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.


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

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

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