3D Composite Preform Undulations Prevent Wrinkling
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Solution Overview
Problem
Manufacturing 3D fiber-reinforced composite parts with non-planar surfaces and flanges is challenging due to material wrinkling caused by shear forces at curved edges, as existing methods do not provide sufficient length and surface area to conform to desired contours without wrinkling.
Innovation Solution
The method involves forming an intermediate preform blank with undulations at edge portions using Automated Tape Laying (ATL) or Automated Fiber Placement (AFP), which are then shaped on a mold with 3D contours to create a final preform with extra length and surface area, preventing material wrinkling during the resin infusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional flat preform blanks are used for 3D composite parts, then manufacturing process is simple, but material wrinkling occurs at curved edges due to insufficient length and surface area
Solution Approach 1:
The preform blank is prepared in advance with built-in undulations at edge portions that anticipate the curvature requirements of the final 3D shape. This preliminary geometric configuration ensures sufficient material length and surface area are available before the resin infusion process, preventing wrinkles during molding while maintaining manufacturing simplicity
Solution Approach 2:
The preform blank transitions from a conventional two-dimensional flat geometry to a three-dimensional form with controlled undulations. These undulations add vertical dimensionality to edge portions, providing extra material length and surface area that conforms to curved mold surfaces without requiring complex manufacturing processes
2Reliability
If extra length and surface area are added to preform edges, then material wrinkling is prevented, but manufacturing complexity increases
Solution Approach 1:
Instead of making the entire preform blank complex, undulations are applied locally only at edge portions where curvature and wrinkling risks exist. The central and flat regions maintain simple geometry, ensuring that manufacturing complexity is minimized while reliability is enhanced precisely where needed
Solution Approach 2:
The geometric parameters of the preform blank are modified by introducing controlled undulations at edge portions. This changes the local surface area and length parameters without fundamentally altering the overall manufacturing process, maintaining ease of fabrication while improving preform integrity during resin infusion
Data Source
AI summary
A method for the manufacturing of three-dimensional (3D) preforms and composite structures having non-planar surfaces and flanges such that the fibrous or composite material used for shaping the final 3D structure has the necessary length and surface area to conform to the desired contours of the molding tool without wrinkling. The manufacturing method begins with the formation of an intermediate preform blank by automated placement of fiber tapes or prepreg tapes, followed by shaping the blank on a molding tool with 3D contours to form the final 3D structure.