Development of plant and tool technology with process data analysis for the pultrusion of sustainable recyclable lightweight structures

The CaproPULL project aims at developing a manufacturing process including the technology for the production of continuous fibre reinforced thermoplastic profiles. Pultrusion is a continuous process for the production of composites with a constant cross-section. Made of glass fibre reinforced polyamide 6, those profiles are of high quality while being recyclable, offering the potential to serve as energy- and resource-efficient parts in different segments. Deployment of a thermoplastic matrix enables subsequent forming as well as thermal joining. The procedure promotes lightweight engineering concepts reducing CO₂ emissions during and after the end of product life. Another focus of the project lies in process data analysis, which includes the definition of interfaces, cloud-based data processing and live feedback with recommended adaptations for quality assurance and process optimization.

On behalf of Fraunhofer ICT, simulation methods for optimisation of injection chamber geometry are being developed at FAST’s Division Lightweight Technology. Using a finite volume method, a simulation model of the pultrusion process is implemented, simulating impregnation of the glass fibres, in-situ polymerisation of ε-caprolactam to polyamide 6, and the pulling force.

Research Content:

• Creating a parameterised simulation model of the injection chamber
• Carrying out simulation studies with a variation of the injection chamber geometry under different process parameters
• Validation of the simulation based on experimental findings
• Creation of an easy tool for the technical design of the injection chamber as a function of selected process parameters