Light Weight Structures Research Group
Next Generation Composite Structures from Multi-Architecture Pre-Form Systems
This one year collaborative project between Loughborough University and the University of Nottingham, with M. Wright and Sons Ltd contributing as an industrial partner, was concerned with the use of advanced out-of-autoclave (OOA) manufacturing techniques, together with multi-architecture composite pre-form systems and automated manufacturing, for the development of next generation composite structures.
Different fibre architecture solutions were investigated, including Non-Crimp Fabrics (NCF), 3D woven textile pre-forms, and Directed Carbon Fibre Pre-Forming (DCFP). The impetus for this work was the need to address the current challenges facing the transport sector, such as the increasing requirements for light weight, production flexibility for low to medium production volumes, and a reduction of cost for high value structures.
- Funding bodies
- ERDF / EMDA (Transport iNet)
- Project duration
- 12 months
- Project team (researchers)
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Dr Paul Cunningham, Dr Alan McMillan (Loughborough University)
Professor Nick Warrior, Dr Tom Turner (University of Nottingham) - Industrial collaborators
- Michael Wright and Sons Ltd
- Contact
- Dr Paul Cunningham
Project outputs / results
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Various materials and processing technologies have been considered.
- Non-Crimp fabrics.
- Multi-axis carbon fibre pre-forms (3D woven stiffeners).
- Directed carbon fibre pre-forming.
- Braided prismatic sections.
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Technology demonstrators moulded using vacuum infusion and novel application of breathable tooling.
- Study conducted to ascertain the benefits of using breathable tooling on the percentage void content of vacuum infused complex structures.
- Void content of <0.25% achieved with breathable tooling and gas permeable / resin impermeable membrane.
- Demonstrator panel quality extremely high for out-of-autoclave process.
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Flexible automated manufacturing cell established.
- Pre-form handling.
- Tufting / Stitching.
- Integration with braiding machine.
- Component trim and drill.
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Cost modelling study conducted.
- Capital equipment and tooling investment costs dominate the costs at lower volumes.
- Differences in raw materials and labour costs begin to become apparent at production levels >100.
- Autoclave to oven curing can result in 16% cost reduction.
- 35% cost savings with automated production and automation-optimised stiffening technology.