Fraunhofer IFAM

TRiPP | Thermoplastic Release-film Preforming Platform

Description of the company

The Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) is part of the Fraunhofer-Gesellschaft, the world’s leading applied research organization. At our site in Stade, we develop solutions in automated assembly, joining, and machining, serving primarily the aerospace and wind energy industries. Our focus areas include large-structure assembly; adhesive bonding and surface technologies; innovative lightweight materials; production-oriented prototyping; robotic systems; process optimization; digital factory planning; and metrology.

Situation

Peel^PLAS®, a release film developed by Fraunhofer, is suitable for a wide range of composite manufacturing processes, including hand lay-up, vacuum infusion, and resin transfer molding (RTM). The film conforms to the tool surface like a second skin and is applied under vacuum using a stretch-forming method. During application, the degree of elongation varies with the tool-surface geometry. As most Peel^PLAS® release films are thermoplastic, they can be stretched further by applying heat.

Problem

Tooling can be broadly divided into two categories, each with its own challenges for the film. In a female mold, the film can be drawn over the cavity; the key issue is localized strain, as the film stretches mainly into the deepest areas while the surrounding regions remain almost unstretched. This can prevent proper conformity in very tight corners. Targeted manual heating in these areas can correct the fit. In male tooling, applying the film is more challenging because it cannot be tensioned over a cavity. Excess slack leads to overhang and wrinkling during application. However, manual application is feasible using an auxiliary tensioning frame.

Aims of the project

Over the course of this project, a test platform will be developed to address the challenges of both female and male tooling. The platform will enable testing of various films and part geometries and will incorporate a vacuum stretch-forming device. Another critical aspect is the heating concept: it must allow localized heating, with temperatures that can be set and verified. The test platform should be approximately the size of a DIN A2 sheet, with deviations possible.

Scopes

The project scope includes:

• Review the state of the art in thermoforming, stretch forming, and heating methods.
• Define subproblems and requirements, including:
  • Fixturing and sealing
  • Tool and part geometry
  • Heating concept
• Investigate candidate technologies for solving the subproblems.
• Develop concepts.
• Evaluate and present the results.
• Simulate and visualize the final system.

Target group (students)

We are looking for a committed, open minded and interdisciplinary team in which everyone can contribute with their expertise and would like to do some hands-on work. Your field of study might be:

• Systems engineering of e.g. aircrafts, renewable energies, automotive, ships
• General Engineering Science
• Product development, Materials and Production
• Materials science
• Mechanical engineering
• Mechatronics
• Robotics

Bachelor students are very welcome.

If your course of studies is not listed, don’t worry, this list is not exhaustive. Feel free to apply.

Dates
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Registration
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