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

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
A03 Injection moulding embedding of locally functionalised fibre-reinforced plastic inlays
Summary
The DediGrad subproject A03 investigates the injection moulding-based embedding of locally functionalised fibre-reinforced inlays to tailor mechanical properties in graded structures. The focus lies on the controlled reorientation, impregnation, and fixation of fibre bundles during the moulding process. By combining experimental investigations with simulation-based approaches, the underlying process–structure relationships are systematically analysed and modelled. The objective is to achieve a comprehensive understanding of anisotropic flow and structural mechanisms, as well as to predict optimal process conditions. The results enable the targeted design of graded flat structures with locally adapted performance characteristics.
001 Objectives

Functionalised Fibre Inlays

  • Development of injection moulding-based technologies for local grading
  • Adaptation of mechanical properties through out-of-plane reorientation of fibre bundles
  • Investigation of the governing mechanisms of impregnation, fixation, and orientation
  • Analysis of process–structure–property relationships in locally functionalised inlays
  • Prediction of optimal manufacturing conditions and component properties
002 Scientific Questions

Anisotropic Flow Mechanisms

  • How can locally graded material transitions be achieved through the reorientation, impregnation, and fixation of fibre bundles?
  • What functional relationships exist between the material, process, and structural parameters of locally functionalised inlays?
  • How can numerical simulations be used to calculate mould filling and predict the manufacturing process?

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

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

Targeted fibre reorientation for load-adapted lightweight 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
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
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Project Leaders
Christian Brecher, Michael Emonts
Cooperation Projects
A01 A03 A04 A05 B01 B05 C03 C04 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
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Shaping the Future of Adaptive Lightweight Structures.