Integration of features into parts made from thermoplastic, unidirectional tape - Overview and case study

Thermoplastic composite materials have lately been considered increasingly for application in structural components. Especially semi-finished products with continuous fiber-reinforcement such as woven fabrics or unidirectional tapes have a high potential to increase part performance significantly. However, due to their limited drapability and flowability the forming of highly complex structures such as ribs is not feasible. This paper presents an overview of desired features that are commonly part of complex technical applications. It shows how implementation of those can be achieved with continuous-fiber- reinforced structures by combining them with short and long fiber-rein forced material. The subsequent case study presents a related investigation on overmolding of unidirectional tape inserts. In conclusion, an outlook is given on how these results can be transferred to more complex components.