Advanced high-tech polymer composites combine the superior properties of the reinforcement material, such as glass or carbon, with the ultra-light weight and low cost of polymer matrix materials (plastics). The performance, controlability of properties and flexibility for customization are even higher if the reinforcement is integrated in the form of woven fabric (textile reinforced polymer composites or TRPC).
Commercial applications of TRPC are nowadays unfortunatelly restricted to very few cost intensive and small series niche markets. In spite of the promising application potential and impressive research research progress in this area, the successful exploitation of its overwhelming market potential is hindered by several factors, such as the wide range of possible constituents and difficulty to process them, the high cost due to slow, inflexible and expensive production processes including -mostly handmade- draping, as well as lay up processes, and the lack of flexibility in the realization of complex pre-forms with three-dimensional geometry.
The project 3D-LightTrans was launched with the vision of overcoming the existing limitations through an innovative TRPC manufacturing approach, based on individual processes explored by the partners in previous research activities, such as thermoforming of hybrid yarn textiles and intermediate fixation of the 3D of textile pre-forms.
| Spacer fabric manufactured in a single weaving step | 3D-TRPC made by thermoforming of deep draped multilayer fabric woven in hybrid yarn |
3D-LightTrans will in this way create a manufacturing chain based on an innovative approach that will, for the first time, enable a highly flexible and cost-effective mass production of complex textile reinforced polymer components, fulfilling strict quality requirements.