Press & Joining Technologies

This field of competence focuses on the development of new materials and processing technologies for so-called organic sheets, discontinuously and continuously reinforced (CF, rCF, GF, NF), with standard or modified thermoplastics. Based on staple fiber technology, innovative forming technologies as well as concepts for more efficient processes for component manufacturing are being developed.

A key area in compression molding of SMC, LFT and GMT is the use of renewable raw materials as filler materials and process development for natural fiber reinforced composites using conventional or biobased polymers. Another focus is on combining process and customized highly efficient joining technologies to develop special procedures for the welding of thermoplastic FRPC and metal-FRPC hybrid materials.

Prof. Dr.-Ing.

Thomas Neumeyer

Research Director Manufacturing Science & Manager Press & Joining Technologies

Special expertise: Fiber-reinforced composites polymer foams, special injection molding processes, additive manufacturing with plastics, sustainability aspects and their quantitative assessment

Telephone: +49 631 2017 103

thomas.neumeyer@leibniz-ivw.de

Vita

Special Expertise

Development of special profile shapes, open and closed
Combination of continuous fiber / discontinuous fiber reinforcement
Biocomposites
In-line and off-line process solutions
Mapping of the entire process chain
Industrial scale equipment:
- SMC-production line
- Continuous compression molding press
- Thermoforming press
- 800 t parallel controlled press
- Plastification units and convection oven
- Welding robot (JEC Innovation award)
- Test rigs for induction welding

Economic Sectors	Applications (Examples)
Aeronautics & Space	Spoiler, panels, fuselage structures, clips and cleats
Automotive	Body structures, body shells, spoilers and wind deflectors, interior paneling
Engineering	High accelerated machine parts, paneling
Medical Engineering	Various
Energy	Various

Materials and Questions

Typical Materials

Fiber reinforcement GF, CF, rCF, NF, AF in form of textiles or cut fibers
Combinations of continuously and discontinuously reinforced systems
PP, PA, PPS, PEI, PEEK, PU, EP, UP, biopolymers, vitrimers, etc.

Typical Questions

Do composites made of renewable raw materials have a limited service life?
How can valuable CF waste be reused for high-quality components?
How to proceed with the hybridization of processes?

Projects in this field

AIRPOXY

Vitrimers Bridging the Gap between Thermoplastics and Thermosets

Systematic development of lightweight bio-based composites with excellent heat resistance for structural applications.

BioSMC

Use of Bio-Based and Renewable Raw Materials in SMC

Composites and Sustainability

This project aims to apply the TMOR method for determining thermal volume expansion of polymers and composites and as well as the fundamentally related material phenomena.

drivEcomp II – Advanced Composite Solutions

Increasing the power density of electrical drive systems for rail and road applications by using fiber composite technology

increase the power density of electrical drive systems for rail and road applications by using fiber composite technology

Durobast

Durable and Resoure-Saving Bast Fiber Reinforced Composite Components

increase the power density of electrical drive systems for rail and road applications by using fiber composite technology

HyBe

Automated hybrid welding of metallic fasteners to fiber-plastic composite components

IMAPRESS

Innovative Tools for Extra Wide Organo Sheets

Development of a novel tool technology to increase the impregnation performance of continuous compression molding

Induction Welding of CFK

Increasing the velocity of the induction welding process

Large Forming Plant

Processing of thermoplastic and thermoset semi-finished products in a pressing process with a maximum pressing force of 2600 tons on a clamping area of 2 x 3 m². The integration of a horizontal injection molding unit enables the production of hybrid compo

NaturePerformance

Modeling the Mechanical Properties of Natural Fiber- Reinforced Polymer (NFRPs)

Development of a highly automated manufacturing process for CFRP-structural parts, such as aircraft frames, with thermoplastic-matrix

NeuRecA

SMC semi-finished materials for structural high-temperature applications based on recycled carbon fibers

Introduction of a new methodology that enables the production of closed FRP box structures efficiently and enables new possibilities of construction

Prozessoptimierung des Induktionsschweißens

Prozessoptimierung des Induktionsschweißens von CFK-Organoblechen

Hauptziel ist die Steigerung der Geschwindigkeit des kontinuierlichen Induktionsschweißprozesses von kontinuierlich kohlenstofffaserverstärkten Thermoplasten, speziell von Organoblechen, in Verbindung mit einer resultierenden Fügequalität auf Autoklavniveau.

Recycling of CFRP with thermoplastic matrix

In addition to the recycling of valuable materials after an aircraft has been in use, the reprocessing of production waste in the manufacture of components can also make a contribution to protecting the environment and reducing costs.

SOPHIA

Smart Processes and Optimized Designs for High Production Cadences

Development of a new integral foam construction with thermoplastic cover layer for cabin components using the sidewall as an example

Thermoforming Simulation of Organosheet Materials

Forming behavior of continuous fiber reinforced thermoplastics

Forming behavior of continuous fiber reinforced thermoplastics in the thermoforming process and to make statements about resulting fiber orientation, final contour, and wrinkling

TraNa – Colorable and Flame-Resistant Sheet Molding Compo

Development of flame-retardant and translucent SMC semifinished products for interior applications in aircraft

Life time enhancement of thermoplastic FRP-metal-hybrids by reducing process induced residual stresses

ZEUS

Integral Thermoplastic Design Concepts and Processes

Active hybrid structures enable a novel situation-dependent adaptation of aircraft aerodynamics, which increases efficiency and reduces noise pollution.

Publications from the IVW papers in this field of competence

Becker, S.(2022)
Untersuchung und Optimierung des induktiven Aufheizverhaltens von textilverstärkten CFK-Organoblechen
- Download Abstract
Goergen, C.(2020)
Quasiplastisches Verformungsverhalten von Organoblechen aus recyceltem Kohlenstoff-Stapelfasergarnen
- Download Abstract
Gortner, F.(2019)
Bio-basierte und nachwachsende Füllstoffe für dichtereduzierte Sheet Molding Compounds
- Download Abstract
Kracke, C.(2019)
Dimensionierung werkzeugseitiger Fließkanäle im RTM Prozess
- Download Abstract
Hümbert, M.(2019)
Induktiver Schweißprozess für glasfaserverstärkte Thermoplaste und Stahl
- Download Abstract
Jung, G.(2018)
Development of continuous fiber and long fiber reinforced thermoplastic materials with multilayered hybrid structure, and then crash application thereof
- Download Abstract
Dzalto, J.(2018)
Entwicklung eines großserientauglichen Aufheizprozesses für naturfaserverstärkte Kunststoffe
- Download Abstract
Schieler, O.(2016)
Auswahl einer Fugetechnologie für faserverstärkte Thermoplaste im Helikopterbau
- Download Abstract
Hildebrandt, K.(2015)
Material- und prozessspezifische Einflüsse auf Oberflächeneigenschaften von endlosfaserverträrkten Thermoplasten
- Download Abstract
Christmann, M.(2015)
Optimierung der Organoblechherstellung durch 2D-Imprägnierung
- Download Abstract
Bayerl, T.(2012)
Application of Particulate Susceptors for the Inductive Heating of Temperature Sensitive Polymer-Polymer Composites
- Download Abstract
Moser, L.(2012)
Experimental Analysis and Modeling of Susceptorless Induction Welding of High Performance Thermoplastic Polymer Composites
- Download Abstract
Mitschang, P(2010)
Prozessvariable Entwicklung von Faser-Kunststoff-Verbunden auf PBT-Basis
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Steeg, M.(2009)
Prozesstechnologie für Cyclic Butylene Terephthalate im Faser-Kunststoff-Verbund
- Download Abstract
Medina, L.(2008)
Materialentwicklung und Prozessoptimierung von naturfaserverstärkten Kunststoffen mit geringem Matrixanteil für Automobilanwendungen
- Download Abstract
Velthuis, R.(2007)
Induction Welding of Fiber Reinforced Thermoplastic Polymer Composites to Metals. 2007
- Download Abstract
Lahr, R.(2007)
Partielles Thermoformen endlosfaserverstärkter Thermoplaste
- Download Abstract
Sommer, M. M.(2006)
Eigenschaftserweiterung von langfaserverstärkten thermoplastischen Fließpresshalbzeugen
- Download Abstract
Breitel, J.(2005)
Zur presstechnischen Verarbeitung naturfaserverstärkter Thermoplaste
- Download Abstract
Wöginger, A.(2003)
Prozesstechnologien zur Herstellung kontinuierlich faserverstärkter thermoplastischer Halbzeuge leider vergriffen
- Download Abstract
Blinzler, M.(2002)
Werkstoff- und prozessseitige Einflussmöglichkeiten zur Optimierung der Oberflächenqualität endlosfaserverstärkter thermoplastischer Kunststoffe
- Download Abstract
Nowacki, J.(2001)
Prozessanalyse des Umformens und Fügens in einem Schritt von gewebeverstärkten Thermoplasten
- Download Abstract
Edelmann, K.(2001)
Prozessintegrierte Analyse des Fließverhaltens von faserverstärkten thermoplastischen Pressmassen für die Serienfertigung
- Download Abstract
Rudolf, R.(2000)
Entwicklung einer neuartigen Prozess- und Anlagentechnik zum wirtschaftlichen Fügen von thermoplastischen Faser-Kunststoff-Verbunden - leider vergriffen!
- Download Abstract
Mattus, V. (1999)
Zur werkstofflichen Verwertung lang- und endlosfaser-verstärkter Thermoplaste
Mayer, C.(1999)
Prozeßanalyse und Modellbildung zur Herstellung gewebe-verstärkter, thermoplastischer Halbzeuge - leider vergriffen!

External Publications „Press & Joining Technologies“

Influence of fungal decay on mechanical properties of bio-based sheet molding compounds (SMC)

https://doi.org/10.1177/09673911221145050

Investigations on thermoforming of carbon fiber reinforced epoxy vitrimer composites

https://doi.org/10.1016/j.compositesa.2021.106791

Commercial Vehicle Technology 2020/2021

DOI 10.1007/978-3-658-29717-6

Multiple regression analysis of the chemical components effect on wettability at ps laser micro-structured surfaces on stainless steel 304

https://doi.org/10.1016/j.apsusc.2022.154852

HyBe in der Welt der FKV

https://www.unserebroschuere.de/AVK_Composites_Report_07_DT/WebView/

Digitalisierung eines CFK-Fertigungsprozesses

https://www.unserebroschuere.de/AVK_Composites_Report_06_DT/WebView/

Process Improvement of Continuous Induction Welding of Carbon Fiber-Reinforced Polymer Composites

https://doi.org/10.1007/s11665-022-06842-0

3R Composites: Knockdown Effect Assessment and Repair
Efficiency via Mechanical and NDE Testing

https://doi.org/10.3390/app12147269

Investigation of an optimized hot press process design for manufacturing structural polyethersulfone foams

https://doi.org/10.1080/20550340.2023.2269021

Use of bio-based and renewable materials for sheet molding compounds (SMC) – Mechanical properties and susceptibility to fungal decay

https://doi.org/10.1016/j.jcomc.2022.100242

Deep drawing of organic sheets made of hybrid recycled carbon and thermoplastic polyamide 6 staple fiber yarns, Journal of Thermoplastic Composite Materials
journals.sagepub.com

Tiefziehbare Organobleche aus recycelten Carbonfasern, Zeitschrift Kunststofftechnik 1/2019
www.kunststoffe.de

Bending properties of structural foams manufactured in a hot press process

https://doi.org/10.1080/20550340.2022.2077277

Challenges in Manufacturing of Hemp Fiber-Reinforced Organo Sheets with a Recycled PLA Matrix

https://doi.org/10.3390/polym15224357

Influence of polymer matrix on the induction heating behavior of CFRPC laminates

https://doi.org/10.1016/j.compositesb.2021.109561

Increasing the performance of continuous compression moulding by local pressure adaption

https://doi.org/10.1080/20550340.2021.1888209

Kostenanalyse der Prozesskette zur Herstellung von rCF-Stapelfaser-Organoblechen, erschienen in der Technischen Textilien 3/2018
PDF

Entwicklung einer Prozesskette zur Herstellung von NFPP-Tapes

https://www.unserebroschuere.de/AVK_Composites_Report_07_DT/WebView/

Data for: New approach for processing recycled carbon staple fiber yarns to unidirectional reinforced recycled carbon staple fiber tape

https://zenodo.org/records/10148562

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