Production Optimization of high Performance Carbon Fiber Reinforced Thermoplastic Composite Crash-Elements

The production of carbon fiber reinforced thermoplastic (CFRTP) parts consists of time and energy consuming steps that have great potential for optimization and automation. The research at the DLR in Augsburg aims at efficient thermoplastic composite production utilizing the advantages of a hot press that is integrated in a flexible robot cell. The potential for improvement is analyzed along the whole process chain from as-delivered material to the finished part. This paper presents a set of optimization approaches along this process chain. The investigated process steps include preforming, transfer of ply-stacks, and consolidation of ply-stacks to organo sheets. Special focus will be given to the reduction of process steps and an optimized vacuum consolidation. At the DLR in Augsburg an efficient CFRTP-production has been setup, optimized and verified