Mould-integrated heating technology for efficient and appropriate processing of fibre-reinforced thermoplastics

Abstract

Automated large-scale production of hybrid structures is a key requirement to bring lightweight design into high volume industrial applications. Promising material combinations for hybrid structures consist of short and continuous fibre reinforced plastics and metals. The aim of this study is to develop economic strategies for automated final-shape manufacturing processes for these structures. This paper addresses the development of a mould-integrated heating technology for efficient and appropriate processing of continuous fibre-reinforced thermoplastics. Due to challenges in ensuring required processing parameters during manufacturing, inefficient process chains dominate the composite industry. The most critical parameter is the temperature of the composite during forming and over moulding. To enable such complex process chains, the material must conventionally be heated high above its melting point to balance temperature losses during subsequent process steps. In this study, conventional processes and heating strategies are investigated to evaluate their potential of a mould-integrated heating technology. As reference, external infrared radiation heating is used. The mould-integrated heating makes use of transparent areas within the cavity to enable in-mould infra-red radiation. The main benefit of this technology is the increase of energy efficiency due to isothermal moulding processes.