Structural parts made of high performance thermoplastic composites have several desirable properties. They are tough, have very good mechanical properties, they can be welded for easy assembly and offer short processing times. These properties make them highly attractive for structural high performance aircraft parts. On the other hand, there are some challenges that have held back the widespread adoption of these materials. One important factor is the high processing temperature which can contribute to process induced deformations. The UBC-DLR cooperation addresses these challenges.
Improvement of thermoplastic manufacturing processes including tape laying, tooling concepts and joining technologies by using simulation methods and by optimizing manufacturing parameters. Implementation of the complete engineering chain including iterative feedback loops leading to a digital twin.
Investigation and simulation of thermoplastic manufacturing technologies including material models for semi-crystalline matrices (e.g. PEEK). Design and manufacturing improvements of structural parts by combining processing experiments and simulations. Validation of simulation methods through manufacturing of large or complex structures.