CompositesWorld
Issue link: https://cw.epubxp.com/i/841219
JULY 2017 28 CompositesWorld FEATURE: AUTOMATED PREFORMING, PART 1 system accommodates parts up to 2m by 2m, which Rubertsberger claims readily handles automotive parts, including roofs, hoods and backwalls at the upper limit of this range. Rupertsberger cites an unusually short cycle time of 10-15 seconds per layer. "e dual feeders effectively double the rate of material delivery to the pick-and-place station," he explains. More importantly, the vacuum gripper collects and places each layer's tapes simultaneously, instead of one at a time. "We can also reduce the waste by integrating nesting of cut tapes digitally into the process," he says, adding, "We also check the direction of the fiber and the shape of the completed preform." In addition to the MultiLayup System, FILL is working with Engel (Schwertberg, Austria) to develop thermoplastic tape preforming. "Our equipment makes the layup, and Engel has the machine to add the injection material and thermoform the part," says Ruperts- berger. For automotive, the unidirectional tapes use polyamide (PA) as a matrix. He explains that these parts can use carbon fiber, but it is expensive and, therefore, important to place it with precision only where needed. "Our machine feeds, cuts, positions and consoli- dates the tapes to create a tailored organosheet inline, achieving the benefits of injection molding with the properties of composites," he claims. "We are exploring this technology for cycle time reduc- tion and also for the recyclability of parts," he adds, but also notes, "Parts manufacturers would rather have the fiber and matrix already together in a semipreg thermoplastic material in order to simplify and avoid a chemical process in the line." 40-second preforms, 90-second parts e Quilted Stratum Process (QSP) focuses squarely on thermo- plastic tapes, pultruding them inline and then assembling them into preforms for use as inserts in a thermoforming process. Started in 2013, with a pilot production line completed in 2015, QSP is a FIG. 2 Picks, places and consolidates 4-5 layers per minute The MultiLayup System from FILL Gesellschaft (Gurten, Austria) feeds UD tape from two sides to a central station where a vacuum gripper with integrated heating picks, places and consolidates each layer's tapes to build preforms at 10-15 seconds per layer. Source | Fill FIG. 4 Millions of parts per year and 25% less scrap Working with BMW and SGL, Compositence has developed stitched, dry fiber multifunctional tow and demonstrated preform production at rates up to 250 kg/hr — 3.5 million parts/yr — besting NCF with equal or better drapability and resin flow in subsequent molding but 25% less scrap. Source | Compositence FIG. 3 Quick change head processes multiple materials quickly Preforming systems developed by Compositence (Leonberg, Germany) can process towpreg, dry fiber and thermoplastic tape, using an exchangeable, quick-release AFP head to produce as many as four net-shape preforms, simultaneously, in 1 minute. Source | Compositence