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Selective Tape-Laying for Cost-Effective Manufacturing of Optimised Multi-Material Components

Objective

The aim of the Stellar project is to develop the manufacturing process for high-speed placement of carbon, glass and polymer fibre reinforced matrices, in selected locations in a composite structure, to provide the optimum reinforcement, weight and cost profile within a part.

The use of composite materials in structural components is becoming well established in a range of applications, and the materials can offer significant benefits in mechanical properties, weight and through-life environmental impact. However, whilst some hybrid structures do exist, these are typically combinations of relatively isotropic materials, which only go part of the way to optimising the amount of materials used in the structure. The ideal structure has different combinations of composite materials in predetermined locations in a hybrid multi-material structure, but to date this has not been achievable because cost-effective manufacturing processes have not been available.

The concept of this project is therefore to develop the design methodologies, manufacturing processes, equipment and control systems needed for localised placement of different fibre-reinforced thermoplastic composite tapes onto different substrates, creating locally reinforced components that are fully weight-optimised. To achieve this, the project will focus on development of the Automated Tape Laying (ATL) process to selectively place reinforced thermoplastic tapes in 3 manufacturing routes:

• Selective reinforcement of existing components
• Direct additive manufacture of components
• Manufacture of selectively reinforced tailored blanks for compression moulding

The manufacturing process developed will have a significant effect on the weight of structures, as for the first time it will allow different reinforcement fibres (polymer, glass, carbon) to be used synergistically in the same thermoplastic polymer matrix, to produce hybrid multi-material structural components with optimised performance and weight.

Call for proposal

FP7-2013-NMP-ICT-FOF(RTD)
See other projects for this call

Funding Scheme

CP-FP - Small or medium-scale focused research project

Coordinator

NETCOMPOSITES LIMITED
Address
Bridge Way 4A Broom Business Park
S41 9QG Chesterfield
United Kingdom
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 768 365
Administrative Contact
Gordon Bishop (Mr.)

Participants (9)

TOYOTA MOTOR EUROPE NV
Belgium
EU contribution
€ 69 668
Address
Bourgetlaan 60
1140 Brussel
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Andrew Willett (Dr.)
AIRBORNE COMPOSITES AUTOMATION BV
Netherlands
EU contribution
€ 48 671
Address
Laan Van Ypenburg 70
2497 GB S Gravenhage
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Tahira Ahmed (Dr.)
GUBESCH THERMOFORMING GMBH
Germany
EU contribution
€ 188 757
Address
Industriestrasse 1
91489 Wilhelmsdorf
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Marcus Schuck (Dr.)
ADVANCED FIBRE PLACEMENT TECHNOLOGY BV
Netherlands
EU contribution
€ 45 400
Address
Van Der Duinstraat 24
5161BP Sprang-capelle
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Roel Baas (Mr.)
CGTECH LIMITED
United Kingdom
EU contribution
€ 110 400
Address
Third Avenue 34 Curtis House 34
BN3 2PD Hove East Sussex
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
John Reed (Mr.)
ESI GROUP
France
EU contribution
€ 206 811
Address
100-102 Avenue De Suffren
75015 Paris
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Pierre Marquette (Mr.)
MONTANUNIVERSITAET LEOBEN
Austria
EU contribution
€ 299 052
Address
Franz Josef Strasse 18
8700 Leoben
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Ralf Schledjewski (Prof.)
FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.
Germany
EU contribution
€ 860 847
Address
Hansastrasse 27C
80686 Munchen
Activity type
Research Organisations
Administrative Contact
Andrea Zeumann (Ms.)
AFPT GMBH
Germany
EU contribution
€ 176 295
Address
Trinkbornstrasse 10
56281 Dorth
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Roel Baas (Mr.)