UROP Project

Conceptual design, manufacturing and practical testing of a flexible forming fixture for joining thermoplastic prepregs and functional structures

Continuous fiber reinforced thermoplastics (FRTP) are increasingly being used for lightweight construction parts due to their ability to use further functionalization processes like injection molding or welding. Currently used processes such as an integrated injection molding processes are already used for serial applications. However, production of smaller series remains challenging and leads to high costs due to the necessity of manufacturing complex two sided moulds. In the context of a public research project the Institute of Plastics Processing (IKV) is developing a flexible, combined forming and joining process to manufacture functionalized, FRTP-parts. This new processing technique shall enable its users to produce functionalized FRTP-parts without a two-sided mold technique. Instead, a combination of functional elements like ribs or onserts manufactured via rapid-prototyping with continuous fiber reinforced prepregs in a flexible forming fixture as a one sided mold is applied.

Task

• Conceptual design of the forming fixture considering different functional elements • Engineering detail drawing of the forming elements • Testing of the fixture in production trials using different material combinations

Requirements

• Knowledge of engineered detail drawings • Basic knowledge of CAD-software • Konwoledge of FRTP processing