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Roving & Tape Processing

Research goal is the development of more efficient manufacturing processes by filament winding, tape laying, and 3D-printing with continuous fiber-reinforced thermosetting and thermoplastic matrices including process specific tooling and novel manufacturing equipment solutions.

Research focuses on quality management, process control, process optimization, and process automation such as in-line direct impregnation, ring winding technology, “out-of-autoclave” process by in-situ consolidation or the extension of additive manufacturing technologies (3D printing) with continuous filaments in load direction.

Dr.-Ing.

Jens Schlimbach

Deputy Research Manager Manufacturing Science & Manager Roving & Tape Processing

Special Expertise: Development of efficient processing methods, process optimization, out-of-autoclave technologies, economic feasibility studies, process hybridization, additive manufacturing, AFP, winding technology

Telephone: +49 631 2017 312
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Special Expertise

  • Mechanical characterization of materials using modern high-performance measurement technology
  • Validation of FE models for materials
  • FE modeling with ABAQUS and LS-Dyna
  • Development of procedures specially for large quantities
  • Special tape-laying developments (TP tapes, TS tapes, binder tapes, towpregs)
  • 3D-Printing with endless fiber reinforcement
  • This integrated process development covers all relevant aspects of the processes winding, tape laying and prepreg technology
  • Industrial scale equipment:
    • Industrial robot with tape laying head (Innovation Award)
      and external rotation axis (robot winding)
    • Patented solution of the first layer problem
    • 7-axis winding machine for conventional wet winding and thermoplastic winding
    • Ring winding head with 48 rovings for increased throughput (JEC Innovation Award)
    • Siphon impregnation technology
Economic Sectors Applications (Examples)
Aeronautics & Space Fuselage and tail structures, rod structures, window frames, ISO-grid structures
Automotive Body structures, drive shafts, structural components, fuel tanks, pressure vessels
Mechanical Engineering Highly accelerated machine parts, shafts, prototypes, engine housings, containment shells
Sports & Recreation Bicycle accessories (e.g. bottle cage, pinion or handlebar), rackets (e.g. for tennis or hockey), sports shoes (3D printed individual sole)
Energy Pressure vessels, high voltage insulators, fuel tanks, rotor gear shaft (wind power)

Materials and Questions

Typical Materials

  • GFRP
  • CFRP
  • Rovings & tapes
  • Prepregs
  • Epoxy resin, polyester resin
  • P, PA, PPS, PEI, PEEK, etc.

Typical Questions

  • Is the siphon technology ready for series production?
  • Can towpregs be used economically for pressure vessel production?
  • What are the advantages of unidirectionally reinforced thermoplastics?

Projects in this field

[Translate to English:]

CarboSteer

Effective Recycling of Carbon Fibers

In the research project CarboSteer a new process technology

to recycle carbon fibers and to reuse the material

in high performance parts is investigated.

[Translate to English:]

Deformation behavior of UD staple fiber organo sheets

Process analysis of the pseudo-plastic deformation behavior

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.

DigiTain - Digitalization for Sustainability

Knowledge about the impregnation behaviors of reinforcement textiles

Fast Multiaxial Tape Laying Machine

[Translate to English:]

Fiber-reinforced bipolar plates for fuel cells

Development of fiber-reinforced compound film bipolar plates for compact lightweight fuel cells

This project aims at the incorporation of carbon fibers into compound foils to increase the power density of hydrogen fuel cells

[Translate to English:]

Large Component Made of Thermoplastic CFRP

MaTaInH2

Material-Efficient Industrialization of H2Pressure Tanks

Within the 3 year project “MaTaInH2”, the project partners Mahle, TUM and IVW are pursuing the goal to industrialize high volume hydrogen pressure vessels production at reduced product costs.

Optimierung einer stationären Siphon-Imprägniereinheit

Zusammen mit dem IFB entwickelt das IVW eine stationäre, robuste Inline-Siphon-Imprägniereinheit für die Verarbeitung von bis zu 6 x 50k Kohlenstofffaserrovings zur Herstellung modularer CFK-Strukturen im Bauwesen.

[Translate to English:]

OSFIT

Thermoplastic Integral Frames in One Shot Process

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

[Translate to English:]

pro-TPC-Structure

High-Performance Structural Components in One Shot

In the pro-TPC structure project, thermoplastic continuous fiber reinforced inserts are combined with thermoplastic short fiber reinforced injection molding material.

WaVe

Innovative FRP Tank Structure for Hydrogen Storage

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

[Translate to English:]

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

  • Domm, M.

    Additive Fertigung kontinuierlich faserverstärkter Thermoplaste mittels 3D-Extrusion

  • Mack, J.

    Entwicklung eines adaptiven Online-Bebinderungsprozesses für die Preformherstellung

  • Brzeski, M.

    Experimental and Analytical Investigation of Deconsoldiation for Fiber Reinforced Themoplastic Composites

  • Holschuh, R.

    Lokal lastgerecht verstärkte Multimaterialsysteme auf Basis von Polypropylen-Polypropylen-Hybriden

  • Miaris, A.

    Experimental and Simulative Analysis of the Impregnation Mechanics of Endless Fiber Rovings

  • Khan, M. A.

    Experimental and Simulative Description of the Thermoplastic Tape Placement Process with Online Consolidation

  • Schlimbach, J.

    Ökonomische Prozessanalyse und Modellintegration zur Kostenberechnung von Faser-Kunststoff-Verbunden

  • Schlottermüller, M.

    Zur Eigenspannungsausbildung bei der wickeltechnischen Verarbeitung thermoplastischer Bandhalbzeuge

  • Latrille, M.

    Prozessanalyse und -simulation von Verarbeitungsverfahren für faserverstärkte thermoplastische Bändchenhalbzeuge

  • Beresheim, G.

    Thermoplast-Tapelegen - ganzheitliche Prozessanalyse und -entwicklung

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