07 August 2018
07 August 2018
ZSK has developed a tailored fibre placement (TFP) process designed to cuts cost, wastage and manufacturing times for carbon composites, while offering new possibilities for improved component design and enhancing end of life recyclability.
Unlike the conventional approach of weaving the fibres of a composite into a perpendicular arrangement then cutting the fabric to the required shape, TFP arranges the fibres in bundles exactly where they are most needed for structural performance and stitches them into position on a compatible base layer. ZSK says this offers freedom of positioning, allowing fibres to be placed in the optimum directions to carry the loads, ensures that they do not move during processing, and cuts fibre wastage to only 3% instead of the usual 30-70% on a typical automotive component. ZSK’s machines are able use TFP to create 3D preforms which match the finished shape of a typical automotive part.
ZSK has improved the TFP method through a number of patented innovations that speed up the deposition of fibres, increase versatility and streamline the design process. Process improvements include:
“The demand for lightweight materials, to improve CO2 emissions and product performance as vehicles become heavier and more complex, has never been greater but the cost of composite manufacture has remained unaffordable in all but the most specialist niche applications,” explains Melanie Hoerr, Manager for Technical Embroidery at the German textile engineering firm. “Our approach using TFP breaks through that barrier by eliminating most of the manual processing and waste of conventional composite manufacture, while increasing design freedom and improving quality control.”
TFP allows the composite preform to be produced with a mix of fibres, including optical or metallic materials to provide specific properties such as electrical continuity or impedance. Naked antenna wires and isolated feed wires have already been combined by this method to make up RFID components.
TFP can also incorporate polymers commingled with carbon fibre to be melted later during moulding to form the matrix, accelerating the production of complex parts and improving the resin-to-fibre distribution, especially in the extremities of the mould. Current difficulties with end-of-life recycling of composites could be largely overcome by choosing appropriate polymers for re-melting to simplify separation during end-of-life recycling.
ZSK can either provide expertise to help automotive suppliers develop prototypes and establish new TFP facilities, or recommend one of its network of specialist manufacturers to co-develop TFP parts. The company also provides ongoing manufacturing support, with both Cloud-based and off-line solutions for quality control and an Industry 4.0 solution (MY.ZSK) to connect sensors and evaluate data from the manufacturing process.
Photo provided by ZSK
Cobra International will showcase a range of composite products at CAMX 2018, including carbon fibre components for the automotive, transportation, marine, water sports and luxury sectors.
UK company Prodrive Composites has developed a process for manufacturing recyclable composite components that can satisfy future end-of-life requirements without any compromise in the performance of the original parts. The company says the P2T (Primary to Tertiary) process not only simplifies recycling, but endows a composite material with the potential to fulfil three or more useful lifetimes.
Designers at Elemental Motor have utilised tailored fibre placement (TPF) to extend the use of carbon composites in its RP1 sports car.