Digitalized Process & Material Development

Digitalization forms the basis for enhanced and efficient product development. In this competence field, the focus is on the corresponding hardware and software based digitalization "tools" themselves, which are researched from their basics to application.

One core area is process data acquisition. Following the principle of "the right sensor at the right place", holistic concepts for data acquisition are developed and realized, combining virtual studies with process simulation models making it possible to minimize data acquisition effort while at the same time maximizing information value. In addition to the basic topic of Ontology, this research area also includes the use of machine-learning methods such as deep-learning for effective analysis and utilization of both experimental and simulative data. Another focus is on micro-scale material simulation for more accurate prediction of material behavior during processing and application. Together with the other CFs in the department, integrated multiscale approaches realize continuous simulation chains from the fiber to the component level. To build up the necessary material understanding, validate models and generate input data, innovative experimental methods for characterizing the processing behavior of semi-finished products are also developed.

These technologies are developed for the entire spectrum of composite process chains and materials. A special focus, however, is on liquid composite molding (LCM) processes. The scientific foundation is provided by basic research regarding the effects of structural material variations and varying process conditions on the processing behavior of the materials during preforming (e.g. draping behavior) and impregnation (e.g. permeability). Experimental studies using self-developed measurement systems and acquired process data are synergistically combined with self-developed simulation methods to achieve a deeper process and material understanding. On this basis, new and further development of LCM preform technologies including customized reinforcement prepreg material, tooling and equipment design can be carried out.

In summary, important research objectivesare the development and implementation of hardware (sensor systems, machine vision) and software (ontology, machine-learning based material and process analysis and micro-scale material simulation) based digitalization tools for composites product development.

PD Dr.-Ing. habil.

David May

Research Director Digitalization & Manager Digitalized Process & Material Development

Special expertise: Process monitoring, experimental-simulative characterization of processing behavior (esp. permeability), Resin injection/infusion, Preforming

Telephone: +49 631 2017 400

david.may@leibniz-ivw.de

Vita

Special Expertise

Patented measuring systems for in-plane and through-thickness permeability
GeoDict© software for material simulation
Manufacturing concept development including data acquisition strategies
LCM-"one-stop-shop": tooling design, material selection, manufacturing, testing
RTM technology tooling with extensive sensor equipment
RTM injection systems for thermosets and reactive thermoplastics (e.g. ε-caprolactam)

Economic Sectors	Applications (Examples)
Mobility	Data acquisition and end-to-end RTM simulation chains
Sports & Recreation	Solid resin systems for yacht building
Energy	Infusion technologies for rotor blades

Materials and Questions

Typical Materials

Liquid and solid resin systems, acrylic resin, reactive PA6
Glass/carbon fiber-based rovings and textiles, new and recycled
Thermoset and thermoplastic binder materials

Typical Questions

Which sensor types and positions provide the most meaningful process data?
How can machine-learning methods be used to analyze the data?
How can manufacturing processes be simulated from fiber to component level?
Which liquid impregnation process is suitable for my application?

Projects in this field

Curved Composites

Subsequently Formable Profiles made of FRP

Development of a material model for unidirectional and continuous fiber reinforced thermoplastics

EasyEntry2TPC

Thermoplastic liquid impregnation

Thermoplastic liquid impregnation for rapid entry into the production of continuously fiber-reinforced thermoplastic composites based on established thermoset process chains

Hypersaddle

High-Performance Bicycle Saddle in Hybrid Design

The aim is the development of an individualized bicycle saddle that unites comfort, lightweight design and durability on a high level.

HyRoS

Multifunctional Hybrid Rotor Blade Protection System

Development of an erosion protection layer for wind energy plants and a rotor blade heating system

InTeKS

Innovative textile structures from carbon staple fibres

Development and manufacturing of rCF staple fiber based organo sheets and the creation of an associated FE-model for the simulation of the thermoforming process of this material.

MarineCare

Sustainable Composite Materials for Maritime Applications

The aim of MarineCare is to develop a sustainable composite material from recycled and bio-based materials and to develop a corresponding waste-reducing manufacturing process.

Math2Composites

Material Simulator for Textile Based Composites

Development of a simulation software module for the determination of material parameters, which replaces experimental tests by validated simulations.

Next-Move

Concepts of Next Generation of Moveables

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

PowderTape

Flexible Prozesskette für Thermoplast-Composites

Ziel des Projekts PowderTape ist die Umsetzung einer flexiblen Prozesskette für die Herstellung hochleistungsfähiger Thermoplast-Composites auf Basis pulverimprägnierter Fasertapes und die Entwicklung einer entsprechenden Anlagentechnik.

rCF-Mobil

Recycled High Performance Composites for Automotive Industry

High-pressure capillary rheometer is used to investigate the melt flow behavior of thermoplastic polymers and blends.

Retention

Research Cooperation IVW and CACM Auckland, New Zeeland

High-pressure capillary rheometer is used to investigate the melt flow behavior of thermoplastic polymers and blends.

SusComTrab

Flame Retardant Sustainable Composites

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

Through-the-Thickness Permeabiltiy of the Reinforcing Tex

Design of a more efficient resin injection process

Knowledge about the impregnation behaviors of reinforcement textiles

Publications from the IVW papers in this field of competence

Willenbacher, B.(2023)
Bestimmungsmethoden für das transversale Imprägnier- und Deformationsverhalten textiler Verstärkungssturkturen
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May, D.(2022)
Prozessentwicklung für Faser-Kunststoff-Verbunde: Studien zu Verarbeitungseigenschaften von Halbzeugen als Basis einer ganzheitlichen Forschungsmethodik
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Rimmel, O.(2020)
Grundlagen der Imprägnierung von Dry Fiber Placement Preforms
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Kühn, F.(2020)
Sequenzielle Imprägnierung thermoplastischer Puler-Towpregs
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Neumann, U.(2017)
Kontinuierliches Ultraschall-Preformen zur Fertigung von CFK-Bauteilen in der Luftfahrt
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Grieser, T.(2017)
Textiles Formgebungsverhalten beim kontinuierlichen Preforming
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May geb. Becker, D.(2015)
Transversales Imprägnierverhalten textiler Verstärkungsstrukturen für Faserkunststoffverbunde
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Arnold, M.(2014)
Einfluss verschiedener Angussszenarien auf den Harzinjektionsprozess und dessen simulative Abbildung
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Weiland, F.(2013)
Ultraschall-Preformmontage zur Herstellung von CFK-Luftfahrtstrukturen
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Rieber, G.(2011)
Einfluss von textilen Parametern auf die Permeabilität von Multifilamentgeweben für Faserverbundkunststoffe
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Molnàr, P.(2007)
Stitching Technique Supported Preform Technology for Manufacturing Fiber Reinforced Polymer Composites
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Ogale, A.(2006)
Investigations of sewn preform characteristics and quality aspects fort he manufacturing of fiber reinforced polymer composites
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Stadtfeld, H.(2006)
Entwicklung einer Messzelle zur Bestimmung von Kompaktierungs- und Permeabilitätskennwerten bei flächigen Faserhalbzeugen
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Mitschang, P. (Hrsg.)(2004)
Prozessentwicklung und ganzheitliches Leichtbaukonzept zur durchgängigen, abfallfreien Preform-RTM Fertigung. BMBF Projekt - leider vergriffen!
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Stöven, T.(2004)
Beiträge zur Ermittlung der Permeabilität von flächigen Faserhalbzeugen
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Weimer, C.(2002)
Zur nähtechnischen Konfektion von textilen Verstärkungsstrukturen für Faser-Kunststoff-Verbunde
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Kissinger, C.(2001)
Ganzheitliche Betrachtung der Harzinjektionstechnik - Messsystem zur durchgängigen Fertigungskontrolle
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Reuter, W.(2001)
Hochleistungs-Faser-Kunststoff-Verbunde mit Class-A-Oberflächenqualität für den Einsatz in der Fahrzeugaußenhaut - leider vergriffen!
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External Publications „Digitalized Process & Material Development“

Modeling transverse mirco flow in dry fiber placement preforms

Journal of Composite Materials 04/2019

https://doi.org/10.1177/0021998319884612

Impact of Stitchin on Permeability and Mechanical Properties of Preforms Manufactured by Dry Fiber Placement, Polymer Composites 5/2018
doi.org

Out–of–plane capillary pressure of technical textiles

Composites Part A: Applied Science and Manufacturing 09/2019

https://doi.org/10.1016/j.compositesa.2019.105495

Wet Fiber Placement: A novel manufacturing technology for continuous fiber reinforced polymer composites

Journal of Composite Materials 06/2018

https://doi.org/10.1177/0021998318786998

Integrated Product Development with Fiber-Reinforced Polymers

Integrated Product Development with Fiber-Reinforced Polymers | David May | Springer

Evaluation of different bonding strategies for glass fibre-reinforced epoxy resin with embedded elastomer layers

https://doi.org/10.1080/14658011.2022.2111512

Out-of-plane permeability of 3D woven fabrics for composite structures

The Journal of The Textile Institute 08/2019

https://doi.org/10.1080/00405000.2019.1682759

Recycling langer Kohlenstofffasern, Kunststoffe 5/2018
www.kunststoffe.de

In-plane permeability characterization of engineering textiles based on radial flow experiments: A benchmark exercise

Composites Part A: Applied Science and Manufacturing 06/2019

https://doi.org/10.1016/j.compositesa.2019.03.006

A combined experimental–numerical approach for permeability characterization of engineering textiles

https://doi.org/10.1002/pc.26064

An overview on current manufacturing technologies: Processing continuous rovings impregnated with thermoset resin

https://onlinelibrary.wiley.com/doi/full/10.1002/pc.26274

Solid epoxy prepregs with patterned resin distribution: Influence of pattern and process parameters on part quality in vacuum-bag-only processing

https://doi.org/10.1002/pc.27696

Textile-Integrated Elastomer Surface for Fiber Reinforced Composites

22^nd Symposium on Composites 06/2019

https://doi.org/10.4028/www.scientific.net/KEM.809.53

Development & Validation of Recycled Carbon Fiber-Based Binder Tapes for Automated Tape Laying Processes, Journal of Composite Materials 11/2018
doi.org

Metrological determination of inhomogeneous hydrodynamic compaction during unsaturated out-of-plane permeability measurement of technical textiles

Advanced Manufacturing: Polymer & Composites Science 04/2019

https://doi.org/10.1080/20550340.2019.1598049

Out-of-plane permeability measurement for reinforcement textiles: A benchmark exercise

https://www.sciencedirect.com/science/article/abs/pii/S1359835X21002025

Saturated out-of-plane permeability and deformation metrology of textiles at high levels of injection pressure

https://www.tandfonline.com/doi/full/10.1080/20550340.2022.2064070

A Novel Simulative-Experimental Approach to Determine the Permeability of Technical Textiles

22^nd Symposium on Composites 06/2019

https://doi.org/10.4028/www.scientific.net/KEM.809.487

Präzise Charakterisierung von Verstärkungstextilien
PDF

Dry fiber placement of carbon/steel fiber hybrid preforms for multifunctional composites

Advanced Manufacturing: Polymer & Composites Science 03/2019

https://doi.org/10.1080/20550340.2019.1585027

Concept for Darcy-based viscosity measurement for fast-curing resin systems

https://doi.org/10.1016/j.coco.2021.100881

Structural topology optimization and path planning for composites manufactured by fiber placement technologies

https://doi.org/10.1016/j.compstruct.2022.115488

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