Process Chain Modelling and Analysis for the High-Volume Production of Thermoplastic Composites with Embedded Piezoceramic Modules

Abstract

Active composite structures based on thermoplastic matrix systems are highly suited to applications in lightweight structures ready for series production. The integration of additional functional components such as material-embedded piezoceramic actuators and sensors and an electronic network facilitates the targeted control and manipulation of structural behaviour. The current delay in the widespread application of such adaptive structures is primarily attributable to a lack of appropriate manufacturing technologies. It is against this backdrop that this paper contributes to the development of a novel manufacturing process chain characterized by robustness and efficiency and based on hot-pressing techniques tailored to specific materials and actuators. Special consideration is given to detailed process chain modelling and analysis focusing on interactions between technical and technological aspects. The development of a continuous process chain by means of the analysis of parameter influences is described. In conclusion, the use of parameter manipulation to successfully realize a unique manufacturing line designed for the high-volume production of adaptive thermoplastic composite structures is demonstrated.