Design and Development of Extreme Lightweight Carbon Composite Structures Made by Tailored Fiber Placement
The additive preform manufacturing process Tailored Fiber Placement (TFP) offers outstanding capabilities in production of composite parts with extremely high lightweight potential due to the possibility to apply reinforcing fibers in arbitrary directions with very high flexibility and accuracy. Additionally, such parts are near net-shape manufactured with very good material utilization under economical aspects. At present, the carbon fiber reinforced plastic (CFRP) window frame of the Airbus 350 XWB is one of the most sophisticated composite parts made by TFP. Also for other applications the TFP process offers an outstanding potential by applying a variable-axial fiber design. However, a critical aspect for the application of the variable-axial preform technology is still the requirement to engineer and to simulate such complex composite structures based on a curvilinear fiber pattern. Within the presentation a non-commercial example of a variable-axial TFP structure is presented. The complete process chain from the part’s design and simulation up to its manufacturing is explained using the example of a truss like rear wing attachment for the 2016th car of the (TU Dresden) student racing team Elbflorace.
Author: Axel Spickenheuer
Conference: SAMPE Seattle 2017