Development of methods and concepts for the integral web-based manufacturing of complex 3D net-shaped fabrics in reproducible quality

• Applicant: Dr.-Ing. Cornelia Sennewald
• Subject Area: Lightweight Construction, Textile Technology
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 551914902

Textile 3D net-shape reinforcement semi-finished products are necessary for complex fiber-reinforced plastic composite components and medical applications. So far, the design and implementation of these semi-finished products have been done individually for each component, involving a significant trial-and-error effort and the use of specially developed machines. Jacquard weaving offers excellent technological conditions for implementing any weave, particularly without requiring significant modifications to the machines, and it allows for the generation of a wide variety of structures. A methodology enabling the implementation of various 3D net-shape weaves (3D-NSW) using standard weaving technology has not yet been established and is, therefore, to be developed in this project. Thus, the objective of this project is to develop universally applicable CAE-based methods for the development of complex 3D preforms, and to research and implement different concepts for their design, as well as for the integral weaving-based production of 3D net-shape fabric preforms using Jacquard weaving technology. To develop methods for unwinding the 3D geometries, the shaping principle must be understood. Therefore, the weaving transformation mechanisms are first scientifically investigated, described, and used to develop specifications for the unwinding and arrangement of the necessary partial surfaces (body part surfaces and shaping surfaces). Thus far, these weaving mechanisms have been inadequately described and utilized to a limited extent, and there is a lack of specifications for component unwinding. The primary focus of this work is on developing new methods and algorithms, and combining them into a universal process chain. Initially, unwindings and 2D surface arrangements are computer-generated from the 3D component geometry, considering weaving technical mechanisms (3D-2D transformation). Based on this, weaves are developed using software, and the 2.5D fabrics produced in an integral weaving process are shaped into 3D net-shape fabric preforms (2.5D-3D transformation). The development of a universal process chain for CAE-supported manufacturing of 3D-NSW provides mass-reduced, high-strength, and cost-efficient components suitable for series production, even in complex geometries, for lightweight construction. This contributes to economic growth, resource efficiency, mobility, particularly e-mobility, and the reduction of energy consumption.

• DFG Programme: Research Grants