INTALES 18 October2018€¦ · composite parts. 3D-LightTrans A Project co-funded by the EC in the...

INTALES18 October 2018

www.3D-LightTrans.com

Marianne HörlesbergerAIT Austrian Institute of Technology

Project Management of 3D-LightTrans

3D-LightTrans

A Project co-funded by the EC in the 7th Framework Programme

AIT Austrian Institute of Technology

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Infrastructure Systems

Next Generation Solutions

Applied ResearchSystem Competence

bmvit

Tomorrow Today

Austria‘s largestRTO

Federation ofAustrian Industries

Centers8employees1,300

over

m EUR total revenue143

SubsidiaryEnterprises

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3D-LightTrans


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3D-LightTrans


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3D-LightTrans


The Core Idea of 3D-LightTransLarge scale manufacturing technology for high-performance lightweight 3D multifunctional composites

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3D-LightTrans


Project Objectivesto establish and provide access to ground breaking, highly flexible and adaptable low-cost production technologies

for manufacturing high performance light weight

3D multifunctional textile reinforced polymer composites

for structural components.

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3D-LightTrans


State of the Art (when 3D-LightTrans started)

MANUFACTURING CHAIN

Transfer Preform onto toolautomated

Thermal Pressingautomated

THER

MO

FOR

MIN

G

Fixation

DrapingInfiltration

PREPR

EG A

UTO

CLAVE O

R

CO

MPR

ESSION

MO

ULD

ING

Place Material on Tool

Manual

Drape or Deform

Manual

Tool Pre‐Head and Cure

Slow

Storage/Transport

Low Temperature

PRE-

FOR

MIN

G

Pre‐heat & Transfer to Tool

Tool Pre‐Head

Drape/Preform

Cure

Slow

PrepregFabric

Matrix

Up to an hour

Inject Thermoset Resin

Yarn

Weaving Fabric

Matrix

Weaving

Hybrid Fabric

Hybrid YarnWeaving

Air co‐mingling

Yarn Matrix

3D-LightTrans MANUFACTURING CHAIN

RESIN

TRA

NSFER

M

OU

LDIN

G (R

TM)

Up to several hours

Yarn

PRE-FO

RM

ING

1-5 minutes

Preform

Storage/ TransportROOM

Temperature

3D-LightTrans


The 3D-LightTrans Concept

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Hybrid yarnMultilayeredand spacer fabrics

Draped and fixated pre-form

Thermo-pressed final composite parts

3D-LightTrans


Our Innovation in a Nutshell

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Hybrid yarn Woven fabric Automation Consolidation

• Reduction of fibre displacement during thermoforming > 50%

• Reduction of composite forming time > 50% (with thermoforming and off-the-tool draping)

• Automated draping with rolling/sliding double action robot gripper and force control

• Novel process for geometry fixation

• Manufacturing chain suitable for mass production

• Industrial weaving of cross woven spacer fabrics in one-shot-process

• Significant reduction of yarn abrasion

• Multilayers with additional Z reinforcement

• Double reed for high warp density

• High homogeneity of the glass/polymer distribution

• High reproducibility & speed (500 m/min)

• Flexibility in the choice of yarn (e.g. 70:40, 70/30, 80/20 mass content PP/Glass or PET/Glass, 600-2000tex)

3D-LightTrans


The Consortium

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3D-LightTrans


Results – New FindingsIssues for the

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3D-LightTrans


Air-Mingling Yarn Developed yarn architecture Upscaling of the air-mingling

process at PD-GOschatz to TRL 6

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Commingled hybrid yarn

3D-LightTrans


Dornier – New Loom

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3D-LightTrans


Michel Van De Wiele – New Loom TRL 6-7

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TUD

3D-LightTrans


Pre-Fixation fixation process using milled black PET powder and melting it by laser is

verified

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3D-LightTrans


Thermo-Pressing

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3D-LightTrans


Joining / Metal Part Integration

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3D-LightTrans


Demonstrator Spare Wheel Well

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3D-LightTrans


Demonstrator Tailgate

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3D-LightTrans


Handling and Draping

Handling systems join robotic systems

One handling device for the 3 main workstations• Textile cutting• Draping • Thermoforming

3D-LightTrans


Robot for Draping

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3D-LightTrans


Model for Manufacturing Chain

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3D-LightTrans


Multi-Scale Mechanical Modeling

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3D-LightTrans


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Meso-scale modelling of dry fabrics

Meso-scale modelling of thermoformed composite, taking into account small misalignments

3D-LightTrans


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Draping simulations of tailgate (left) and spare wheel well (right)

Thermoforming simulation of tailgateSimulation of complete process chain

3D-LightTrans


Manufacturing Value-Added Cost (MVA)

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Based on the time spent in the specific manufacturing step, (calculated in the previous

simulations), the energy cost ( ) is obtained.

Energy Cost

· ·

Manufacturing Value-added Cost

· ·

The calculated results can guide changes to the commodities and assembling stations and provide invaluable information to the capacity planners and schedulers to estimate the required number of processing stations and resources to meet the customer demand.

the energy consumed per unit of time per processing step

time spent in the specific processing step; i.e., time in which the processing station is working

unit cost of energy

incurred processing cost per unit of time per processing step

resource cost per unit of time per resource used

cost of the scrapped partscost of the energy

3D-LightTrans


Optimization and Scaling-up of the Production Process

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In this part of the project the functional relationships between various factors will be investigated in order to find the better configuration (i.e., optimal configuration) for the manufacturing process, as well as to investigate the parameters driving the scaling-up.

Objective Function

· ·1π λ θ ξ ζ

χ∑ ∑ ∑ · · 1π λ

∑ ∑ ∑ · · 1π λ φmin , τ

This objective function needs to be implemented in a post processing module and investigated

using Design of Experiment and Response Surface Methodology (Steppan et al., 1998).

SCHEDULED PRODUCTION S REALIZED PRODUCTION R

3D-LightTrans


Life Cycle Assessment (LCA)

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EU

3D-LightTrans


LCIA – Tailgate Use Phase

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3D-LightTrans


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Life Cycle Analysis Conclusions

Along the whole life cycle, the 3D-LT solution shows:

Advantages in use phase thanks tothe light weighting

The benefits in use phase are, anyway, not enough to balance the environmental burdens in production

Anyway, the commingling step, the most environmentally critical, could be further improved/optimized

Use of recycled material could improve significantly the 3D-LT solution (check on the quality requirements)

3D-LightTrans


Scientific Output 3 publication in reviewed journals 10 further contributions to conferences (presentations and posters) 6 invited presentations 4 contributions in newsletters 3 PhD theses

Jean Emile ROCHER, UORLExperimental characterization and modelling of the mechanical behaviour of 3D comingled

composite reinforcements

Stefan JACQUES, UGentDevelopment of a Framework for the Construction of Meso-Scale Finite Element Models of

Textile Composite

Matthias Hübner, TU DresdenDrapingsimulation

1 Master Thesis Andrea DIETRE, CRF / University Trento

Development of an Automotive Component in Thermoplastic Composite Material

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3D-LightTrans


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3D-LightTrans


Three Years After Bentley is still considering the use of thermoplastic composite structures for

secondary (trim substrate) structures. the 3D-LightTrans approach remains valid, with some modification.

Van De Wiele 3-LightTrans opened up a bigger international exposure of Van De

Wiele as a possible contact in composites related production, both in industrial and in research environments. No real 3D-LightTrans machine sales have been realized, but some

specialty machines have been sold to new contacts.

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3D-LightTrans


Three Years After TU Dresden / ITM 3D-LightTrans project is still alive: further development in the

lightweight material arena; Working very closely with the industry partners during the project helped to develop more innovative ideas that can fulfill the requirements of industry.

LKR (AIT) 3D-LightTrans was to gain experience in joining fibre reinforced

plastic with metals via pin technology. Since this project, LKR has further grown in the field of pin-

technology. Every year we receive contract research requests for the pin-

technology – the last once were for automotive and marine application.

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3D-LightTrans


3D-LightTrans

A project co-founded by the European Commission under the 7th Framework Program within the NMP thematic area.

THEME: NMP-2010-3.4-1Manufacturing systems for 3D-shaped, multilayered products based on flexible materials

Full Title: ”Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites“

Grant agreement no: 263223

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3D-LightTrans


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Marianne Hö[email protected]

Project Management of 3D-LightTrans

INTALES 18 October2018€¦ · composite parts. 3D-LightTrans A Project co-funded by the EC in the...

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