TPRC successfully finalizes overmolding project with aerospace and automotive partners

The ThermoPlastic composites Research Center has successfully closed a two year collaborative project on the overmolding of thermoplastic composites with the design and manufacture of an advanced demonstrator part.

The part was realized as the result of a two year collaboration between TPRC, its members and renowned companies contributing from different areas of expertise: Autodesk, Harper Engineering Co., KraussMaffei, Safran S.A., Samvardhana Motherson Peguform (SMP) and Victrex PLC. The part features a typical grid stiffened panel that can be found in larger numbers in aerostructure applications. The stiffness and strength performance combined with extreme dimensional accuracy puts high demands on the manufacturing process.

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Research Spotlight: Overmolding

Stamp forming can be used for high volume production of continuous fiber reinforced thermoplastic parts with excellent mechanical properties. The process is, however, currently limited to relatively simple shell-like structures.

The overmolding technology potentially overcomes this limitation by combining two processes. Firstly, a continuous fiber reinforced thermoplastic composite blank is shaped in a stamp forming step. Secondly, additional features, such as ribs or inserts, are over-injection molded onto the stamp-formed part. Of course, the two processes can be performed in the same tooling and equipment. This way, overmolding combines the high specific strength and stiffness of the continuous fibers with the design freedom and flexibility of a (short fiber reinforced) injection molding grade. Moreover, the process can be easily automated and is well suited for high volume production.

Looking to collaborate with the TPRC in the field of overmolding? Make sure to contact us!

PhD title for Yibo Su

Yibo Su is the fourth TPRC Ph.D. student to receive his Ph.D. title.

On January 19th, Yibo Su defended his PhD thesis in the field of hybrid metal-thermoplastic composites joints. His research on hybrid joints is very topical and aligns well with the current trend of applying 'the right material in the right place', resulting in multi-material parts and structures. The challenge in such structures lies in the design and manufacturing of the multi-material joints as these will govern the performance of the structure as a whole.

Yibo Su investigated the performance hybrid metal - thermoplastic composite, joints. Conventionally, metals and composites are joined through either adhesive bonding or mechanical fastening. When using a thermoplastic matrix based composite, however, a third joining technique enters the fray: co-consolidation. Metal inserts are in this case effectively co-bonded with the thermoplastic composite material during the pre-preg consolidation process. This omits expensive and tedious post-processing steps and as such reduces manufacturing time and costs.

Interested in the technology or scientific results? Please do not hesitate to contact us for information.
 

Vaupell | SB Aero, ATC Manufacturing and TAI join TPRC as new Tier members

Vaupell | SB Aero

As of November 1st 2016, Vaupell | SB Aero has joined the ThermoPlastic composites Research Center (TPRC)  as a Tier 1 member.

Vaupell | SB Aero, a business unit of Sumitomo Bakelite Co. Ltd. (SB), will collaborate with TPRC, its industrial members and leading universities to accelerate scientific and technological developments for new applications of thermoplastic composites in aerospace, automotive and other value chains.

Henny van Dijk, Managing Executive Officer of Vaupell | SB Aero is looking forward to the partnership with the TPRC: ’Thermoplastic composite technology, in materials as well as parts, is instrumental to the future success of Vaupell | SB Aero. It is exciting to be part of this team, this diverse group, united in their commitment to thermoplastic composites.’

ATC Manufacturing

As of October 1st 2016, ATC Manufacturing joined the ThermoPlastic composites Research Center (TPRC)  as a Tier 1 member.

ATC Manufacturing is a premier manufacturing company specializing in the press forming of thermoplastic composites. ATC Manufacturing provides high quality composite parts primarily to the aerospace industry, but remains interested in all projects relating to our core competencies. ATC Manufacturing was established in April 2004.

TAI

As of March 1st 2017, TAI has joined the ThermoPlastic composites Research Center (TPRC) as a Tier 2 member.

The TAI focuses on design, development, modernization, manufacturing, integration and life cycle support of integrated aerospace systems, from fixed and rotary wing air platforms to UAVs and satellites. TAI ranks among the top hundred global players in aerospace and defence arena