The JEC Best Paper Award


JEC Group and ITHEC again agreed on an event partnership. Again, there will be a Best Paper Award in close cooperation with the JEC Composites Magazine. Based on the manuscript quality and a deep review by the International Programme Committee of ITHEC, 7 manuscripts are nominated for this award. The winner will receive a publication in the JEC Composites Magazine.

The final winner will be announced during an Official Ceremony, in our conference and exhibition platform:
at October 13, 1pm and again at 7pm in the second session - JOIN US!</a>

This years nominees are:

Aerospace

Application of Lightning Strike Protection on Thermoplastic Structures by Automated Fiber Placement The application of Lightning Strike Protection (LSP) material on the outer surface of a carbon fibre reinforced thermoplastic part with Automated Fiber Placement (AFP) had been analysed. Beside the development of a hybrid LSP material, which fulfils the requirements of an AFP process, automated layup trials with Xenon heating flash lamp had been realised to determine capable process parameters. Furthermore, test specimens with different layup designs and material combinations had been manufactured and their electrical properties had been investigated. The fundamental trials presented in this paper demonstrate the feasibility of the integration of a LSP layer using AFP.
Authors:
C. Nguyen, DLR e. V., Stade, Germany
A. Kolbe, DLR e. V., Stade, Germany
C. Bäns, DLR e. V., Stade, Germany
--> See the lecture at ITHEC:
October 13, 10.40 am
October 13, 4.40 pm

Post Flight Analysis of an in situ Consolidated Thermoplastic Rocket Module with Integrated Fiber Optic Temperature Sensors
As part of a high-altitude research rocket mission, the Chair of Carbon Composites of Technical University Munich developed and implemented a manufacturing concept for a thermoplastic fiber composite module of a high-altitude research rocket. In the manufacturing concept, the Automated Fiber Placement process is combined with press-formed long-fiber-reinforced thermoplastic structures. The AFP-laminate and its joint to the LFT-structure is realized by in situ consolidation.
The developed module is more than 40% lighter than the conventional aluminum modules and was launched in March 2019 as a structural part of the REXUS-23 rocket at an altitude of 75.42 km. The rocket had a “hard landing” as the main parachute did not open properly which led to considerable additional loads. The module was analyzed via computer tomography to investigate flight- or impact-induced defects. The concept was able to prove its airworthiness being the first in situ consolidated structural component of a rocket mission.
Authors:
R. Engelhardt, Technische Universität München, Garching, Germany
S. Ehard, Airbus Group, Manching, Germany
R. Jemmali, DLR e. V., Stuttgart, Germany
J. Oelhafen, fos4X GmbH, München, Germany
A. Kollmansberger, Technische Universität München, Garching, Germany
K. Drechsler, Technische Universität München, Garching, Germany
--> See the lecture at ITHEC:
October 13, 12 pm
October 13, 18 pm

Automotive:

Integrated Process Simulation as Key for the Efficient Product and Process Development
The integration of process simulation into a holistic virtual process chain enables to accurately predict the part's behavior in terms of dimensional stability and structural performance. Based on this, the knowledge on the manufacturing process and the part’s structural behavior is significantly increased in early development phases. This presentation shows by means of different thermoplastic process routes how manufacturing effects can be predicted and how these can be taken into account in subsequent simulation on basis of a functional virtual process chain.
Authors:
M. Hohberg, SIMUTENCE GmbH, Karlsruhe, Germany, and Karlsruher Institut für Technologie, Karlsruhe, Germany
D. Dörr, SIMUTENCE GmbH, Karlsruhe, Germany
B. Fengler, SIMUTENCE GmbH, Karlsruhe, Germany, and Karlsruher Institut für Technologie, Karlsruhe, Germany
C. Krauß, Karlsruher Institut für Technologie, Karlsruhe, Germany
N. Meyer, Karlsruher Institut für Technologie, Karlsruhe, Germany
L. Kärger, Karlsruher Institut für Technologie, Karlsruhe, Germany
F. Henning, Karlsruher Institut für Technologie, Karlsruhe, Germany, and Fraunhofer-ICT, Pfinztal, Germany
--> See the lecture at ITHEC:
October 14, 9:35 am
October 14, 3:35 pm

Methodology for Material Selection in Skeleton Design
In order to give an indication if a material offers economic potential by substituting another an index based on material indices by Ashby and lightweight costs is derived. Glass fibres offer huge potential regarding material costs whereas its density is slightly higher compared to carbon fibres. The indices are derived for the main loading conditions for unidirectional fibre reinforced thermoplastic composites. The relative mechanical properties are derived for pultruded carbon and glass fibre reinforced polyamide 6. It is shown that glass fibre reinforced thermoplastics offer potential for strength dominated profiles under compression and bending loading regarding weight and costs. In addition, an optimization workflow using cross section and evolutionary optimization is developed. Its scope is to identify the right material in a skeleton structure under displacement boundaries minimizing its material costs. It is shown that a 12 % cheaper structure can be achieved using this approach.
Authors:
A. Maier, S. Yueksekkale
BMW Group, Research and Innovation Center, Munich, Germany
N. Schramm, L. Kroll, Institute of Lightweight Structures, Chemnitz University of Technology, Germany
--> See the lecture at ITHEC:
October 13, 11:35 am
October 13, 5:35 pm

Emerging Technologies:

Development of a Structural Subframe for a Battery Electric Vehicle using Continuous Fibre Reinforced Thermoplastics
Within the scope of a joint development project between MAHLE International GmbH, Chemnitz University of Technology and thermoPre Engineering GmbH a holistic development of a new subframe for usage in a battery electric vehicle was developed. The result of this development process is a new type of structural components made of long and continuous fibre reinforced plastics. The newly developed subframe achieves the same static performance and cost-neutral production despite the significant mass saving of 33% compared to the reference part made of steel.
Authors:
S. Iwan, thermoPre GmbH, Chemnitz, Germany
S. Schneider, Mahle International GmbH, Stuttgart, Germany
T. Timmel, thermoPre GmbH, Chemnitz, Germany
W. Nendel, Technische Universität Chemnitz, Chemnitz, Germany
--> See the lecture at ITHEC:
October 13, 10:15 am
October 13, 16:15 am

Natural Fibre Reinforced Bioplastics for Use in High Performance Structural Parts
In the future, composite materials based on a biopolymer matrix and continuous natural fibre reinforcement (Bio-NFC) will also be used for lightweight structural components that can withstand high loads at low weight and guarantee stability. Using the example of a child safety seat as demonstrator structure, the possibilities of the newly developed materials, technologies and component design concepts for natural fibre reinforced biopolymers are shown. In the scope of this presented research project, two kinds of Bio-NFC materials were developed, a short fibre and a continuous fibre reinforced plastic material. In a hybrid process, short fibre Bio-NFC is used for injection moulding. Locally improved mechanical properties are gained by inserting a reinforcing UD-tape based laminate. An electron beam crosslinking of the thermoplastic biopolymer is investigated to reach thermoset-specific properties. The developed processing technology allows a processing of flax fibres to a quasi-endless reinforced UD-tapes. Finally, a material adapted part and mould design for the Bio-NFC seat is used for the validation of the developed materials.
Authors:
S. Heßner, Evonik Operations GmbH, Essen, Germany
K. Lehmann, Evonik Operations GmbH, Essen, Germany
I. Jahn, Fraunhofer IMWS, Schkopau, Germany
M. Zscheyge, Fraunhofer IMWS, Schkopau, Germany
R. Rinberg, Technische Universität Chemnitz, Chemnitz, Germany
S. Buschbeck, Technische Universität Chemnitz, Chemnitz, Germany
M. Begert, EDAG Engineering GmbH, Fulda, Germany
A. Ohlzen-Wendy, Engineering GmbH, Hamburg, Germany
S. Bondarik, EDAG Engineering GmbH, Hamburg, Germany
T. Brückner, SachsenLeinen GmbH, Markkleeberg, Germany
L. Kneisel, SachsenLeinen GmbH, Markkleeberg, Germany
K. Kölzig, SachsenLeinen GmbH, Markkleeberg, Germany
--> See the lecture at ITHEC:
October 13, 11:35 amam October 13, 5:35 pm

3D Printing:

New Technique for Impregnating Rovings with High Viscous Melts
The impregnation of rovings with high viscous melts is still a challenging task. A new technique developed by German Aerospace Center is shown, to achieve high impregnation quality within small installation space. This technology is based on the introduction of high frequency sound waves in a thermoplastic melt, which encloses a fiber roving. Possible application scenarios range from the production of continuous fiber-reinforced semi-finished products to the integration in a 3D-printing head.
Authors:
M. Titze, DLR e. V., Braunschweig, Germany
M. Rege, DLR e. V., Braunschweig, Germany
J. Riemenschneider, DLR e. V., Braunschweig, Germany
--> See the lecture at ITHEC:
October 15, 9:35 am
October 15, 3:35 pm

Winner 2018:


Rapid Manufacturing of a Tailored Spar by AFP and Stamp Forming
T.K. Slange, Y.M. Buser, University of Twente, Enschede, The Netherlands, and ThermoPlastic composites Research Center, Enschede, The Netherlands, S. Wijskamp, ThermoPlastic composites Research Center, Enschede, The Netherlands L.L. Warnet, W. Grouve University of Twente, Enschede, The Netherlands R. Akkerman, University of Twente, Enschede, The Netherlands, and ThermoPlastic composites Research Center, Enschede, The Netherlands