Heat supported single point incremental forming of hybrid laminates for orthopedic applications

Abstract Ecofriendly composite fibers are increasingly applied as a substitutional material instead of the expensive carbon fibers. Within this context a hybrid laminate was developed combining an aluminum sheet with basalt fiber-reinforced thermoplastic polyamide 6 (BFRP). As a condition for the formability it is necessary to transform the polyamide matrix into a semi-fluidized state. Therefore, a single point incremental forming process supported with hot air heating was utilized to form the hybrid laminate into the desired shape. During the forming process the composite was inserted between two metal sheets and two Teflon layers which were used to improve the sliding of the hybrid laminate during the forming operation. Furthermore, the metal sheets were used to ensure an efficient processing and protect the hybrid laminate against wear caused by friction between the forming tool and the composite. In addition, the squeeze out of the melted polymer matrix out of the hybrid laminate was reduced. The results of the investigation of the experimental process parameters are presented. The proposed method offers the possibility to manufacture individual orthopedic products or prototypes of medical implants.