MAPICC 3D

One-shot Manufacturing on large scale of 3D up graded panels and stiffeners for lightweight thermoplastic textile composite structures

 Partecipanti

Mappa

 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

 Obiettivo del progetto (Objective)

'The MAPICC 3D project and concept aims at developing manufacturing system for 3D shaped, multilayered products based on flexible materials. The ultimate goals are:

> The development of integrated and automated process chain able to produce from hybrid thermoplastic yarn to 3D complex shaped thermoplastic composite structure in single step thermoplastic consolidation process.

> The development of flexible industrial tools, able to produce customized final composites: possibility to reinforce the preform by coating, weaving multilayers, by injection of foam, by introduction of sensors (control quality of preform during the production or monitor the integrity of composite during use)

> The development of modelling tool in order to help understanding of the mechanisms involved in the new technologies and to prototype virtually 3D preform, predictive tools to evaluate the physical and mechanical properties of final 3D preform and final composites structure and at the last step reverse engineering.

The speed of production and the cost of manufacturing the 3D preform will be in accordance with the transport, building and energy thanks to: • The use of raw materials at low cost based on thermoplastic polymer, or regenerated fibres, • A decrease of production time. The polluting, labour-intensive and expensive steps of cutting, forming and joining, of current composites production could be avoiding. • A dynamic quality control during the production to improve the process robustness, • A decrease of quantity of wastes in comparison to current 2D preform based composite structures manufacturing.

The consortium allows integrating the entire process chain and involves the industrial stakeholders from machine tools, automation and modelling processing of flexible materials, yarn and textiles, composites and end users for transport: industry insures the leadership of the project.'

Introduzione (Teaser)

A new cost-efficient process makes possible the manufacture of 3D high-performance lightweight thermoplastic composites based on flexible materials.

Descrizione progetto (Article)

Fibre-reinforced composites with a thermoplastic polymer matrix are well suited for use in the transport and energy industries. To date, it has been very laborious to manufacture such composites in large quantities since it involves joining fibre preform layers for structure weight reduction.

The EU-funded project http://mapicc3d.ensait.fr/ (MAPICC 3D) is developing a one-shot manufacturing process for 3D preforms that avoids all these joining steps, thus decreasing production time. In particular, this automated process will ultimately allow the production of 3D complex thermoplastic composite structures from hybrid thermoplastic yarns. Use of raw materials based on thermoplastic polymer or regenerated fibres should decrease cost.

This innovative concept will enable the precise steering of fibres in three dimensions in a fully interlaced manner to tailor mechanical properties. Modelling tools will predict the final properties of designed 3D preforms and composites, enabling easier design of customised end products. Sensor, tube or wire integration will ensure good control of preform quality during production or monitoring composite integrity during use.

MAPICC 3D is also expected to demonstrate a highly efficient automated and adaptable manufacturing system for preform high-volume production and ultimately thermoplastic composites at industrial scale. Compared to current 2D preform methodologies, productivity should increase as much as 30 %.

Scientists have already established and validated the methodology of simulating weaving, knitting and braiding processes for manufacturing 3D preforms. The team has managed to interlock and manufacture braiding cross stiffeners. Work has also been geared toward producing weaving fibre and knitting panel preforms. Ultimately, a new formulation has allowed to improve mechanical and electrical properties as well as sensor sensitivity.

MAPICC 3D promises improved productivity and low cost composite production. The developed lightweight composites with enhanced mechanical properties are set to replace metal structures in the automotive, railway and energy industries.