Multi-scale visualisation – key to an enhanced understanding of materials

Now it is possible to implement a user-friendly cross-model concept which enables the multi-scale visualisation of individual sets of simulation results. It was jointly developed by the Institute of Lightweight Engineering and Polymer Technology (ILK) and the Chair of Computer Graphics and Visualisation (both part of TU Dresden) within the framework of ScaDS Dresden/Leipzig – Competence Center for Scalable Data Services and Solutions.

Dipl.-Ing. Robin Höhne, Research Fellow, Institute of Lightweight Engineering and Polymer Technology (ILK), TU Dresden,
Dipl.-Medieninf. Joachim Staib, Staff, Chair of Computer Graphics and Visualisation, TU Dresden,

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Comprehensive research and technology enables new kind of sandwich panel manufacturing

With a combination of six new technologies the Composites Manufacturing Lab (CML) at the GE Global Research facility in Munich proves a novel concept for the manufacturing of sandwich panels. The process involves forming of dry fiber Automated Fiber Placement (AFP) as well as stitched foam cores and Fiber Patch Preforming.

Stefaan van Nieuwenhove, Andreas Lutz, Thomas Kluge, Anja Nieratschker,
Composites Manufacturing Lab, GE Global Research, München,

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Fully automated design and manufacturing of complex geometries with dry fibers

While the automated processing of fiber composites with resin injection processes like RTM is already industry standard, efficient and automated fiber placement processes for complex geometries are still challenging. Until now, narrow radii and angles, strongly convex and concave shapes and undercuts are a challenge for every fiber composite engineer when faced with automation for high volumes.

Felix Michl, CTO, Cevotec GmbH, Taufkirchen,

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Honeycomb core range broadened with 4 mm cell size in 5 mm and 6 mm thickness

ThermHex Waben’s polypropylene honeycomb cores offer today a reduction of costs and weight to a wide variety of applications such as truck and trailer bodies, in caravan industry or manufacturing of prefabricated bathrooms, shower tubs and swimming pools.

Jana Heinrich, internal sales & customer service manager, ThermHex Waben GmbH, Halle,

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T-RTM lauded perfect combination for modern lightweight construction

Continuous fibers, short cycle times, welding and recycling capability: KraussMaffei's Thermoplastic Resin Transfer Molding (T-RTM) procedure unites the benefits of reaction process machinery, thermoplastic materials and shaping in the RTM procedure.

Erich Fries, Head of the Business Unit Composites/Surfaces, KraussMaffei Technologies GmbH, München,
Philipp Kraus, Research and Development, Forward Engineering GmbH, München,

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Multilayer basalt tube suitable for application in demanding settings

With their new multilayer basalt tube Franconian producer CG-Tec and its Austrian development partner NBG Systems GmbH present a type of new composite core. It combines high-performance basalt fiber, high strength stainless steel tubes, a communication element (optical fibers, coax or copper wires) and optionally a polyamide, polyethylene or high-density polyethylene sheath.

Oliver Kipf, Dieter Schleier, CG TEC GmbH, Spalt,

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Expediting induction welding of CFRPC

The application of carbon fiber reinforced polymer composites (CFRPC) in mass production is still hindered by a lack of lightweight and economical joining technologies. Therefore, the Institut für Verbundwerkstoffe (IVW) develops advanced joining technologies for thermoplastic FRPC which provide excellent bonding strengths combined with a high automatization level.

Stephan Becker, M.Sc., Manufacturing Science, Institut für Verbundwerkstoffe (IVW) GmbH, Kaiserslautern,

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Diamond coated tools work highly demanding special materials

The materials employed in the aerospace, automotive and medical industries present toolmakers with increasingly demanding requirements. What’s more, there are challenging processes such as micromachining in which tools with a diameter of 0.03 to 1 millimetre process components with dimensions in the 1 mm to 1 cm range. Matched tools and application-specific surface solutions such as the Balinit Diamond family of coatings from Oerlikon Balzers can not only meet these challenges, but can also minimize costs.

Marco Schuite, Global Business Development Manager Diamond, Oerlikon Balzers Coating Luxemburg S.A.R.L.,

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Newly developed micro cutting tools also for CFRP-/ GRP applications

HPTec GmbH located in Baden-Wuerttemberg produces micro cutting tools in the nominal diameter range of 0.05 – 7.00 mm. For the processing of CFRP and GRP materials HPTec has now developed its new tools – MCT (Micro Cutting Tools).

Michael Gründler, Key Account Manager, HPTec GmbH, Ravensburg,

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German-japanese cooperation promotes new multi filament winding machine

Fibre-reinforced plastics (FRP) are well known for their high weight-related characteristics. This potential leads to an increase in the use of FRP in many industries. However, for a full market penetration and to make FRP suitable for series production, economic and efficient manufacturing processes are needed – as are implemented in the new multi filament winding machine MFW-48.

Univ.-Prof. Prof. h.c. (MGU) Dr.-Ing. Dipl.-Wirt. Ing. Thomas Gries, Institutsleiter, Pia Münch M. Sc.,

Composite Division/Abt. für geflochtene Verstärkungshalbzeuge, Institut für Textiltechnik der RWTH Aachen University (ITA), Aachen,

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