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Double-sided incremental forming of continuous fiber reinforced thermoplastics
Citation Link: https://doi.org/10.15480/882.17702
Publikationstyp
Journal Article
Date Issued
2026-07-20
Sprache
English
TORE-DOI
Volume
210
Article Number
110096
Citation
Composites Part A Applied Science and Manufacturing 210: 110096 (2026)
Publisher DOI
Scopus ID
Publisher
Elsevier
Continuous fiber reinforced thermoplastics (CFRTP) combine excellent mechanical properties with recyclability, weldability, and reshapeability. However, their conventional processing requires part-specific tooling, imposing high initial cost and lead times. This limits their applicability to small lot sizes. A flexible alternative could be Incremental Sheet Forming (ISF), which creates parts by moving a small, part-agnostic tool along numerically controlled paths. While ISF is established for metals, its adoption for CFRTP started only recently. In particular, the Double-Sided Incremental Forming (DSIF) process, which employs a second forming tool to improve quality and flexibility, has not been investigated in detail for CFRTP. Therefore, this work presents the first extensive study into DSIF of CFRTP, with a focus on establishing a baseline process. The conducted process characterization includes temperature and force assessments. Forming strategies were compared by forming cone frusta, yielding a multi-stage strategy combining spiral and fiber-following toolpaths, which produced wrinkle-free parts with good accuracy. Micrographs indicate good consolidation for the tested material and process conditions. Furthermore, a preliminary process parameter analysis, including temperature, support force, and step size, was conducted. The results indicate that DSIF can become a viable, flexible manufacturing route for CFRTP components and provide a sound foundation for future research.
Subjects
Composite
Fiber reinforced plastic
Incremental sheet forming
Manufacturing process
DDC Class
629.1: Aviation
Publication version
publishedVersion
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Name
1-s2.0-S1359835X26005439-main.pdf
Type
Main Article
Size
6.15 MB
Format
Adobe PDF