Title: Selective high-speed tape placement using cut-on-the-fly for local reinforcement of GMT substrates towards a waste-reducing production of multi-material components

Authors: Christian Brecher; Tido Peters; Henning Janssen

Addresses: Department of Production Machines, Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany; Chair of Machine Tools at Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Steinbachstraße 19, Aachen 52074, Germany ' Department of Production Machines, Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany ' Department of Production Machines, Fraunhofer Institute for Production Technology IPT, Steinbachstraße 17, Aachen 52074, Germany

Abstract: Cost-efficient production technologies for lightweight composite components are the key enabler for a broad range of application. Manufacturing technologies like laser-assisted tape placement offer the opportunity to produce thermoplastic multi-material composite parts with optimum reinforcement, weight and cost profile. By the selective tape placement and in-situ consolidation of continuous unidirectional fibre-reinforced thermoplastic tapes in predetermined locations of existing composite structures, composite parts can be efficiently and economically manufactured. Enhanced by the new manufacturing process route, the weight of components can be significantly reduced by the combination of different reinforcement fibres in one single structure. This allows the achievement of an optimised relation between performance and weight. As a key enabler for drastically reducing the waste as well as the production times during in-situ selective tape placement the findings presented in this paper focus on the system and process technology to make an add-&-cut-on-the-fly process possible. Further findings focus on the increase in the process velocity and the influence of the lay-up pattern when using selective laser-assisted tape placement for the local reinforcement of a high-volume-suited polyamide 6-based glass mat thermoplastic substrate material.

Keywords: continuous unidirectional fibre-reinforced tape; multi-material components; selective reinforcement; tape placement; high-speed placement; cut-on-the-fly; local reinforcement; GMT substrates; glass mat thermoplastics; waste reduction; lightweight composites; thermoplastic tapes; polyamide 6.

DOI: 10.1504/IJAUTOC.2016.082069

International Journal of Automotive Composites, 2016 Vol.2 No.2, pp.113 - 138

Received: 02 Jan 2016
Accepted: 30 Aug 2016
Published online: 06 Feb 2017 *

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