Advanced Textile Techniques for Composite Material Manufacturing

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Today, aircraft structures are built using composite materials that represent up to 50% of their total weight. Composite materials derive their strength from aligning ultra-strong micro- or nano-fibers along the macro-scale load paths. These fibres are embedded in a matrix material that holds them in position and insures load transfer. While working for an aircraft manufacturer, I observed that the main approaches for manufacturing high performance composite structures is the use of robotic unidirectional fibre placement methods or layer-by-layer manual or robotic deposition of thin fabrics. These methods are preferred because the movement of fibres in subsequent manufacturing operations is limited. The lack of precise knowledge about the movement of fibres is a bottleneck that prevents the introduction of new manufacturing methods using novel materials. Consequently, there is a need for developing fundamental knowledge of the behaviour of fibre reinforcements when they are subjected to complex manufacturing operations and their effect on the final product's properties. I propose here a 5-year research program that will first characterize the mechanical behaviour of fibre yarns of different materials and fibrous mixtures (inorganic, polymers, biosourced). We will develop specific testing apparatus to mimic the loads applied to yarns during textile operations and advanced manufacturing techniques. I will use these observations to model this behaviour using the multi-chain digital element approach. The modelling will allow us to predict the deformation of yarns and complex fabric structures during textile assembly and manufacturing. We will produce composite structures with accurate prediction of the reinforcing elements and their impact on mechanical properties. This research program will accelerate the integration of new composite materials and manufacturing techniques into highly regulated industries such as the aerospace, transport, and bio-medical.**