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A01 Multi-criteria optimisation of in-situ reorientation processes for defined graded profile structures

Project Area

A01

Project Leaders

Lothar Kroll

Matthias Klärner

Cooperation Projects

A02 A03 A04 A05 B01 B02 B03 B04 B05 C01 C02 C05 C06 Z01
A01 Multi-criteria optimisation of in-situ reorientation processes for defined graded profile structures
Summary
The DediGrad subproject A01 investigates the multi-criteria optimisation of in-situ reorientation processes for the manufacturing of load-adapted, three-dimensionally graded fibre-reinforced structures. The focus lies on the targeted local adjustment of fibre architecture during injection moulding in order to realise continuous transitions between reinforced and non-reinforced regions. By combining experimental investigations with numerical simulations and data-driven optimisation approaches, the interactions between material, process, and structural parameters are systematically analysed. The aim is to develop robust manufacturing strategies and scalable models for describing anisotropic properties and enabling the efficient design of graded profile structures.
001 Objectives

Adaptive Fibre Grading

  • Enhancement of the lightweight potential of press-processed hybrid shell structures
  • Development of methods for creating graded transition zones
  • Investigation of the influence of local grading on further processing and transition-zone formation
  • Analysis of process–structure–property relationships by experiment and simulation
  • Demonstration of functionality using the EFS demonstrator
002 Scientific Questions

Process–Structure Interaction

  • How can load-adapted local grading of continuous fibre-reinforced thermoplastics be achieved by braiding?
  • To what extent can fibres be lofted by targeted laser treatment without damage?
  • How does the grading of the preform affect subsequent press processing and the formation of the transition zone?
  • How can the relationships between mechanical properties, transition-zone phenomenology, and process parameters be used to enhance lightweight potential?

Related Project Members

Project-related publications

Klärner, M., Haugk, L., Decker, R., Reinhardt, H., Kroll L. Verbesserte Rippenanbindung an thermoplastische Organobleche durch lokale Gradierung. In: Seefried, A.; Stommel, M. (eds.): Tagungsband Technomer 2025 – 29. Fachtagung über die Verarbeitung und Anwendung von Polymeren, p. 56. Chemnitz. ISBN: 978-3-939382-17-1 – https://www.bibliothek.tu-chemnitz.de/uni_biblio/frontdoor.php?source_opus=41078

Subprojects

A01

Contributors

Matthias Klärner Lukas Haugk Ricardo Decker Heiner Reinhardt Lothar Kroll

Related Projects

All projects related to Combined production processes

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A02 High-volume production of individualised, graded and variant-rich laminates for combined manufacturing chains

A02 High-volume production of individualised, graded and variant-rich laminates for combined manufacturing chains

Scalable manufacturing of graded high-performance laminates

Project Area
A02
Project Leaders
Christian Brecher, Michael Emonts
Cooperation Projects
A01 A03 A04 A05 B01 B05 C03 C04 C06 Z01
A03 Injection moulding embedding of locally functionalised fibre-reinforced plastic inlays

A03 Injection moulding embedding of locally functionalised fibre-reinforced plastic inlays

Functionalised inlays for locally tailored mechanical properties

Project Area
A03
Project Leaders
Lothar Kroll, Isabelle Roth-Panke
Cooperation Projects
A01 A02 A04 A05 B01 B02 B03 B04 B05 C01 C03 C05 C06 Z01
A04 Press processing of functionalised flat and tape substructures with a flanged section

A04 Press processing of functionalised flat and tape substructures with a flanged section

Process-integrated design of graded transition zones

Project Area
A04
Project Leaders
Niels Modler, Andrés Fabián Lasagni
Cooperation Projects
A01 A02 A03 A05 B01 B02 B03 B05 C04 C05 C06 C07 Z01
A05 Adaptive models for in-line process monitoring and control

A05 Adaptive models for in-line process monitoring and control

Data-driven real-time monitoring of complex manufacturing processes

Project Area
A05
Project Leaders
Steffen Ihlenfeldt, Alexander Dementyev
Cooperation Projects
A01 A02 A03 A04 B01 B03 B05 C04 C06 Z01
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Shaping the Future of Adaptive Lightweight Structures.