon fibers are due to their high price interesting for recycling. The results of the project RecyCarb enable the multiple use of carbon fibers as functional re-use. First demonstrator parts in the areas of medical technology and automotive prove the industrial feasibility.

Re-Use of Recycled Carbon Fibers in Sophisticated Composite Parts

Kunststofffasern

Second Life for Carbon Fibers

Additives often consist of additive mixtures of heterogeneous components. Their anisometry leads to part properties that depend very strongly on the orientation of the additives. For this reason, it is essential to describe such orientation behavior at an early phase of development when additized plastics parts are being designed.

Simulating the Orientation Behavior of Additive Mixtures

Additiv-Konzentrate

Prozesssimulation

Spritzgießsimulation

Füllstoffe, allgemein

Additiv-Batches

Füllstoffe für Kunststoffe

Additive

Elektrisch leitende Füllstoffe (Metalllegierungen, Ruß, Graphit)

When Fibers Mix with Platelets

With innovations in metrology, processing and automation, the film industry is again pursuing the goal of process optimization and digitalization this year. But efficiency and sustainability are also the focus of the machine manufacturers, who will be serving up pioneering innovations at K 2019.

The Circular Economy – Sustainable yet Efficient?

Flachfolienanlagen

Flachfolien- und Plattenextrusion

Verpackungstechnik

Folienabzug- und -aufwickelmaschinen

Extrusionswerkzeuge

Folienreckanlagen

Folienblasanlagen

Kreislaufwirtschaft

A Perfect Concept All Round

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.

Thermoplastic Sandwich Structures for Large Series Applications

Schaumspritzgießen

Spritzgießwerkzeuge

Spritzgieß-Sonderverfahren

Industrieroboter

Making It Big with Small Bubbles

At the start of the year, Toray opened a European R&D center near Munich, Germany, dedicated to automotive applications. From specially manufactured carbon fibers and engineering plastic compounds to battery elements such as separator foils, a wide portfolio is on offer from a single source. Kunststoffe spoke to Toray Group managers about their evaluation and strategy. 

With a New R&D Center, Toray Is Setting its Sights on the European Automotive Industry 

Hochleistungskunststoffe

Polyamide

Japanese Multi-Material Specialists 

"The right material in the right place" is the maxim of the multimaterial design. A lack of economical production methods has so far prevented commercialization at current batch sizes. To overcome this obstacle, a modular control and production plant concept was developed and demonstrated in the MoPaHyb collaborative project. 

Development of a Production Plant for Hybrid Fiber Composite Components 

Automatisierungstechnik

Montageeinrichtungen

Modular Thinking 

Long glass-fiber-reinforced polypropylene and polyamide are used in automotive lightweight construction especially where high impact toughness, very good crash behavior and low weight are required. However, care must be taken during injection molding, since not every screw is suitable for these materials. To maintain the fiber length reliably and obtain a uniform distribution of the fibers, Engel has developed a new plastification system especially for processing long glass-fiber-reinforced materials. 

Plastification System Optimized for Processing Long Glass Fiber Materials 

Spritzgießmaschinen

Better Part Properties thanks to Fewer Fiber Breakage 

The combination of fiber-reinforced face layers with a lightweight foam core combines high strength and stiffness with low part weight. However, when processing, it is anything but easy to combine anisotropic FRP materials with lightweight, cost-effective foams. A tailored material system now makes processing by high-pressure resin transfer molding possible at low temperatures and pressures, with short cycle times. 

Rapid and Cost-Effective Sandwich Parts with PU Resin and PET Core Foam 

Polyethylenterephthalat

Harze

Reaktionsharze

Polyurethan

Hard Shell, Lightweight Core 

The combination of luminous fibers with plastics or fiber reinforced-plastics will open up a future-oriented field for functionalizing lightweight materials. Designers will appreciate being able to create previously unperformable filigree contour lines and uniform lighting effects on components. 

Accessing New Fields of Application by Integrating Optical Fibers 

Mehrkomponenten-Spritzgießen

Hybridtechnik

Gewebe, technisch

Luminous Fibers as Design Elements  in Plastics Parts 

Plastics reinforced with continuous fibers were long considered a cost driver because the processing technologies did not support large quantities. Thanks to thermoplastic matrix materials in combination with new semi-finished goods and processing methods, this material class is now coming very close to industrialization. 

Fiber-Reinforced Thermoplastics for Large Series 

Halbzeuge und Zwischenprodukte

Lightweight Cost Benefits 

Induction as contactless heating technology is also attractive for composite materials. The efficiency of the technology has so far been limited by the resulting complex temperature distribution. Therefore, it is necessary to fundamentally investigate the influences of the laminate parameters on the induction heating behavior of CFRP. 

Influences of Laminate Parameters on the Induction Heating Behavior of CFRP 

Heizung

Polypropylen

Induction Heating of CF-Reinforced Polymers 

Individually manufactured and tailored to major automated fiber placement processes, cevoTape from Cevotec GmbH, Taufkirchen, Germany, offers a new option for series production at reasonable economics. As the right fiber is crucial for the quality of a composite part, Cevotec developed cevoTape, a dry-fiber spread tow made from high-quality carbon fiber rovings, bindered with a copolyamide adhesive. 

Alternative to Aeronautic-Certified Tapes 

CevoTape 

The two AZL Partners Conbility GmbH and Fraunhofer Institute for Production Technology IPT, Aachen, Germany, have started a long-term cooperation for the further development and for the commercialization of Fraunhofer´s tape-placement and tape winding systems with in-situ-consolidation by the usage of laser or IR heat sources. With this cooperation, the company Conbility makes 25 years of expertise in special machine development of tape placement systems of the Fraunhofer IPT commercially available. 

Tape Placement and Tape Winding Systems 

Warmformen / Thermoformen

Conbility and Fraunhofer IPT Join Forces 