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    Item type:Publication, Access status: with files ,
    Single point incremental forming of multi-matrix continuously-reinforced composites: a feasibility study
    (Materials Research Forum LLC, 2025-05)
    Rath, Jan-Erik
    ;
    Nettig, Doran
    ;
    Palubiski, Dominic
    ;
    Schüppstuhl, Thorsten
    ;
    Ivanov, Dmitry S.
    Fibre-reinforced plastics offer remarkable strength-to-weight ratios, making them an excellent choice for lightweight engineering solutions. However, the forming of precursor materials such as preforms or prepregs poses substantial challenges, with defects such as delaminations or fibre misalignments occurring frequently. One approach to de-risk composite parts manufacturing are Multi-Matrix Continuously-Reinforced Composites (MMCRCs), pre-structured with formable and non-formable matrix materials connected by continuous fibre reinforcement. Regions with a matrix of covalent adaptable networks (CANs, aka vitrimers) can be locally formed to the desired shape, while unformable regions with a conventional thermoset matrix restrict undesirable deformations. As targeted local forming operations are required, incremental sheet forming is proposed as a flexible forming process that does not involve expensive moulds. To evaluate the feasibility of incrementally forming MMCRCs, a simple corner geometry is formed using single point incremental forming (SPIF) in this study. The prepared sample with a formable hinge region is attached to a metal dummy sheet with a vacuum bag and heated to forming temperature. Using a specifically developed toolpath strategy, the layup is deformed in a robotic SPIF setup. Albeit revealing challenges in the simultaneous forming of metal and MMCRC sheets, results prove that the proposed approach is promising in allowing the manufacture of high-quality composite parts in decoupled production and forming processes.
    Publicationtype: Conference Paper
      47  35
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    Item type:Publication, Access status: with files ,
    A preliminary study: support-free manufacturing of rotationally symmetric pipes from continuous carbon fiber reinforced polymers with multi-axis 3D printing
    (Materials Research Forum LLC, 2025-05)
    Kállai, Zsolt
    ;
    Kipping, Johann
    ;
    Bremer, Jan
    ;
    Schüppstuhl, Thorsten
    This paper presents an innovative approach that combines multi-axis fused filament fabrication (FFF) with continuous carbon fiber reinforced polymers (CFRP) to evaluate the feasibility of manufacturing rotationally symmetric CFRP pipes without mandrels or support structures. Traditional methods, such as filament winding, encounter limitations with geometric complexity and require tooling that makes them unsuitable for producing complex, individual parts. The proposed process uses the manufacturing flexibility of FFF and advantageous material properties of CFRP to create rotationally symmetric pipes on-demand. In this article, the experimental setup is described, the material and process-related challenges are discussed and a preliminary study that involves the printing of rotationally symmetric pipes to verify the viability of the process is presented. The findings aim to advance additive manufacturing techniques, enabling the production of lightweight, customized pipes for various industrial applications, and establishing this method as a cost-effective and efficient alternative.
    Publicationtype: Conference Paper
      39  18
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    Item type:Publication, Access status: with files ,
    Hot double sided incremental forming of continuous fiber reinforced thermoplastics: Process analysis and system design
    (Materials Research Forum LLC, 2025-05)
    Nettig, Doran
    ;
    Rath, Jan-Erik
    ;
    Schüppstuhl, Thorsten
    ;
    Frank, Johannes
    ;
    Riecken, Björn
    Interest in fiber reinforced thermoplastics (FRTP) is increasing due to their superior recyclability and processability over thermoset composites, but the need for part-specific tooling constrains their application in small-lot production. Incremental sheet forming (ISF) presents a flexible manufacturing alternative. However, existing ISF methods, predominantly developed for metals, need to be adapted to the specific process requirements of FRTP. Prior research into the ISF of FRTP has focused on single-point incremental forming (SPIF). To enable new processing strategies, this work presents the development of a robot-based hot double sided incremental forming (DSIF) setup for FRTP. A process analysis serves as the basis of the design and integration of the core system components. The setup shows great potential as a platform to explore a wide range of new ways to advance the ISF of FRTP.
    Publicationtype: Conference Paper
      48  37