High performance thermoplastic composite sandwich panels: process development, modeling, and optimization

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Composite solid and sandwich panels can be made of thermoplastic commingled materials through continuous roll forming operation. The final products can be used for many different applications including transportation and construction. Composite road guardrails, impact resistance walls for covering large electrical facilities, and floor panels for mini-trucks are possible applications of thermoplastic solid and sandwich panels. By applying a metal mesh at different locations through the thickness, it has been shown that the impact performance can be improved. The objective of this project is to establish the criteria for the selection of the right material system, to develop manufacturing know-how, to model and optimize the process, and to characterize the product by generating enough experimental data. The final product will have longer life and will be recyclable.