Integration of NDT into the manufacturing process chain of functionalized UD-tape components

Complex structures made of thermoplastic unidirectional tape (UD-tape) composites are often manufactured in a series of individual steps. Defects may be induced at each of the process steps, altering irreversibly the final product quality. One of the effective defect correction methods is by creating a digital representation of the manufacturing steps and quality characteristics by recording the steps through integration of suitable sensor technologies. In that regard, quality assessment during the production of complex thermoplastic UD-tape composites, using hybrid injection molding with process-integrated Non-Destructive Testing (NDT) formed the key focus of this study. Multiple locations in the process chain for quality assessment; two (post-consolidation and final demonstrator steps) of which will be discussed in this paper. The quality of the laminate was evaluated using integrated eddy-current sensors and that of the final part with ultrasonic testing in this investigation. The application and potential of these NDT to create a holistic digital quality footprint for manufacture of highly complex function-integrated parts using thermoplastic composites are discussed in this study.