Tooling Systems


The production of composite components is carried out using molds. New requirements on the manufacturing processes (e.g. cycle time reduction) and on the component (e.g. optimization of mechanical properties, weight reduction) lead to increased demands on the tool. Integral mold design allows the full potential of CFRP to be realised. This design approach results in complex geometries and to the use of different materials (multi-material approach or hybrid design). Different material properties (e.g. specific thermal expansion) affect the design of a tool significantly. By integrating sensors into the tool and the component, the process parameters can be monitored and optimized. The collected findings lead to cost-effective, efficient and robust manufacturing processes.

Removable Core Systems for Hollow Components

Hollow components achieve higher performance than post-bonded skins. Developing and evaluating new core systems for the production of hollow parts will lead to reduced costs and improved mechanical properties. Various processing methods such as RTM and vacuum bag process are taken into account in order to achieve the best properties.

Figure: Meier R, et al. Online process monitoring systems - benchmark and test study. In: Proceedings of FPCM-11 Conference. Auckland, July, 2012

Process Monitoring

The recording of process parameters during the production of composite components contributes to an increased understanding of the process. This in turn enables reduced cycle times and improved part quality.

Development of Holistic Mold Systems

The consideration of all the factors during the manufacturing process is necessary as they affect the properties of the final part. The relationship between process parameters and geometry are considered regarding the component properties. Another focus is the study of energy-efficient tooling systems. Therefore it has become essential to consider the mold system before starting any production.