Research

The integration of individual processes into combined production systems for load-dedicated modular flat and profile systems with graded material transitions is the focus of Project Area A. The resulting insights define key constraints for selecting process-specific models and methods and for advancing the core injection moulding and pressing processes. These processes must remain highly flexible to enable combinations with each other and with additional technologies such as pultrusion, extrusion, and tape laying. Semi-finished product processes play a key role within these technology combinations, as they create important degrees of freedom for designing modified injection moulding and pressing processes.

The investigation of fundamental effects governing continuous property transitions between FRP and plastic substrates is the focus of Project Area B. Emphasis is placed on physical effects enabling active and passive adjustment of direction-dependent and graded properties in injection moulding, pressing, and semifinished product processes, as well as on clarifying the resulting coupling phenomena. Process-specific manipulation of fibre arrangements is intended to “resolve” substrate interfaces. Sensor elements support production monitoring and data acquisition, enabling holistic feedback with the overarching iDP system. This creates a self-regulating system linking target and actual states within structure–process–property relationships.

The analysis and development of a simulation system based on multi-criteria methods for designing FRP/plastic structures with graded material transitions and load-adapted anisotropic characteristics is the main goal of Project Area C. Strategies, procedures, and solutions developed in the production-oriented project areas are integrated into an overarching holistic framework. The formalisation process incorporates existing expertise and prior modelling work related to specific challenges in plastic and FRP processing from the research locations in Chemnitz, Aachen, and Dresden.