Rapid Processing of Net-Shape Thermoplastic Planar-Random Composite Preforms

A novel thermoplastic composite preforming and moulding process is investigated to target cost issues in textile composite processing associated with trim waste, and the limited mechanical properties of current bulk flow-moulding composites. The thermoplastic programmable powdered preforming process (TP-P4) uses commingled glass and polypropylene yarns, which are cut to length before air assisted deposition onto a vacuum screen, enabling local preform areal weight tailoring. The as-placed fibres are heat-set for improved handling before an optional preconsolidation stage. The preforms are then preheated and press formed to obtain the final part. The process stages are examined to optimize part quality and throughput versus processing parameters. A viable processing route is proposed with typical cycle times below 40s (for a plate 0.5 × 0.5m2, weighing 2kg), enabling high production capacity from one line. The mechanical performance is shown to surpass that of 40wt.% GMT and has properties equivalent to those of 40wt.% GMTex at both 20°C and 80°

Rapid processing of net-shape thermoplastic planar random composite preforms

A novel thermoplastic composite preforming and moulding process is investigated to target cost issues in textile composite processing associated with trim waste, and the limited mechanical properties of current bulk flow- moulding composites. The thermoplastic programmable powdered preforming process (TP-P4) uses commingled glass and polypropylene yarns, which are cut to length before air assisted deposition onto a vacuum screen, enabling local preform areal weight tailoring. The as-placed fibres are heat- set for improved handling before an optional preconsolidation stage. The preforms are then preheated and press formed to obtain the final part. The process stages are examined to optimize part quality and throughput versus processing parameters. A viable processing route is proposed with typical cycle times below 40 s (for a plate 0.5 × 0.5 m2, weighing 2 kg), enabling high production capacity from one line. The mechanical performance is shown to surpass that of 40 wt.% GMT and has properties equivalent to those of 40 wt.% GMTex at both 20°C and 80°C

L'HYDROPTERE: HOW MULTIDISCIPLINARY SCIENTIFIC RESEARCH MAY HELP BREAK THE SAILING SPEED RECORD

In 2009, l’Hydroptère broke the symbolic barrier of 50 knots and became the world fastest sailing boat over both 500 meters and 1 nautical mile. This major achievement relied on the high skills of the sailing team but also on technical advances of the boat, resulting from the scientific collaboration between the Hydroptère Design Team and the Ecole Polytechnique Fédérale de Lausanne (EPFL). In the present article, we highlight the multidisciplinary research activity performed within EPFL in the course of this collaboration involving aero- and hydrodynamics, materials and structure as well as computer vision. Various foils were tested at reduced scale in a high speed water tunnel, and the results used to validate the numerical simulations. Composite materials, their processing parameters and assembly components were tested. The structural behaviour was also investigated to determine strains and stresses in normal and extreme sailing conditions, taking waves into account, and a combined model was derived for dynamic simulation. Finally, advanced computer vision methods were developed and implemented on the boat to monitor foil immersion and cross beams deformations