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Investigation of thermoplastic polymers with regard to their suitability as mold material in the FRP manufacturing process

Neumann, Fabian and Rings, Benedikt and Golombek, Hannes Lasse (2023) Investigation of thermoplastic polymers with regard to their suitability as mold material in the FRP manufacturing process. DLRK 2023, 2023-09-19 - 2023-09-21, Stuttgart, Deutschland.

[img] PDF - Only accessible within DLR
[img] PDF - Only accessible within DLR


Context: The choice of material, manufacturing process, and molding tool significantly effects the quality, environmental impact, and cost efficiency of fibre reinforces polymer (FRP) components. Producing one-piece hollow profiles with smooth inner surfaces and undercuts presents major challenges for conventional mold concepts. A promising solution are shape memory polymers (SMP) as tooling material. Objectives: This study aims to identify thermoplastic polymers which are suitable as mold material in the FRP manufacturing process. The overarching objective is to develop an high-rate manufacturing process for onepiece FRP hollow profiles with undercuts. This process should omit residual cores, wash- or melt-out cores which are associated with dirt an multi-part cores. Methods: First a manufacturing and curing process for a FRP is introduced. From this, boundary conditions for the mold material are defined. An assessment of the properties of thermoplastic polymers from literature research is carried out. An evaluation matrix allows the preselection of three polymers. PET, PPS, PA6 and PA6.6 are further analyzed by DSC and DMA. The results are used to tune the manufacturing process. Results: Semi-crystalline thermoplastics are more suitable as mold material than amorphous ones. When heated above their glass transition temperature (Tg) the elastomeric state allows for one-piece demolding. The material properties of 31 semi-crystalline polymers are assessed. PET, PPS, PA6 and PA6.6 are found as most likely suitable as mold materials for the introduced curing process. Their Tg is evaluated by DSC and DMA. Conclusion: PET, PA6 and PA6.6 meet the process parameters of the defined FRP production process. Further research has to be carried out regarding their shape memory behaviour and demolding capabilities.

Item URL in elib:https://elib.dlr.de/197509/
Document Type:Conference or Workshop Item (Speech)
Title:Investigation of thermoplastic polymers with regard to their suitability as mold material in the FRP manufacturing process
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Neumann, FabianUNSPECIFIEDhttps://orcid.org/0000-0002-7514-8427148264119
Date:19 September 2023
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Keywords:thermoplastic; mold; tooling; FRP; manufacturing; SMP; hollow profile
Event Title:DLRK 2023
Event Location:Stuttgart, Deutschland
Event Type:national Conference
Event Start Date:19 September 2023
Event End Date:21 September 2023
Organizer:DGLR e.V.
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Components and Systems
DLR - Research area:Aeronautics
DLR - Program:L CS - Components and Systems
DLR - Research theme (Project):L - Production Technologies
Location: Aachen
Institutes and Institutions:Institut für Systemleichtbau > Production Technologies BS
Institute of Structures and Design > Design and Manufacture Technologies
Deposited By: Neumann, Fabian
Deposited On:07 Dec 2023 15:21
Last Modified:24 Apr 2024 20:57

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