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3D Fibre spraying – Automated preforming for
structural RTM parts
Prof. Dr.-Ing. Christian Hopmann
Dipl.-Ing. Marc Linus Fecher
Dr.-Ing. Kai Fischer
8th INTERNATIONAL CFK-VALLEY STADE CONVENTION, STADE
25th of June 2014
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Institute of Plastics Processing (IKV) in Industry and
Skilled Crafts at RWTH Aachen
Founded in 1950, supported by a Sponsors'
Society (currently > 240 members)
Associated with RWTH Aachen University
6 departments
Composites & PU
Extrusion & rubber processing
Injection Molding
Part Design / Materials Technology
Centre for analysis and testing of plastics
Training and further education
Staff
80 scientific employees
50 employees in laboratories, workshops
and administration
~220 student workers
Facilities Pontstr. 49
Facilities Seffenter Weg 201
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Outline
Institute of Plastics Processing (IKV) at RWTH Aachen University
Introduction and motivation
Advantages of the fibre spraying technology
Functional principle of the 3D Fibre spraying developed at IKV
Binder technologies used in the 3D Fibre spraying
Selected results
Conclusion and outlook
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General advantages of continuous fibre reinforced
composites
High fibre volume content > 50 %
High strength and stiffness
Defined fibre orientation
Reproducible manufacturing of
reinforcing fabrics
Good optical appearance
[BMW]
[Airbus]
[IKV Aachen]
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Cost distribution for the RTM-process
Post
processing RTM-process Preforming Textiles
Rovings /
Resin
50 % 20 % 25 % 5 %
[Cher13]
Preforming causes up to 50 % of the total part costs
Up to 30 % scrap during fibre cutting
Often high manual work effort necessary
Draping of single fibre layer
Integration of functional elements (e.g. cut-outs, inserts, stiffening profiles)
Automated preforming technologies for the manufacturing of complex and functional
integrated preforms often need a high machine employment
Challenges in manufacturing of thermoset composites
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Advantages of the fibre spraying technology for
thermoset structural parts
30 % less scrap
Automated process
No thermoforming & cutting
Part manufacturing Preforming Textile manufacturing
Raw materials Cutting Textile
manufactuing Layup Forming
RTM-
process Cutting
Post-
processing
[BMW, Owens Corning, Dieffenbacher, KraussMaffei, Schuler, SGL Carbon]
Preforming
Raw materials RTM-
process 3D Fibre spraying
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Process chain of fibre spraying and consolidation for
thermoset composites
RTM-part Roving & binder Preform
RTM-process
Output: 150 kg/h
Anisotropy: up to 3:1
3D Fibre spraying
FVC: 40 %
Cycle time: 10 min
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Functional principle of the 3D Fibre spraying
process developed at IKV
fibre guide
unit
layup
mould
10 cm
chopper
fibre guide unit
vacuum
layup mould
preform
hot-air
h
v s
v: layup velocity
h: layup height
s: gap width
venturi
nozzle
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Binder activation
Different binder technologies, used in the
3D Fibre spraying process
Thermoplastic binders:
Commingled yarns with different
thermoplastic binders
Activation with hot air
No clogging of the vacuum suction
Thermoset UV-binder:
Epoxy and acrylic thermoset
UV-binder
Activation with UV-light
Rapid curing in less than 30 s
Binder application 1 2
Binder activation Binder application 1 2
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Materials used for the manufacturing of RTM
structural parts with fibre sprayed preforms
Roving: R63SX3 (OCV)
Resin: EPIKOTE 05475
Curing agent: EPIKURE 05443
(Momentive)
Binder: KUPER
Commingled Yarn
Materials
FVC: 40 %
Fibre length: 50 mm
Inj. pressure: 2,5 bar
Curing temp.: 80 °C
RTM process parameter
Roving: R63SX3 (OCV) Binder build up
Glass fibre
Polyester
Copolyamide
0,208 mm
2 cm
Contraction of the binder due to
the binder build up
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Flexural strength depending on the output
according to DIN EN ISO 14125
0
100
200
300
400
500
600
700
800
36 kg/h 78 kg/h 120 kg/h 150 kg/h
Fle
xura
l str
ength
[
N/m
m²]
Output
parallel to adjusted fibre orientation perpendicular to adjusted fibre orientation
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Flexural modulus depending on the output
according to DIN EN ISO 14125
0
5
10
15
20
25
36 kg/h 78 kg/h 120 kg/h 150 kg/h
Fle
xura
l m
odulu
s
[G
Pa]
Output
parallel to adjusted fibre orientation perpendicular to adjusted fibre orientation
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0,5
1
1,5
2
2,5
3
0 40 80 120 160
Anis
otr
opy r
atio
Output [kg/h]
Anisotropy ratios of the manufactured parts
depending on the output
3 : 1
2,5 : 1
2 : 1
1,5 : 1
1 : 1
0,5 : 1
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Analysis of the achievable fibre orientation by
Micro-CT pictures
Low orientation of the sprayed
fibres
High orientation of the sprayed
fibres
Adju
ste
d fib
re o
rienta
tion
Fibre volume content: 40 %
Fibre length: 50 mm
1 mm 1 mm
Output:
36 kg/h
Output:
150 kg/h
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Conclusion and outlook
The 3D Fibre spraying is a high volume capable and productive process with
an output from up to 150 kg/h.
Reduction of process steps, scrap and part costs compared to conventional
processes
Locally adjustable fibre orientation, fibre length and preform thickness
High mechanical properties, competitive to RTM-parts made from textile
fabrics
Investigation of additional material combinations (e.g. different binder
technologies, carbon)
Investigation of the direct integration of functional elements (e.g. cut-out,
inserts and stiffening profiles)
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Thank you for your kind attention!
The research project (17646 N) of the Forschungsvereinigung
Kunststoffverarbeitung has been sponsored as part of the "industrielle
Gemeinschaftsforschung und -entwicklung (IGF)" by the German
Bundesministerium für Wirtschaft und Energie (BMWi) due to an enactment of the
German Bundestag through the AiF. We would like to extend our thanks to all
organizations mentioned.
Contact:
Dipl.-Ing. Marc Linus Fecher
Seffenter Weg 201
D - 52074 Aachen
Tel: +49 241 80 28330
Email: [email protected]
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3D Fibre spraying – Automated preforming for
structural RTM parts
Prof. Dr.-Ing. Christian Hopmann
Dipl.-Ing. Marc Linus Fecher
Dr.-Ing. Kai Fischer
8th INTERNATIONAL CFK-VALLEY STADE CONVENTION, STADE
25th of June 2014
