Periodic Reporting for period 2 - FIONA (FIbre OrientatioN Analysis of FRP components)
Reporting period: 2021-08-01 to 2023-10-31
Fibre reinforced plastics (FRP) are increasingly used as alternatives to load-bearing metals for multiple applications within a range of industries (such as e.g. electric vehicles) due to the superior design flexibility and high strength-to-weight ratio of composite materials.
The maximum reinforcement effect of the fibres in such materials can be obtained by optimizing the degree of alignment between fibre orientation and loading directions. Currently, fibre orientation is determined through design cycles which involve multiple test castings and manual 2D experimental validation of fibre distribution in small FRP samples; a method which is resource-wasteful, time-consuming and labour-intensive. Furthermore, it is estimated that FRP components only provide ~30% of their maximum strength under such design cycles. This suboptimal result stems from a lack of 3D imaging tools that provide accurate structural information across entire FRP parts and enable improvement of the designflows.
The FIONA project aims at developing the 3D FibreScanner, a simple and cost-effective X-ray add-on module for structural 3D imaging of FRP components, enabling full exploitation of FRP mechanical properties and great improvements of design and development cycles.
At the completion of the FIONA project we have successfully build and demonstrated an in-house 3D FibreScanner prototype capable of performing fast and robust 2D and 3D fiber characterization of fibre-reinforced plastics parts. We have worked closely with representatives of the plastic moulding industry, academic research institutions, providers of injection moulding software solutions and X-ray CT manufacturers to validate the technology, ensure a good product-market fit and for preparation for an introduction of the 3D FibreScanner to the market in 2024.
The maximum reinforcement effect of the fibres in such materials can be obtained by optimizing the degree of alignment between fibre orientation and loading directions. Currently, fibre orientation is determined through design cycles which involve multiple test castings and manual 2D experimental validation of fibre distribution in small FRP samples; a method which is resource-wasteful, time-consuming and labour-intensive. Furthermore, it is estimated that FRP components only provide ~30% of their maximum strength under such design cycles. This suboptimal result stems from a lack of 3D imaging tools that provide accurate structural information across entire FRP parts and enable improvement of the designflows.
The FIONA project aims at developing the 3D FibreScanner, a simple and cost-effective X-ray add-on module for structural 3D imaging of FRP components, enabling full exploitation of FRP mechanical properties and great improvements of design and development cycles.
At the completion of the FIONA project we have successfully build and demonstrated an in-house 3D FibreScanner prototype capable of performing fast and robust 2D and 3D fiber characterization of fibre-reinforced plastics parts. We have worked closely with representatives of the plastic moulding industry, academic research institutions, providers of injection moulding software solutions and X-ray CT manufacturers to validate the technology, ensure a good product-market fit and for preparation for an introduction of the 3D FibreScanner to the market in 2024.
During the project period, progress have been challenged by first the COVID-19 pandemic and later by the impact of the war in Ukraine. However, despite the initial challenges the project has succeeded in reaching all project goals and the 3D FibreScanner is currently being prepared for commercialisation in 2024.
Highlights of the activities conducted during the project period include
• Development of a simulation framework for omnidirectional scattering imaging systems allowing for optimization of key design parameters.
• Design and construction of an in-house 3D FiberScanner prototype allowing for optimization of data collection protocols, calibration procedures, and a number of demonstration experiments.
• Design of a compact X-ray Tensor Tomography (aka 3D FiberScanner) add-on for commercial microCT systems utilising state-of-the-art X-ray optics and robotics.
• Development of advanced 3D data reconstruction and analysis software with cloud API enabling seemless integration with third party injection moulding simulation tools.
• Integration of the 3D FiberScanner add-on module onto two different commercial microCT platforms.
• Continuous dissemination activities, involving publication of scientific papers, presentations at conferences and presentations in industry workshops and user meetings.
• Discussions with potential commercialisation partners.
Highlights of the activities conducted during the project period include
• Development of a simulation framework for omnidirectional scattering imaging systems allowing for optimization of key design parameters.
• Design and construction of an in-house 3D FiberScanner prototype allowing for optimization of data collection protocols, calibration procedures, and a number of demonstration experiments.
• Design of a compact X-ray Tensor Tomography (aka 3D FiberScanner) add-on for commercial microCT systems utilising state-of-the-art X-ray optics and robotics.
• Development of advanced 3D data reconstruction and analysis software with cloud API enabling seemless integration with third party injection moulding simulation tools.
• Integration of the 3D FiberScanner add-on module onto two different commercial microCT platforms.
• Continuous dissemination activities, involving publication of scientific papers, presentations at conferences and presentations in industry workshops and user meetings.
• Discussions with potential commercialisation partners.
The FIONA project addresses challenges that are common across the whole FRP industry, namely regarding the production of FRP components with optimized properties by closing the gap between injection moulding simulation and the final processing parameters. In fact, to optimize fibre-reinforced parts with high mechanical performance requirements, it is vital to tune the manufacturing process to align fibres with the main loading directions. Given the importance of composite materials to the development of new applications within many different segments (e.g. aerospace; automotive; construction; energy; medical industries), the optimization of the process has evolved to become a key market within FRP industry.
Xnovo’s approach provides clear cost benefits for FRP companies, which will contribute to the competitiveness of the FRP industry and it will provide a step-change by bringing a tool that can simplify the development process of the FRP components as well as improving the quality control of the produced parts. Providing the lack of true alternatives, FibreScanner3D has the potential to become the de facto standard in the industrial segments using FRP parts.
Xnovo’s approach provides clear cost benefits for FRP companies, which will contribute to the competitiveness of the FRP industry and it will provide a step-change by bringing a tool that can simplify the development process of the FRP components as well as improving the quality control of the produced parts. Providing the lack of true alternatives, FibreScanner3D has the potential to become the de facto standard in the industrial segments using FRP parts.