Preforming Cell based on single fibre manipulation

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At the Institute for Aircraft Design (IFB) at the University of Stuttgart, lightweight structures and innovative manufacturing techniques in the field of high-performance fibre-reinforced composites (FRC) are researched, developed and transferred into application-oriented prototypes. For this purpose, virtual design and calculation methods are created in parallel, resource-efficient and sustainable material and product manufacturing processes are developed and validated with the help of certified testing techniques. For the research area of lightweight construction simulation and manufacturing technology of FRC, the IFB is applying for an integrative preforming cell based on single fibre manipulation in order to open up new research approaches for FRC structures in aviation in future. The integrative preforming cell based on single fibre manipulation aims to combine different processing techniques, so-called processing modules of single fibres into a rapidly configurable, interlinked, networked, self-monitoring and sensor-supported production environment for components made of FRC at laboratory level. The targeted and sensor-monitored manipulation and guidance of one or more directed reinforcement fibres during processing characterises the single-fibre manipulation in order to generate specifically adjustable fibre architectures of the load-path-compliant and near-net-shape parts. The reinforcement fibres should be able to be processed in the form of rovings, yarns, spread and bindered tapes (incl. thin-ply) and tow-pregs in order to explore future semi-finished fibre products for high-performance applications. For the production of flat, planar and near-net-shape preforms, additive single-fibre laying processes will be used, which, in addition to curved, contour-following fibre paths, can also produce straight, unidirectional paths. In another processing module, three-dimensional hollow fibre architectures are to be created using a new bobbin carrier technology in the braiding process. The freely configurable individual fibre manipulation in the radial braiding process is to be achieved through the first-time use of electronic bobbin units, which are to be developed for this cell on the basis of the institute's own preliminary work. The yarn force that can thus be variably adjusted in the process will lead to completely new load-appropriate fibre architectures in addition to a significant shift in the current process windows. Due to the variable yarn force during braiding as well as the possibility of a targeted material feed and retraction, it is thus also possible to process component geometries that were previously impossible to braid. As the basis for a software-defined manufacturing approach, the plant modules are to be digitally linked via an IoT platform. Continuous process data acquisition, storage and parallel evaluation provide a previously unavailable basis for research into future digitally supported product and process developments.