Circular Solutions/Recycling > Technologies

Simulation-based design of waste-free non-crimp fabrics for sustainable solutions in 3D lightweight applications

Saal A
Donnerstag, 12.09.2024, 09:25 - 09:50 Uhr

Fibre-reinforced composites (FRCs) offer significant technical advantages over metallic materials and are increasingly used in various industrial sectors due to their efficiency and cost-effectiveness. Warp knitting technology plays a crucial role in maximizing resource and cost efficiency in the production of textile reinforcements, being the most productive textile manufacturing process. Newly developed technologies for creating waste-free non-crimp fabrics for 3D lightweight applications are set to further enhance the application of FRCs in industry by optimizing preform production and reducing post-processing waste.

Sprecher
Konrad Zierold (ITM TU Dresden)
Co-Authoren
Lars Hahn (ITM TU Dresden), Chokri Cherif (ITM TU Dresden)
The presentation explores advancements in resource efficiency for the manufacturing of fibre-reinforced composites (FRC), targeting the prevalent issue of material waste associated with the use of textile structures in the form of roll goods with constant width. Highlighting the potential of multi-axial fabrics, it presents a novel approach to significantly reduce waste and enhance ecological and economic outcomes. A key innovation introduced is a technology for the inline production of alternating weft threads, offering substantial savings in the use of high-performance fibers, notably carbon fibers, thus making production more cost-effective. Additionally, a newly designed algorithm optimizes the arrangement of weft and warp threads according to component geometry and load requirements, paving the way for more efficient manufacturing processes. This research signifies a pivotal shift towards sustainable manufacturing in the textile industry, suggesting a method that not only reduces waste but also leverages advanced textiles for improved FRP components. The findings promise to transform traditional practices, contributing to the development of more sustainable and economically viable manufacturing methods.