A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

Mohammad Rakhshbahar,Michael Sinapius

doi:10.3390/jcs2030042

Mohammad Rakhshbahar, Michael Sinapius

Open Access

https://doi.org/10.3390/jcs2030042

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Abstract

Automated processing techniques such as automated fiber placement (AFP) or automated tape laying (ATL) are well known nowadays. However, there is still a lot of potential for these methods to achieve better results, especially for large and complex composite structures. In this experimental work, the gap effect with the Automated Fiber Placement is shown and a solution to overcome this drawback is presented. The gaps are particularly apparent on complex and/or double-curved surfaces and reduce the mechanical properties of the composite structure. In order to cover the unavoidable weak area of this effect, a plurality of fiber composite layers are laid on top of one another in order to increase the mechanical properties of components. This in turn makes the components heavier and more expensive to produce. In this new method, the gaps are detected by profile sensor after placement of the tape on the mold. The gaps are filled with the aid of a 3D printer with carbon continuous-fiber reinforced plastics. By combining the 3D printing and AFP technology, composite parts can be manufactured in a more homogeneous manner. Subsequently, the components are produced faster, cheaper and even lighter because of the avoidance of the additional layers.

Highlights

A variety of automated manufacturing techniques have been developed for the production of lightweight composite structures
The tensile strength, interlaminar shear strength, and flexural strength of the laminate with gaps were reduced by about 13% compared to the laminate without gaps
As the most important manufacturing defects, the gaps significantly reduce the mechanical properties of the structure

Summary

Introduction

A variety of automated manufacturing techniques have been developed for the production of lightweight composite structures. AFP/ATL technologies are ideally suited for the production of large and/or geometrically complex components. Their main advantages over manual laydown are their productivity and reproducibility. Thermoplastic or thermoset unidirectional (UD)-Prepregs are often used for the automated production of modern high-performance composite materials. The different processability of the matrix systems and the different molecular structures of thermosetting and thermoplastic semi-finished products are the main differences in the fiber placement process. The AFP head has to be cleaned after every use due to the stickiness of the Prepreg material. This is time-consuming, and is a health issue due to the chemicals used. Opposite to the thermoset Prepregs, thermoplastic Prepregs can be stored for almost unlimited years

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Results

Conclusion