Sustainable processes for next generation thermoplastic composites
Thermoplastic composites are very suitable as advanced engineering materials in a circular economy. They are increasingly fulfilling the promise of recyclability as new manufacturing strategies are being developed. Added to that, the TPRC is looking into greener production methods, for example by the reduction of the use of consumables.
Repair
As is the case with every component, damages of composite components occur during their lifespan. Several repair methods already exist for thermoset composite materials, but as the application of thermoplastic composite material within the aerospace industry is relatively new, so are their repair methods. The ability to melt and weld thermoplastic composite materials makes these materials very attractive for repair without using adhesives or relatively heavy bolt-on metal plates. The TPRC is researching the options to repair TPC materials for:
- Planned aircraft maintenance
- In-situ aircraft repair
- Manufacturing repair
Recycling
Recyclability has been a long-promised benefit of using thermoplastic composites. Their ability to melt makes thermoplastic composites easy to recycle. The compression moulding of shredded waste or end-of-life material is a promising method to create new parts. To this end, the TPRC has built expertise on:
- Fiber length controlled shredding technology
- Mixing of thermoplastic composite flakes without fiber breakage
- Rheology of long fiber-reinforced fluids
- Design and manufacture of parts
Consumable-free manufacturing
Release agents and films are widely used in composite parts manufacturing. The TPRC is looking into the reduction in the use of these consumables by modifying the surface of the tools used in the manufacturing of thermoplastic composite parts, by:
- Identification of stick mechanisms
- Microscale surface topology optimization by laser ablation
- Creating surface topology design tools
