Joint R&D Projects

Together with the AZL Partner Companies, we regularly realize Joint Partner Projects on different lightweight research and development questions.

Benefits of Participants:

〉〉  Detailed, pre-competitive investigation of lightweight materials, systems or processes
〉〉  Cost-effective budget based on joint cost sharing
〉〉  Exclusive projects with AZL Partner Institutes and AZL Partner Companies

New  Joint Partner Projects starting in 2019:

Inductive Double Belt Press Follow-Up Project with Focus on Process Evaluations (Impregnation, Consolidation)

Within the Joint Partner Project “New Designs for Low-Cost and Energy-Efficient Double-Belt Presses” and the Follow-Up Project which was successfully accomplished in May 2019, a prototype machine of an Inductive Double Belt Press was developed, designed and built. The general machine concept has been validated.

This third project with the focus on process evaluations comprises an upgrade and optimization of the system for advanced material and processing studies and will include extensive material and processing studies for demonstration of wide applicability of a novel machine concept to identify which materials can be processed at which speeds, which requirements do exist using the material and which reproducibility can be achieved in impregnation and consolidation. It will also be examined how thermal process parameters influence the product quality and how the different pressure profiles enable different laminate types.

This project is open to join, for more information regarding questions and how to join please contact us directly.

Project Start: September

Project Duration: 6 months

 

 

Latest Joint Partner Projects:

 

Ultra-Fast Manufacturing of Tailored Composite Blanks - Follow-Up

By implementing the prototype machine, the initial Joint Partner Project is completed. The partners decided already to continue the joint research with a follow-up project which comprises the prototype upgrade and optimization for advanced material and processing studies as well as extensive material and processing studies for demonstration of wide applicability of the novel machine concept in the industry.

Completed: New Designs for Low-Cost and Energy-Efficient Double-Belt Presses - Follow-Up

A follow-up project started at the end of 2016 to progress on the developed double-belt press system with the aim to build an industry-scaled machine according to the pursued concepts. The final design phase of the novel double belt press machine system has already been reached. The optimization of the inductor homogeneity is currently in progress, so is the procurement of induction heating equipment. AZL is preparing a scale-up estimation regarding cost and energy consumption of the system.

Completed: New Designs for Low-Cost and Energy-Efficient Double-Belt Presses

Large-scale production of composite sheets can be achieved by a continuous production process using double-belt presses. Current machine designs however suffer from low energy efficiency as well as strong limitations concerning the product geometry flexibility.
In the first project phase, the AZL, together with six partner companies, developed a prototype for proof-of-principle of a novel cost and energy-efficient double-belt press system for the continuous production of composite sheets. A follow-up project will start at the end of 2016 to progress on the developed double-belt press system with the aim to build an industry-scaled machine according to the pursued concepts.

Completed: Thermoplastic Tapes – Material and Processing Benchmark
Thermoplastic Tape Within the first AZL Market and Technology Study, thermoplastic tapes have been identified as one key technology for future process chains for mass production of lightweight components.
The first one-year Joint Partner Project just ended realizing a benchmark of different tape materials and investigating the interactions of tape, processing and resulting laminate properties within the consortium. The AZL Partner Companies currently discuss follow-up activities addressing the correlation of morphology and mechanical properties of TP-FRP laminates.

 

Completed: Ultra-Fast Manufacturing of Tailored Composite Blanks

To increase resource-efficiency in the production of continuous fiber-reinforced plastics, the processing of scrap-optimized blanks with defined fiber alignment (“tailored composite blanks”) on basis of unidirectional semi-finished products (thermoplastic tapes, tow-pregs or dry-fibres) offers high potential compared to textile-based pre-products. Nonetheless, today’s production systems for the manufacturing of tailored composite blanks are limited in throughput per system.
The 18-month Joint Partner Project involves 12 Partner Companies from seven countries to develop a machine prototype for proving the feasibility of a novel manufacturing principle to produce tailored composite blanks in seconds at medium investment cost.

 

 

Completed: End-machining of Fiber-Reinforced Plastics
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Source: © Fraunhofer IPT

Indicating the potential and the limitations of FRP end-machining operations is essential to shorten machining times, to allow high-quality edges without the need for cost-intensive manual re-work and to avoid process-related damage.
In this project proposal, technology benchmarking and feasibility studies of operations such as milling, shearing, water jet cutting, laser cutting are to be implemented with the aim of defining economically efficient FRP end-machining operations. The project scope is currently further defined with interested AZL Partner Companies and is still open to join.

 

 

In addition to Joint Partner Projects, we offer project management for individual research and development project also to companies outside the AZL Partnership, or support you in finding the right partners for your ideas.

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