Design, weaving and manufacture of a large 3D composite structures for automotive applications

The Automotive sector is undergoing transformation from conventional metallic materials to textiles manufactured using conventional 2D processing techniques. It is envisaged that although still immature, composite applications into the sector will grow significantly over the next 5 to 10 years and enter more mass market vehicle applications. With the opportunity offered by 3 dimensional advanced flexible materials, the adoption process could be more attractive to Automotive and wider industrial sectors. Currently the benefits of 3D woven preforms are being exploited in the aerospace sector by Safran ltd, with approximately 30% weight reduction over metallic components for the leap fan blade. These reductions in weight due to superior performance are allowing the development of more efficient aerospace components and are leading the way for adoption into the automotive sector. With the need for high speed manufacturing of composite components, it is expected that weaving 3D woven near-net-shapes could offer superior benefits to the automotive sector. Larger scale components have a particular attraction and when manufactured as a one piece woven structure (preform) will offer significant benefits to a wide range of composite applications. Manufacturing composite components is labour intensive with precise placement of multiple layers of pre-impregnated woven plies required. As the composite industries mature, further development of processes is anticipated, with high deposition rates and repeatability high on the priority list. Although many methods of processing from fibre to fabric structure exist, the ability to reduce layup times combined with rapid manufacturing using high speed looms, weaving multilayers at once is an attractive proposition and capable with conventional weaving machines. Traditionally 3D weaving and 3D woven structures have been classed as expensive and slow to process, severely limiting the adoption in to wider end uses and applications. This paper demonstrates how mass manufacturing capability is linked to woven 3D structures and how output and costs in materials manufacture can be further optimised. Initial designs from CAD software were conducted and inputted into a standard weaving loom without Jacquard technology and then a 3D one piece woven structure was obtained. The considerations of weave design, conformability, and permeability were discussed and large scale single- and various-weave one piece woven preform were designed, woven and resin-infused.