Analysis of New Concepts for the Consolidation Roller in Laser-Assisted Automated Tape Placement Processes

Abstract

The need for more sustainable production has led to an increased popularity of thermoplastic fibre reinforced composites over the last years. Typical production processes rely on autoclave and/or sequential processes, which lead to long cycle times, high energy consumption and high costs. One step in-situ production processes, like the thermoplastic laser assisted automated fibre placement, provide an ideal solution to these challenges while enabling the benefits of circular economy through improved recyclability. An essential part of the production process is to ensure full consolidation during layup. One of the main influences on consolidation is the applied pressure of the compaction roller. Increasingly complex part geometries with curved surfaces place special demands on the deformation and adaptability of these rollers. Here, current solutions quickly reach their limits. This paper investigates new concepts for the consolidation roller to enable successful use of in-situ placement technologies on complex part geometries. Different sheath thicknesses and materials were investigated in experiments, followed by simulative investigation of further compaction roller concepts.