In the 3D-LightTrans innovative manufacturing chain, semi-finished, hybrid yarn fabrics are processed to deep draped pre-fixed multilayered and

multifunctional 3D-textile pre-forms. Fixed forms can be easily stored and transported (if needed) without special temperature requirements. The

final composite part is easily and efficiently produced by thermoforming.

The main objectives of the project are:

1. Substantial increase of achievable complexity and flexibility in the realization of 3D fabrics

2. New procedure for highly efficient production of TRPC parts (up to 70% shorter processing time, less than 0,5 mm. fibre displacement)

3. Establishment of the complete manufacturing chain

4. Enabling mass manufacturing of products with short production times and high customization

Project Coordinator

Dr. Marianne Hörlesberger (AIT)

marianne.hoerlesberger@ait.ac.at

Exploitation & Dissemination Manager

Dr. Ana Almansa (Xedera)

aam@xedera.eu

www.3d-lighttrans.com

Copyright © 2013 3D-LightTrans – All rights reserved

3D-LightTrans concept and objectives

Large scale manufacturing technology for high-performance

lightweight 3D multifunctional composites

Project data

Project progress

Project title

Large scale manufacturing technology

for high-performance lightweight 3D

multifunctional composites

Acronym

3D-LightTrans

Grant agreement no.

263223 FP7-NMP-2010-LARGE-4

Project duration

From April 2011 to March 2015

Consortium

1. Austrian Institute of Technology

GmbH

2. Xedera e.U.

3. Centro Ricerche Fiat SCPA

4. Coatema Coating Machinery GmbH

5. Federal-Mogul Systems Protection

6. Universiteit Gent

7. Grado Zero Espace srl

8. Technische Universität Dresden

9. LEITAT Technological Center

10. Lindauer Dornier GmbH

11. Northwest Textiles Network Limited

12. P-D Glasseiden GmbH Oschatz

13. Michel Van de Wiele

14.Onera - The French Aerospace Lab

15.Bentley Motors Ltd

16. SVUM A.S.

17. PROMAUT S.L.

18. Universite d‘Orleans

Fig. 1- 3D-LightTrans manufacturing chain (all pictures -except battery case and truck- by TU-D)

Development of equipment

- Modified Air Texturing Machine delivered

- Rapier looms with heddle frames andjacquard, adapted for weaving hollowstructures, available at TU-D

- Specific developments on loom for fullautomation on-going at Michel Van de Wiele.

Modified Air Texturing Machine RMT-D in TUD

A project co-funded by the

European Commission within the

7th Framework Programme

For more information please contact:

Contact

Process technology

- Hybrid air mingled yarns with different glassrovings and PP, PA, PET/PES as matrixmaterial

- Strategies to increase the yarn’s abrasionresistance during weaving explored

- Multi-layered and 3D-shaped fabricsproduced with different weave architecture

- Modelling and simulation validated by testresults

- Tests on robotized draping proceduresusing suction cups and needles claws

- Pre-fixation and fixation with speciallyplaced modified fibers and different heatingtechniques.

- Design of thermo-press tools- First definition of thermoforming process

settings- Preliminary analysis of the influence of

relevant factors such as the micro-porosity.

Textile reinforced composite demonstrators- Selection of 3 automotive components (spare wheel well, air vent part and

tailgate) with varying complexity and demanding properties / tolerances.- Specification of requirements and final design finished- Specific target glass/PET yarn composition selected.

3D-LightTrans manufacturing chain- Modeling /simulation of all process steps, from weaving to draping and pressing- Validation by experiments(e.g. from optical analysis, tensile and bending tests).- Analysis of scale-up for mass production, product life cycle and business

market study on-going.

Micro-CT picture of multilayer (UGent)

Project co-funded by the European UnionSeventh Framework Programme (FP7/2007-2013) under grant agreement n° 263223.

For more information please contact:

Contact

Multilayer and spacer fabric arquitecture

CRF‘s tailgate and Bentley‘s spare wheel well