Integrated Process Chain for the Automated and Flexible Production of Fibre-Reinforced Plastic Products "FibreChain"

Lightweight components and their energy-efficient production will form one of the most important key factors for the European industry to fulfil the ever increasing global demands. Nowadays, for 3D-shaped, multi-layered products based on flexible materials only specialized and semi-automated manufacturing equipment is available. The project “Integrated Process Chain for Automated and Flexible Production of Fibre-Reinforced Plastic Products (FibreChain)” aims at the development of worldwide first automated turnkey manufacturing systems for fibre-reinforced thermoplastic composites (FRTC) addressing public and private transportation, mechanical, chemical and civil engineering as well as consumer goods. FibreChain will generate 20.8 billion € in 5 years and promote a world leading European fibre-reinforced plastics (FRP) industry. FibreChain will more than double the productivity by cost-effective, energy-efficient and flexible manufacturing of FRTCs products due to: -Customised and yet highly automated production -Multi-functional (laser) equipment -Near-Net-Shape production (scrap rates down to 3%) -Integrated measurement systems -Knowledge and simulation models along all processes A multidisciplinary consortium from 7 European countries with outstanding competencies in material, machine tools, manufacturing, laser technology, metrology, simulation and control will accomplish an integrated process chain and make available: -Process-adapted prepreg materials with carbon, aramid, glass, basalt and natural fibres -UD-prepregs to overcome drawbacks of fabrics and impregnation processes -Energy-efficient out-of-autoclave production -Laser systems and processes for integration of tape laying, cutting and joining -In-situ integration of holes and inserts during thermoforming -Integrated material/process data base, simulation and quality assurance system Thus, OEMs and SMEs synchronise their production of FRTCs with the technological inputs from lean manufacturing systems.