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 or vacuum.

Preform-LCM processes are among the most popular composite manufacturing processes, especially for high-performance components, and are used for structural components in automotive engineering or aviation as well as for rotor blades of wind turbines or complete ship hulls.

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.

Dr.-Ing.

David May

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
Economic Sectors Applications (Examples)
Aeronautics Fuselage structures
Automotive Chassis structures, structural components
Engineering Highly accelerated machine parts, cabinets
Sports & Recreation Sports equipment, bicycle, ski, boat building
Energy Rotor blades for wind power

Special Expertise

  • Sewing machines and sewing automats
  • Sew-and-cut Technology
  • SPS-controlled infusion System
  • Tool carrier with parallel guidance
  • Permeameter 2D/3D
  • Dry-Tow-Fiber-Placement
  • Autoclave technique as reference procedure
  • Consistent preform-engineering in 2D (CAD to preform)
  • Mapping of the entire process chain (preform to component)
  • Production concept development

Materials and Questions

Typical Materials

  • GFRPC
  • CFRPC
  • AFRPC
  • Epoxy resin, polyester resin, in-situ polymerizing thermoplastics

Typical Questions

  • Is it possible to simultaneously use stitching for the optimization of structural performance and process efficiency?
  • How does the micro structure of a Dry Fiber Placement-Preform influence its impregnation and mechanical characteristics?
  • Does prepreg-pressing allow manufacturing of parts with autoclave-like quality?

Projects in this field

Publications from the IVW papers in this field of competence

  • 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“

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

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

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

    Präzise Charakterisierung von Verstärkungstextilien
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