The project 3D-LightTrans aims

to provide a ground-breaking, highly

flexible, efficient and adaptable

manufacturing chain for the production of

integral large scale 3D textile reinforced

plastic composites (TRPC).

This will enable to shift them from its

current position in cost intensive, small

series niche markets, to broadly

extended mass product applications in

transportation and other key sectors,

like health and leisure.

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 © 2012 3D-LightTrans – All rights reserved

Abstract

Large scale manufacturing technology for high-performance lightweight 3D multifunctional composites

Project data3D-LightTrans Concept

Objectives

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

To demonstrate this, a spare wheel well,

an air vent part and a tailgate will be

produced, featuring:

- Different specific functions (structural,

aesthetic, storage…)

- Size up to 1,37 m. x 0,87 m. x 0,71m.

and varying complexity

- Mass and/or cost reduction (in

comparison with e.g. cast aluminium

and carbon-glass-epoxy composite)

- Demanding mechanical properties

and load requirements: -40°C to

120°C (typically), tolerance to stone

impact, rigidity and torsional

deformation…

- Suitability for subsequent assembly

and post-processing: mechanical

fastening, integration of metallic

inserts, addition of brightwork, etc.

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

In the 3D-LightTrans manufacturing chain, multimaterial semifinished fabrics will be processed to

deep draped pre-fixed multilayered and multifunctional 3D-textile pre-forms. The fixed pre-forms

can be easily stored and transported (if needed) without special temperature requirements.

A project co-funded by the

European Commission within the

7th Framework Programme

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

The final composite part is produced by thermoforming. Neither manual draping of the textile onto

the forming tool nor infiltration/curing are required, since preforms are already fixed in the desired

3D geometry and the thermoplastic matrix integrated in the hybrid yarn before weaving.

- Multilayered and 3D-shaped fabrics with different

weave architecture realised

- Modified machines available in TU-Dresden (rapier

looms with heddle frames and jacquard, adapted for

weaving hollow structures); specific developments on

loom for full automation on-going (Michel Van de Wiele)

- Micro-CT results available, 3D-Finite Elements

simulation of the unit cell on-going

- On-going work on local reinforcement, pre-fixation and

draping (with simulation of in-plane draping behaviour

showing good correlation with experimental results)

- First thermoformed test parts available; process

simulation and part characterization on-going

First project results

For more information please contact:

Contact

- Hybrid air mingled yarns with different glass rovings and PP, PA, PET/PES as matrix material

(tensile modulus of 30 to 36 GPA for a mixture ratio of 70:30 with E-Glass)

Fig. 4- Micro-CT picture of multilayer (UGent)

Fig. 3- Different weave architechtures (TU-D)

- Modelling, simulation and tests on Glass-PP

fibre done

- Running work to decrease/improve abrasion,

ageing and adhesion

Fig. 5-GP/PP Hybrd yarn 17 layered weave (left) and composite (right): Compression approx. 57% (TU-D)

Fig.2- Different hybrid yarns and test results