The anisotropic properties of textile-reinforced plastic composites allow the force-flow-compatible
exploitation of the extraordinary lightweight potential with high-density performance and functionality, but
require new technologies, as well as complex simulation and design methods. In order to fully exploit the
high specific strengths and stiffnesses in lightweight structures, the integration of metallic load
introduction systems is generally indispensable. The varying fibre orientation of textile-reinforced
components and the specific restrictions imposed by the complex manufacturing process complicate the
force-flow-compatible design of embedded metal components with regard to maximum structure strength. The
same applies to short- and long-fibre-reinforced thermoplastic components with metal inserts using the
injection moulding process. With the development of integrative injection moulding processes in association
with in-mould coating, a vital contribution is made to the reduction of resource and energy consumption,
especially for the areas of fibre-reinforced plastics (FRP) and metal/plastic composites. Even when
lightweight construction technologies for composite fibre structures made from natural fibres and
biodegradable polymers are available, environmental conditions must be taken into account. To validate the
developed research methods, representative fundamental components and demonstrators will be utilised, with a
progressive increase in complexity expected throughout the course of the project. The preferred designs will
be fabricated in the integrative lightweight manufacturing complex (ILCx), integrated into the primary
system demonstrator, the Chemnitz Car Concept (CCC), and tested under typical vehicle loads and
environmental conditions.
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Figure: In-situ processes, use of new injection moulding for combination of hybrid components
with additional smart applications
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Investigators:
Bullinger-Hoffmann,
Geßner,
Hardt,
Helbig,
Müller,
W. Nendel,
Odenwald,
von Unwerth,
Wagenführ
Subprojects of the IRD C
| IRD C1 |
Merge technologies with textile/metal components and functional surfaces using integrative
in-mould plastics processes for the CCC system demonstrator
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| IRD C2 |
Process merger of metal die casting/plastics injection moulding technologies for components of
lightweight conveyor systems
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| IRD C3 |
In-situ microinjection moulding process for assembling active modules
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| IRD C4 |
Flexible textile/plastics processes with renewable raw materials
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| IRD C5 |
Merge technologies for physiologically compatible textile/plastic components using anisotropic
effects
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