Design and Manufacturing Technology

High-Temperature Thermoplastic Tape Laying
State-of-the-art tape laying machines at the sites in Stuttgart and Augsburg are used for research and development work into high-performance thermoplastic structures using AFP (Automated Fibre Placement) and the corresponding process technologies.
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Carbon fibre-reinforced thermoplastic prepreg tape
The prepreg tape consists of carbon fibres in a high-temperature thermoplastic polymer matrix. This matrix is typically of the semi-crystalline polyaryletherketones variety, with well-known examples being PEEK, PEKK, and LM-PAEK. These types of polymers can sustain very high service temperatures, have excellent chemical resistances, are recyclable, and enable advanced joining processes such as ultrasonic or resistance welding.
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Resistence welding facility
A resistance welding system can also be found at each of the two sites. The systems are used to produce welds under laboratory conditions in order to determine the key mechanical properties of the joint. They are also used in the production of demonstrators. A temperature of up to 400 °C can be reached in the joining zones of the welding systems within 30 seconds.
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Material and technology in balance

The development of lightweight structures for the aerospace industry or the transport and energy sectors always lies at the heart of the work at the Institute - in one form or another. In the field of design and manufacturing technologies, the journey from the first design idea through to the finished component is viewed as one whole system process. This research field has been using digital processes to develop optimal solutions for more than 30 years. Alongside structural aspects, the specific properties of the materials being used and appropriate production technologies are already taken into account during the design phase. The main focus of this research is fibre-reinforced composites with thermoplastic or duromer matrices.

The following goals are pursued in the area of component development:

  • Development and application of digital development paths for designing and optimising components
  • Development of functionally integrated construction independent of the type of material
  • Demonstration and validation via internal production and testing

The focus in the area of technology development is:

  • Consolidation of fibre-reinforced thermoplastics without autoclaves (vacuum and pressing process)
  • Welding processes for thermoplastic composites

Contact

Sebastian Nowotny

German Aerospace Center (DLR)
Institute of Structures and Design
Component Design and Manufacturing Technologies
Pfaffenwaldring 38-40, 70569 Stuttgart