Curved Composites

Subsequently Formable Profiles made of FRP

Compared with conventional structural profiles, profiles made of fiber-reinforced plastic (FRP) are characterized by both high lightweight potential and excellent resistance to corrosion. Up to now, FRP-profiles have mainly been manufactured from thermoset matrix materials. Since they crosslink irreversibly, profiles produced in this way can no longer be deformed. Therefore, if curved profiles are to be manufactured, a separate tool is required for each individual radius of curvature. Together with the Chair of Forming Technology at Siegen University (UTS), Gustav Gerster GmbH & Co. KG and Bilsing Automation GmbH, IVW is researching material and process technologies that aim at enabling the variable bending of initially straight FRP-profiles. A major innovation is the impregnation of the textile reinforcement with reactive thermoplastics. While retaining the favorable thermoset processing route, these exhibit subsequent hot-forming capability of the matrix. This would allow straight profiles to be produced as standard and subsequently bent to the desired radius. Current research work, besides the development of a bending unit by Bilsing and UTS, is concerned with the design of the textile reinforcements (IVW and Gerster). The textile reinforcement is absolutely critical for the bending process and defines the process limits. The textile architecture should - while retaining the mechanical properties as far as possible - give the manufactured profile the greatest possible forming capability, but at the same time must neither tear nor wrinkle during forming.

The aim of the Curved Composites project is to produce subsequently formable FRP-profiles based on the impregnation of drapeable reinforcement textiles with a thermoplastic resin system.



Alexander Faas

Scientic Staff Digitalized Process & Material Development“

Telephone: +49 631 2017 434


Jan Janzen

Scientific Staff Digitalized Process & Material Development

Telephone: +49 631 2017 461


The project “Curved Composites – Development of Materials and Processes for the Production of Subsequently Formable Profiles made of Fiber-Plastic Composites” is funded by the Federal Ministry for Economic Affairs and Climate Action on the basis of a decision by the German Bundestag (funding reference ZF4052336).