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New benchmark in the tailored blank manufacturing - high volume production in an exceptional quality

: Graf, Matthias; Baumgärtner, Sebastian; Henning, Frank

Vuorinen, Jyrki ; Society for the Advancement of Material and Process Engineering -SAMPE-:
SAMPE Europe Conference 2017 : Leinfelden-Echterdingen, Germany, Stuttgart, 14th - 16th November 2017
Stuttgart, 2017
ISBN: 978-90-821727-7-5
6 S.
Society for the Advancement of Material and Process Engineering (SAMPE Europe Conference) <2017, Stuttgart>
Fraunhofer ICT ()

With the new Fiberforge tapelaying system and the Fibercon tailored blank consolidation system, a new benchmark has been set in the industry for the manufacture of part specific thermoplastic tailored blanks. The new Fiberforge tapelaying system allows to lay UD tapes with any fiber orientation, near net shape, fast and reliable to generate a part specific tape layup. The machine is capable to process four different types of tape into one layup. The new generation of Fiberforge is designed to suit the need of the automobile industry in terms of product dimensions, through-put capacity and material efficiency. The paper will introduce the features and performance which have been achieved, based on several applications. To fully utililize the capabilities of the Fiberforge system, Dieffenbacher has seen the need to find a reliable solution to consolidate the tape layup of discrete blanks. Based on the research activities and newest inventions of Fraunhofer ICT the Fibercon system could be developed which fulfills the needs of large scale production. This technology enables consolidation of tailored blanks with thickness variations in dimension of up to 1,5 x 2 m. The Fibercon has exceptional capabilities to eliminate air inclusions between the layers and reduce impregnation defects of the tapes. Fiberforge and Fibercon together are the key elements of the tailored blank manufacturing line. The concept of such a fully automated production line will be disclosed in the paper.