A New Approach to the Forming of Thermoplastic-Matrix Continuous-Fiber Composites - Part 1: Process and Machine

Conventionally, large components made of thermoplastic matrices and continuous fibers are manufactured in autoclaves using dies. "Die-less forming" is a new concept, intended to manufacture long components of continuous-fiber thermoplastic- matrix composites. This process is based on using movable rollers, which are computer controlled, to incrementally form the shape by local heating.The concept of "kinematically admissible bending" is central to the die-less forming process. The concepts behind die-less forming have been tested in experiments on a two- roller demonstration machine. Induction heating was used to locally heat the composite component as it moved into the forming zone, where it was bent using a specially designed cluster roller. Induction heating combined with a variable velocity profile was successful in establishing a uniform heating profile.