Tailored fiber placement in thermoplastic composites

Fiber path optimization methods combined with the Tailor Fiber Placement (TFP) technology provides the optimum correlation between load case and fiber orientation and therefore leads to unmatched component performance with endless fiber composite materials. The aim of this work is the development of an innovative manufacturing technology for thermoplastic composites (TPC) including sizing-adapted commingled glass fiber (GF) /thermoplastic yarns (SpinCom yarns) to be processed by TFP to textile preforms with variable-axial, load adapted fiber design. Furthermore, this preforms will be consolidated in a low energy and resource consuming process using novel light and low cost forming tools produced by incremental sheet metal forming technology. Finally, a low cost solution for thermal treatment even for complex shaped TPC parts will be presented. Heading towards optimized resource and cost efficiency of the whole process chain, first results of SpinCom yarns, fiber path optimization, tool manufacturing and forming procedure are presented and demonstrated using GF/PBT (polybutylene therephthalate) SpinCom yarns and the geometry of a bicycle saddle.