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Carbon Textiles Solutions
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SAMPE Brazil
Application and Processing of Complex Fabrics for Lightweight structures
Joanne Blakeley
Development Engineer, Sigmatex UK
Tel: +44 (0) 1928 570050
Email: [email protected]
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Contents:
1. Market Opportunities for Lightweight Materials
2. Improving the attractiveness of carbon fibre for high volume
manufacturing sectors (Automotive)
3. Enabling Technologies providing opportunities in lightweight fabrics
4. Processing Capabilities Technologies overview, inc. a comparison of
Material Profiles
5. Powder Coating
Application and Processing of Complex
Fabrics for Lightweight structures
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Contents:
1. Market Opportunities for Lightweight Materials
2. Improving the attractiveness of carbon fibre for high volume
manufacturing sectors (Automotive)
3. Enabling Technologies providing opportunities in lightweight fabrics
4. Processing Capabilities Technologies overview, inc. a comparison of
Material Profiles.
5. Powder Coating
Application and Processing of Complex
Fabrics for Lightweight structures
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Current opportunities in existing markets
• Auto Sports
• Marine
• Automotive
• Aerospace
• Sporting Goods
• Industrial Applications
1. Market opportunities
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Global demand - Size of market and anticipated growth, some indications:
Forecasts are that global demand for carbon fibre will grow from 46,000
(2011) to 140,000 tonnes by 2020
With improved material performance, output and characteristics, Materials
will be increasingly attractive to more widespread applications SOURCE The Carbon Fibre Industry Worldwide 2011-2020
[VALUE]% Aerospace
[VALUE]% Industrial
[VALUE]% Sports goods
2014
[VALUE]% Wind energy & automotive
2020
1. Market opportunities
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Contents:
1. Market Opportunities for Lightweight Materials
2. Improving the attractiveness of carbon fibre for high volume
manufacturing sectors (Automotive)
3. Enabling Technologies providing opportunities in lightweight fabrics
4. Processing Capabilities Technologies overview, inc. a comparison of
Material Profiles
5. Powder Coating
Application and Processing of Complex
Fabrics for Lightweight structures
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"What is the most significant challenge to overcome for composites
to be more widely deployed in high-volume vehicles?"
• 61% from 14 Nations said Cost !!
“What can materials manufacturers do to improve the attractiveness of
Carbon Fibre in high volume applications?
• Output rates + Multifunctional materials = Cost
Hybrid materials
Near net shape materials
Weight output (Kg (lb) / hr)
Length output (LMs (Yrds) / hr)
[VALUE]%
COST
Near net shape Hybrid Materials
2. Improving marketability
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Contents:
1. Market Opportunities for Lightweight Materials
2. Improving the attractiveness of carbon fibre for high volume
manufacturing sectors (Automotive)
3. Enabling Technologies providing opportunities in lightweight fabrics
4. Processing Capabilities Technologies overview, inc. a comparison of
Material Profiles
5. Powder Coating
Application and Processing of Complex
Fabrics for Lightweight structures
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Enabling Technologies and solutions providing opportunities in high
volume lightweight fabrics and high volume heavy weight fabrics:
• 2D Woven
• ST Woven
• 3D Architectures
• Mult-iaxial NCF
• Uni-Directional Materials
3. Enabling Technologies
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Contents:
1. Market Opportunities for Lightweight Materials
2. Improving the attractiveness of carbon fibre for high volume
manufacturing sectors (Automotive)
3. Enabling Technologies providing opportunities in lightweight fabrics
4. Processing Capabilities Technologies overview, inc. a comparison of
Material Profiles
5. Powder Coating
Application and Processing of Complex
Fabrics for Lightweight structures
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4. Overview: 2D weaving
2D Weaving
• Well understood technology
• Largest amount of capacity in the supply chain
• Broader range of possibilities than has to date been exploited
• All fibre types capable High Modulus IM SM etc..
• Multi-axial capability
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2D Weaving provides:
• Wide variety of fibre architecture
• Plain, Standard 2x2 Twill, Satin…
• Scafolded Low crimp Fabrics
• Multilayer woven Uni and Bi Directional hybrids
• Woven geometry
• Fibre linear density Output rates (Kg/hr)
• Cover factor
• Weight
Limitations on output rates for low weight materials has led to ST materials.
Plain Weave
2x2 Twill
5 Harness Satin Scafolded LC
4. Overview: 2D weaving
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Tape materials - High volume linear metres & Low weight materials
“How are Sigmatex using High Speed rapier machines to develop Tape
materials for high volume applications?”
Back to weaving functions:
• Warp – New creel and control method
• Weft Insertion – Flat tow high speed rapier technology
weft accumulation
linear insertion.
• Beat up – Replaced by fell/fabric movement & fibre placement
• Take up – Special features ensure movement of fabric causes
minimum disruption to fibre and fabric tension.
Key to success is also tape manufacture.
4. Overview: Spread Tow weaving
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Pick control – During weft insertion it is essential to ensure pick is not
distorted. Path from package to inserted pick must be linear.
When unwound directly off spool, twist is imparted.
This has been improved with the Linear unwind methods
The ST process uses pre-spread fibre that has been wound onto cassettes
without twist providing a more linear and regular fibre.
Twist and narrowing of fibre
No twist and flatter tow
4. Overview: Spread Tow weaving
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Key enabling features to optimise fabric throughput:
• Tow width
• Warp Tension Control
1. Tow width - directly related to machine throughput in yrds/hr
Machine speed 1 RPM = 1 pick insertion
∴ High speed & wide tow width results in significant output.
2. Warp tension control – if warp tension is not controlled then the
resultant fabric can have significant defects:
• Slack edges during pre-impregnation
• Fabric distortion during post weaving process
• Wrinkling of fabric during wind up
• Fabric Bow
• Fabric Skew
4. Overview: Spread Tow weaving
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Crimped length of the tow be C (mm)
Un-crimped length of the tow be U (mm)
Crimp % (X) = (U – C)/C X 100
Specimen Number
Warp Weft Crimped Length
(mm) Un-crimped Length (mm)
Crimp % Crimped Length (mm)
Un-crimped Length (mm)
Crimp %
1 1000 1005 0.5 1000 1006 0.6
2 1000 1004 0.4 1000 1006 0.6
3 1000 1004 0.4 1000 1005 0.5
4 1000 1005 0.5 1000 1007 0.7
5 1000 1006 0.6 1000 1006 0.6
Average 0.48 % Average 0.6 %
Plain Woven (DV5761250)
Specimen Number
Warp Weft Crimped Length
(mm) Un-crimped Length (mm)
Crimp % Crimped Length (mm)
Un-crimped Length (mm)
Crimp %
1 1000 1001 0.1 1000 1002 0.2
2 1000 1002 0.2 1000 1001 0.1
3 1000 1001 0.1 1000 1003 0.3
4 1000 1001 0.1 1000 1002 0.2
5 1000 1002 0.2 1000 1001 0.1
Average 0.14 % Average 0.18 %
Tape Woven (DV6201400)
4. Overview: Spread Tow weaving
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Standard Woven Fabric
Surface Characteristics
Sigma ST Fabric
High crimp = Surface undulations Low crimp = No Surface undulations
4. Overview: Spread Tow weaving
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In summary for woven fabrics:
Standard weaving can offer high output in Kg/hr and LMs/hr but cover
factor can be reduced if fibre is not spread.
With Tape Weaving high throughput in linear metres can be achieved,
however these are not suitable for heavy weight fabric applications.
Wider tows offer higher throughput
Reduced crimp and flatter surface can be realised with the Spread Tow
fabrics.
4. Materials Profile
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1.4 Metre width
5000 individual
hooks
Full size machine
12mm thickness
25mm under
development
Self monitoring
Multiple structures
capable
“How can 3D weaving offer a solution for light weighting?”
4. Overview: 3D Weaving
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3D woven structures are currently used within the Aerospace industries
for Joining elements, e.g. Pi clips. Also being used in the rear pressure
bulkhead and for engine fan blades.
Other opportunities for 3D include weaving honeycomb structures. These
can be designed to have different cellular sizes all interconnected.
4. Overview: 3D Weaving
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Lightweight opportunities and advantages using 3D structures;
• Reduced engineering time, by building functionality into the 3D preform.
• Parts can be designed and woven in one piece.
• Different fibre types can be woven in different layers
• Different weave styles can be woven on different layers.
• Many types of 3D materials can be woven without the need to change
machine setup, e.g. A solid structure can be woven after an expandable 3D
section.
• High warp weights are available with very high density warps – when
combined with low 90 degree weft fill fibres output can be very high
4. Overview: 3D Weaving
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Multi-axial Non Crimp Fabrics
• 2.54M width
• High speed output (double width at 1270mm)
• Bi-axial, Tri-axial, Quad-axial capability
• 100gsm/layer and lighter if required
4. Overview: Multi-axial NC Fabrics
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Comparison of Surface Characteristics between Standard NCF
Standard NCF Spread NCF
4. Overview: Multi-axial NC Fabrics
‘Eggbox effect’ - Unevenness Improved spread
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0
100
200
300
400
500
600
700
500 600 700 800 900 1000 1100 1200
Outp
ut K
g/h
our
GSM per Layer
Material Output at different Layer weights
For Multi axial warp knitted Non Crimp materials increasing the layer weight
of the materials in conjunction with laying in of the fibres (Triaxial and
Quadraxial formats), increases the weight throughput of manufacturing.
For woven fabrics a similar principle applies, however the machine
throughput is directly related to thread density (picks per inch). High
linear density yarns = higher weight and high throughput during weaving
process.
4. Overview: Multi-axial NC Fabrics
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Summary of 3D and NCF
3D can offer advantages for light weighting although mainly through design
not spread fibre.
High volume by weight can be achieved but not suitable for lightweight
layered structures.
NCF fabrics can be manufactured at high output weights and also suitable
for lightweight materials. Linear output is constant with multiple layers being
created simultaneously.
For higher output in weight per hour, heavier weight fabrics need to be
manufactured.
4. Materials Profile
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Contents:
1. Market Opportunities for Lightweight Materials
2. Improving the attractiveness of carbon fibre for high volume
manufacturing sectors (Automotive)
3. Enabling Technologies providing opportunities in lightweight fabrics
4. Processing Capabilities Technologies overview, inc. a comparison of
Material Profiles
5. Powder Coating
Application and Processing of Complex
Fabrics for Lightweight structures
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The Powder Coating line at Sigmatex facilitates:
1. Powder Coating
2. Heat treatment
3. Lamination – of a single material or one to another.
5. Powder Coating
Working width: 1800mm
Powder Density: 0.5 – 0.7Kg/L
Application: 5 – 800gsm
Installed as part of a CiC funded project,
www.the-cic.org.uk
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Technical information:
• Adaptable Process used to coat a variety of Sigmatex products.
• Epoxy & Polyester powder resin systems currently utilised.
• Fine control of powder add-on.
• IR capability to adapt to customer requirements.
• Laminating temperature range up to 230°C.
• Pressure can be applied depending on the requirement.
Available for powder coating and laminating trials.
5. Powder Coating
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Thank You for your attention
Joanne Blakeley
Development Engineer
Email: [email protected]
Web: www.sigmatex.com
Phone: +44 (0)1928 570 050
