skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Thermoplastic Composites Parts Manufacturing Enabling High Volumes, Low Cost, Reduced Weight with Design Flexibility – Phase 2

Abstract

The deliverable of this IACMI PHASE II project is an innovative thermoplastic composite parts manufacturing process that addressed some of the most challenging aspects for commercial adoption in high volume market applications with requisite design flexibility while lowering cost and weight. The collaborative 15-month joint effort built upon the collective collateral value that was validated in PHASE I, as well as the synergies of a cross- functional team members comprised & lead by DuPont, Fibrtec & Purdue. Specifically, Fibrtec’s uniquely flexible coated tow (FibrFlex®) with DuPont's Rapid Fabric Formation (RFF) technology and a proprietary DuPont polyamide resin, were used to create near net shapes, while Purdue developed new simulation tools to predict the behavior of material system preforms in molding processes. These were ultimately deployed for the manufacturing with “informed” performance of industrially-interesting CFRP parts. Experiments, modeling, and simulations have shown that this process/materials combination offers advantages for producing lower cost continuous fiber reinforced polymer (CFRP) materials that drape well during molding while maintaining outstanding physical properties. This newly deployed process is ideally suitable for adoption in the automotive and other higher volume industries because of the associated cost savings due to reduction of waste and embodied energy. Furthermore, itmore » overcomes the drawbacks of the prevalent two other typically deployed processes; the slow speed and expensive part formation associated with the usage of the stiff and brittle UD tapes, or the release of short conductive carbon fiber strands into the environment associated by the alternate layering of fiber woven fabric with resin film.« less

Authors:
 [1];  [2];  [3];  [4]
  1. E.I. DuPont de Nemours and Company, Inc.
  2. Purdue University College of Engineering, Composites Manufacturing and Simulation Center
  3. Fibrtec Inc
  4. DuPont Company, DuPont Performance Materials
Publication Date:
Research Org.:
IACMI - The Composites Institute
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
OSTI Identifier:
1568820
Report Number(s):
IACMI/R003-2019/3.11
Task 3.11
DOE Contract Number:  
EE0006926
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; carbon fiber; thermoplastic; continuous; UD tapes; drape'; flexibility; rapid manufacturing

Citation Formats

Silverman, Lee, Bodganor, Michael, Davies, Robert, and Dickinson, Jacob. Thermoplastic Composites Parts Manufacturing Enabling High Volumes, Low Cost, Reduced Weight with Design Flexibility – Phase 2. United States: N. p., 2019. Web. doi:10.2172/1568820.
Silverman, Lee, Bodganor, Michael, Davies, Robert, & Dickinson, Jacob. Thermoplastic Composites Parts Manufacturing Enabling High Volumes, Low Cost, Reduced Weight with Design Flexibility – Phase 2. United States. doi:10.2172/1568820.
Silverman, Lee, Bodganor, Michael, Davies, Robert, and Dickinson, Jacob. Wed . "Thermoplastic Composites Parts Manufacturing Enabling High Volumes, Low Cost, Reduced Weight with Design Flexibility – Phase 2". United States. doi:10.2172/1568820. https://www.osti.gov/servlets/purl/1568820.
@article{osti_1568820,
title = {Thermoplastic Composites Parts Manufacturing Enabling High Volumes, Low Cost, Reduced Weight with Design Flexibility – Phase 2},
author = {Silverman, Lee and Bodganor, Michael and Davies, Robert and Dickinson, Jacob},
abstractNote = {The deliverable of this IACMI PHASE II project is an innovative thermoplastic composite parts manufacturing process that addressed some of the most challenging aspects for commercial adoption in high volume market applications with requisite design flexibility while lowering cost and weight. The collaborative 15-month joint effort built upon the collective collateral value that was validated in PHASE I, as well as the synergies of a cross- functional team members comprised & lead by DuPont, Fibrtec & Purdue. Specifically, Fibrtec’s uniquely flexible coated tow (FibrFlex®) with DuPont's Rapid Fabric Formation (RFF) technology and a proprietary DuPont polyamide resin, were used to create near net shapes, while Purdue developed new simulation tools to predict the behavior of material system preforms in molding processes. These were ultimately deployed for the manufacturing with “informed” performance of industrially-interesting CFRP parts. Experiments, modeling, and simulations have shown that this process/materials combination offers advantages for producing lower cost continuous fiber reinforced polymer (CFRP) materials that drape well during molding while maintaining outstanding physical properties. This newly deployed process is ideally suitable for adoption in the automotive and other higher volume industries because of the associated cost savings due to reduction of waste and embodied energy. Furthermore, it overcomes the drawbacks of the prevalent two other typically deployed processes; the slow speed and expensive part formation associated with the usage of the stiff and brittle UD tapes, or the release of short conductive carbon fiber strands into the environment associated by the alternate layering of fiber woven fabric with resin film.},
doi = {10.2172/1568820},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2019},
month = {10}
}