Multi-Step Thermoforming of Multi-Cavity, Multi-Axial Advanced Thermoplastic Composite Parts

This feasibility study aims to improve the thermoforming of multi-layered pre-consolidated thermoplastic parts using a novel hybrid laminate configuration consisting of composite and metal layers. It will implement a controllable multi-actuator press and use it to investigate the forming mechanics of the hybrid sheet at high temperatures. The aim is to use the metal to heat the layup from the inside via Joule heating, melt the metal and then use the molten metal as a low viscosity lubricating medium to eliminate forming defects. The multi-actuator press will squeeze out the molten metal during forming (like toothpaste from a tube), aided by the metals high surface tension. The aim will be to reduce wrinkling in the final formed part and to reduce energy costs associated with heating.

Conducted initial experiments on moulding of metallic sheets.

Project partnerships

Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), Porto

Figure: (a) A modified UBE test with aluminium (painted black) bonded to Region C of a twill-weave, with a pronounced wrinkle; (b) wrinkle prediction in finite element simulation