3D-LightTrans
Large scale manufacturing technology
for high performance lightweight 3D multifunctional components
Abstract
Project data
3D-LightTrans Concept
The project 3D-LightTrans aims to
provide a groundbreaking, highly
flexible, efficient and adaptable
manufacturing chain for the
production of integral large scale
3D textile reinforced plastic
composites (TRP). This will enable
to shift them from its current
position in cost intensive, small
series niche markets, to broadly
extended
mass
product
applications in transportation and
other key sectors, like health and
leisure.
In the 3D-LightTrans manufacturing chain, multimaterial semifinished fabrics
will be processed to deep draped prefixed multilayered and multifunctional 3Dtextile preforms. Storage and transport of the fixed preforms takes place
without special temperature requirements.
Hybrid yarn
production
Hybrid yarn
Thermoplastic
Acronym: 3D-LightTrans
Reinforcement
Grant agreement no.: 263223
FP7-NMP-2010-LARGE-4
a) Multilayered fabrics
Background
b) Spacer fabrics with hollow spaces
manufactured in a single
weaving step
Draping and
fixation
Storage and
transport of 3D
fixed pre-forms
35
30
25
20
15
10
5
0
T6 teel
1
l
6
e
0
s
e
t
6
Al inless lled S iester* oxy*
Sta old ro s/Poy on/Ep
s
C
b
Gla
Car
Price (€/Kg)
Price/strength
Thermoforming
* 60% fiber wb. Fraction
Consolidated compound parts (car
door, battery case)
Fig. 1. Comparison of material price
Reinforced
composites
(often
carbon on thermoset matrix) are
used for aircraft and a few niche
automotive applications, but are too
expensive for the mass market in
spite of the lower material costs,
due to the long processing cycles
and labour intensity.
3D-LightTrans will create a manufacturing chain able to exploit
TRP’s inherent economic potential.
3D-LightTrans concept relies on
individual
processes
and
approaches, with suitability proven
in experimental work performed at
the TU-Dresden.
Large scale manufacturing
technology for high-performance
lightweight 3D multifunctional
composites
Project duration: From April 2011
to March 2015
3D-LightTrans
weaving
processes
TRP (textile reinforced plastic
composites) combine light weight
with
excellent
mechanical
properties, while holding the
potential for huge material cost
savings in comparison with metal.
Project title:
Fig. 3. 3D-LightTrans manufacturing chain
The final composite part is produced by thermoforming. Neither manual
draping of the textile onto the forming tool nor infiltration/curing are required,
since preforms are already fixed in the desired 3D geometry and the
thermoplastic matrix integrated in the hybrid yarn before weaving.
Consortium:
1. Austrian Institute of Technology
GmbH
2. Xedera e.U.
3. Centro Ricerche Fiat SCPA
4. Coatema Coating Machinery
GmbH
5. Federal Mogul Systems
Protection
6. Universiteit Gent
7. Grado Zero Espace Srl
8. Technische Universität Dresden
9. Acondicionamiento Tarrasense
Associacion
10.Lindauer Dornier GmbH
11.Northwest Textiles Network
Limited
12.P-D Glasseide GmbH Oschatz
13.Michel Van de Wiele
14.Office National d‘Etudes et de
Recherches Aerospatiales
15.Bentley Motors Ltd
16.SVUM A.S.
17.PROMAUT S.L.
18.Universite d‘Orleans
Project results
• Specification of
requirements
2011
• Weaving machines for complex
multilayer & 3D-shaped geometries
• Reliable/ repetitive production
of different hybrid glass yarns
• Scale-up for
• Automation, handling
mass production
processes & tools
• 3D-TRP demonstrators
• Modeling &
simulation toolbox
• Fixation process
A project co-funded by the
European Commission
within the 7th Framework
Programme
2015
• Integrated
manufacturing chain incl.
TRP thermoforming
Fig. 4. Project timeline and scheduled results
Weaving
1 €*
Hull
To achieve 3D-LightTrans goals,
the partners will develop know-how,
processes and equipment to
establish automated production
chains for low cost, high quality and
reproducible
industrial
manufacturing of large scale parts
featuring complex 3D geometry.
Differential
Rips
Fig. 2. Spacer fabric and deep draped
multilayer fabric with simple geometry (TU-D)
Contact
Braiding
ca.
100 €
Fabric
Autoclave
Infiltration
Prepeg
67 €*
0h
Time consumption
Integral
In tool
* … durable investment costs
3DLT
Weaving
4 €*
Consolidation
Component
Thermopressing
Fig.5. Cost improvement to be achieved
with 3D-LightTrans
Assembling
For more information please contact:
Dr. Erich Kny (AIT)
erich.kny@ait.ac.at
Project Coordinator
Dr. Ana Almansa (Xedera)
aam@xedera.eu
Exploitation & Dissemination
Manager