Abstract
In order to assess the potential of commingled yarns for cost-effective manufacturing of thermoplastic composites, an integrated cost and consolidation model has been developed. The cost estimation procedure and the consolidation model are applicable to a wide variety of composite processing techniques. Interaction between the cost and consolidation models allowed the determination of the processing conditions necessary to achieve the desired quality at a minimum manufacturing cost. It also permitted study of the material and cost responses to a particular set of processing parameters. This was illustrated for a generic composite hook manufactured by a novel technique, referred to as integrated processing, utilising robotic placement of commingled yarns of carbon and polyamide 12 fibres and over-injection moulding. Comparison with hooks processed by unreinforced polymer via injection moulding also demonstrated the potential of the integrated processing technique for the production of complex-shaped composites with increased performance-to-cost ratio.
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