the project 3d-lighttrans aims to provide a ground-breaking, highly flexible, efficient and...
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The project 3D-LightTrans aims
to provide a ground-breaking, highly
flexible, efficient and adaptable
manufacturing chain for the production of
integral large scale 3D textile reinforced
plastic composites (TRPC).
This will enable to shift them from its
current position in cost intensive, small
series niche markets, to broadly
extended mass product applications in
transportation and other key sectors,
like health and leisure.
Project Coordinator
Dr. Marianne Hörlesberger (AIT)
marianne.hoerlesberger@ait.ac.at
Exploitation & Dissemination Manager
Dr. Ana Almansa (Xedera)
aam@xedera.eu
www.3d-lighttrans.com
Copyright © 2012 3D-LightTrans – All rights reserved
Abstract
Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites
Project data3D-LightTrans Concept
Objectives
1. Substantial increase of achievable
complexity and flexibility in the
realization of 3D fabrics
2. New procedure for highly efficient
production of TRPC parts (up to 70%
shorter processing time, less than 0,5
mm. fibre displacement)
3. Establishment of the complete
manufacturing chain
4. Enabling mass manufacturing of
products with short production times
and high customization
To demonstrate this, a spare wheel well,
an air vent part and a tailgate will be
produced, featuring:
- Different specific functions (structural,
aesthetic, storage…)
- Size up to 1,37 m. x 0,87 m. x 0,71m.
and varying complexity
- Mass and/or cost reduction (in
comparison with e.g. cast aluminium
and carbon-glass-epoxy composite)
- Demanding mechanical properties
and load requirements: -40°C to
120°C (typically), tolerance to stone
impact, rigidity and torsional
deformation…
- Suitability for subsequent assembly
and post-processing: mechanical
fastening, integration of metallic
inserts, addition of brightwork, etc.
Project title
Large scale manufacturing technology
for high-performance lightweight 3D
multifunctional composites
Acronym
3D-LightTrans
Grant agreement no.
263223 FP7-NMP-2010-LARGE-4
Project duration
From April 2011 to March 2015
Consortium
1. Austrian Institute of Technology GmbH
2. Xedera e.U.
3. Centro Ricerche Fiat SCPA
4. Coatema Coating Machinery GmbH
5. Federal-Mogul Systems Protection
6. Universiteit Gent
7. Grado Zero Espace srl
8. Technische Universität Dresden
9. LEITAT Technological Center
10. Lindauer Dornier GmbH
11. Northwest Textiles Network Limited
12. P-D Glasseiden GmbH Oschatz
13. Michel Van de Wiele
14.Onera - The French Aerospace Lab
15.Bentley Motors Ltd
16. SVUM A.S.
17. PROMAUT S.L.
18. Universite d‘Orleans
In the 3D-LightTrans manufacturing chain, multimaterial semifinished fabrics will be processed to
deep draped pre-fixed multilayered and multifunctional 3D-textile pre-forms. The fixed pre-forms
can be easily stored and transported (if needed) without special temperature requirements.
A project co-funded by the
European Commission within the
7th Framework Programme
Fig. 1- 3D-LightTrans manufacturing chain (all pictures -except battery case and truck- by TU-D)
The final composite part is produced by thermoforming. Neither manual draping of the textile onto
the forming tool nor infiltration/curing are required, since preforms are already fixed in the desired
3D geometry and the thermoplastic matrix integrated in the hybrid yarn before weaving.
- Multilayered and 3D-shaped fabrics with different
weave architecture realised
- Modified machines available in TU-Dresden (rapier
looms with heddle frames and jacquard, adapted for
weaving hollow structures); specific developments on
loom for full automation on-going (Michel Van de Wiele)
- Micro-CT results available, 3D-Finite Elements
simulation of the unit cell on-going
- On-going work on local reinforcement, pre-fixation and
draping (with simulation of in-plane draping behaviour
showing good correlation with experimental results)
- First thermoformed test parts available; process
simulation and part characterization on-going
First project results
For more information please contact:
Contact
- Hybrid air mingled yarns with different glass rovings and PP, PA, PET/PES as matrix material
(tensile modulus of 30 to 36 GPA for a mixture ratio of 70:30 with E-Glass)
Fig. 4- Micro-CT picture of multilayer (UGent)
Fig. 3- Different weave architechtures (TU-D)
- Modelling, simulation and tests on Glass-PP
fibre done
- Running work to decrease/improve abrasion,
ageing and adhesion
Fig. 5-GP/PP Hybrd yarn 17 layered weave (left) and composite (right): Compression approx. 57% (TU-D)
Fig.2- Different hybrid yarns and test results
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