Impregnation & Preform Technologies

The focus of this field of competence is on Preform-LCM process chains. In these process chains, near-net shape preforms are first produced from rovings or textiles. The preforms are then impregnated in a liquid composite molding (LCM) process using a low-viscosity, usually thermoset matrix polymer by overpressure and/or vacuum.

The scientific basis of the field of competence is basic research on the effects of structural material variations and varying process conditions on the processing behavior of materials during preforming and impregnation. Experimental studies on self-developed measuring systems are synergetically combined with simulative studies and theoretical models in order to achieve a deeper understanding of processes and materials. On this basis, new and further development of preform LCM technologies, including the materials, tools and equipment used, is carried out.


PD Dr.-Ing. habil.

David May

Junior Research Group Leader TopComposite
- Topology-Optimized and Resource Efficient Composites for Mobility and Transport
& Manager Impregnation & Preform Technologies

Special expertise: Resin injection and infusion processes, preforming, permeability of fiber structures, manufacturing concepts and economic feasibility studies, integrated product development

Room: D.A.Z.
Economic Sectors Applications (Examples)
Aeronautics & Space Fuselage structures
Automotive Chassis structures, structural components
Engineering Highly accelerated machine parts, cabinets
Sports & Recreation Bicycle, ski, boat building
Energy Rotor blades for wind power

Special Expertise

  • Continuous Profile Preforming
  • Programmable sewing machines with real-time process control
  • Dry Fiber Placement
  • SPS-controlled infusion systems
  • Technology carrier tool with extensive sensor equipment
  • Autoclave technology
  • Patented permeability measurement systems
  • GeoDict® - software for material simulation
  • Develoment of production concepts

Materials and Questions

Typical Materials

  • Thermoset resin systems and in-situ polymerizing thermoplastics
  • Glass/carbon fiber-based rovings and textiles, new and recycled
  • Thermoset and Thermoplastic binder and prepreg materials

Typical Questions

  • How to achieve fast and robust impregnation?
  • How to characterize the processing behavior of fiber structures?
  • How to hybridize FRPs with elastomers or steel fibers on material level?

Projects in this field

Publications from the IVW papers in this field of competence

  • May, D.

    Prozessentwicklung für Faser-Kunststoff-Verbunde: Studien zu Verarbeitungseigenschaften von Halbzeugen als Basis einer ganzheitlichen Forschungsmethodik

  • Rimmel, O.

    Grundlagen der Imprägnierung von Dry Fiber Placement Preforms

  • Kühn, F.

    Sequenzielle Imprägnierung thermoplastischer Puler-Towpregs

  • Neumann, U.

    Kontinuierliches Ultraschall-Preformen zur Fertigung von CFK-Bauteilen in der Luftfahrt

  • Grieser, T.

    Textiles Formgebungsverhalten beim kontinuierlichen Preforming

  • May geb. Becker, D.

    Transversales Imprägnierverhalten textiler Verstärkungsstrukturen für Faserkunststoffverbunde

  • Arnold, M.

    Einfluss verschiedener Angussszenarien auf den Harzinjektionsprozess und dessen simulative Abbildung

  • Weiland, F.

    Ultraschall-Preformmontage zur Herstellung von CFK-Luftfahrtstrukturen

  • Rieber, G.

    Einfluss von textilen Parametern auf die Permeabilität von Multifilamentgeweben für Faserverbundkunststoffe

  • Molnàr, P.

    Stitching Technique Supported Preform Technology for Manufacturing Fiber Reinforced Polymer Composites

  • Ogale, A.

    Investigations of sewn preform characteristics and quality aspects fort he manufacturing of fiber reinforced polymer composites

  • Stadtfeld, H.

    Entwicklung einer Messzelle zur Bestimmung von Kompaktierungs- und Permeabilitätskennwerten bei flächigen Faserhalbzeugen

  • Mitschang, P. (Hrsg.)

    Prozessentwicklung und ganzheitliches Leichtbaukonzept zur durchgängigen, abfallfreien Preform-RTM Fertigung. BMBF Projekt - leider vergriffen!

  • Stöven, T.

    Beiträge zur Ermittlung der Permeabilität von flächigen Faserhalbzeugen

  • Weimer, C.

    Zur nähtechnischen Konfektion von textilen Verstärkungsstrukturen für Faser-Kunststoff-Verbunde

  • Kissinger, C.

    Ganzheitliche Betrachtung der Harzinjektionstechnik - Messsystem zur durchgängigen Fertigungskontrolle

  • Reuter, W.

    Hochleistungs-Faser-Kunststoff-Verbunde mit Class-A-Oberflächenqualität für den Einsatz in der Fahrzeugaußenhaut - leider vergriffen!

    External Publications „Impregnation & Preform Technologies“

    Modeling transverse mirco flow in dry fiber placement preforms

    Journal of Composite Materials 04/2019

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

    Out–of–plane capillary pressure of technical textiles

    Composites Part A: Applied Science and Manufacturing 09/2019

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

    Journal of Composite Materials 06/2018

    Integrated Product Development with Fiber-Reinforced Polymers

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

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

    The Journal of The Textile Institute 08/2019

    Recycling langer Kohlenstofffasern, Kunststoffe 5/2018

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

    Composites Part A: Applied Science and Manufacturing 06/2019

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

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

    Textile-Integrated Elastomer Surface for Fiber Reinforced Composites

    22nd Symposium on Composites 06/2019

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

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

    Advanced Manufacturing: Polymer & Composites Science 04/2019

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

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

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

    22nd Symposium on Composites 06/2019

    Präzise Charakterisierung von Verstärkungstextilien

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

    Advanced Manufacturing: Polymer & Composites Science 03/2019

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