Composite Manufacturing

Book Composites for Construction, L. Bank, Chapter 2.3

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Optional Gel Coat

Dry Reinforcement Fabric
Consolidation Roller
Resin

Mould Tool

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Wet Lay-up: application of CFRP sheets on a concrete column at

Structural Engineering Laboratory of Empa-Switzerland

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

To Vacuum Pump

To Vacuum Gauge
Breather/Absorption Fabric

Vacuum Bagging Film

Peel Ply
Sealant Tape

Release Film
Release Coated Mould

Composite Manufacturing

Fibre Composites, FS09

Laminate

Masoud Motavalli

Resin Transfer Moulding (RTM) by applying

vacuum

Resin
Vaccum

Vacuum Channel
Tools Top Element

Tools Bottom Element

Laminate

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Press or clamps to
hold tools together
Mould Tool
Optional Vacuum
Assistance

Resin injected
under pressure

Mould Tool
Dry Reinforcement

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

RTM of large, complex elements with foam core (compotech AG, Weinfelden)

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Korvette YS2000

Manufacturer:
Length:
Width:
Velocity:
4 Gas Turbine:
Carbon Fiber
Matrix:
Manufacturing Process:

Composite Manufacturing

Kockums AB
72
m
10.5
m
> 65
km/h
each 4000
kW
T700:
45 t
Vinyl ester
RTM

Fibre Composites, FS09

Masoud Motavalli

Lok 2000, The Cab

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Lok 2000, The Cab

Roof Member

Side Part
Composite Manufacturing

Front Part
Fibre Composites, FS09

Masoud Motavalli

Resin Injection

Tools Top Element

Vacuum

Sealing

Vacuum

Lok 2000, Resin Transfer Moulding

Resin Channel

Tools Bottom Element

Glass Fiber and Foam Core

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Lok 2000, Laminate Structure of the Wall

Outer Laminate
Core Material
Impact Barrier
Core Material

Inner Laminate

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

CFRP Flap of Boeing 757

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Press Moulding Process

Reinforced Fibers
Composite Manufacturing

Matrix
Fibre Composites, FS09

Pressing
Masoud Motavalli

Press Moulding of a simple window element with

small number of production items,

Compotech AG, Weinfelden, Swiss

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Press Hall SMC-Press, compotech AG, Weinfelden

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Press with a closing force of 1600 Tons makes the production of elements with a
dimension of 2 x 3 m possible (compotech AG, Weinfelden)

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Fibre
Resin Catalyst
Pot
Air Pressured
Resin

Composite Manufacturing

Optional
Gel Coat

Chopper Gun

Fibre Composites, FS09

Masoud Motavalli

Robot

Fiber Spraying

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

TheFibre
Pultrusion
Process
Composites, FS09

Masoud Motavalli

Pultrusion

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Pultrusion

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Centrifugally-Cast Process

Centrifugal Form

Chopped Glass Fibe

Filler
Matrix
Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Centrifugally-Cast Process

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding
Mandrel

Feed-Eye

Resin Impregnation Bath

Winding Angle
Crossing Angle
Mandrel Diameter
Band Width
Support Velocity

Reel Machine
Crossing Angle Winding

Composite Manufacturing

Fibre Composites, FS09

Reel Machine
Parallel Winding

Masoud Motavalli

Manufacturing FRP
Filament winding:
Materials
FRP tubes, poles, tanks, forms
Fibre Roving

Mobile Resin Bath

Rotating Mandrel

Composite Manufacturing

Motor

Fibre Composites, FS09

Masoud Motavalli

Manufacturing FRP
Materials
Filament winding

Composite Manufacturing

Fibre Composites, FS09

ISIS EC Module

Masoud Motavalli

Filament Winding

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Wound CFRP-Shaft

Tnom = 102.7 kNm, m = 32 kg/m

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding, Degree of Freedom

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Filament Winding, another example

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Schindler Waggon, made of GFRP

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Schindler Waggon, made of GFRP

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli

FRP Pre-Fabricated Component

Composite Manufacturing

Fibre Composites, FS09

Masoud Motavalli