Many composite architectures are currently made using hand laying techniques, where multiple flat fabrics are glued together in moulds using resin bonding between each layer
This type of manufacturing method is time consuming and more importantly prone to failure due to delamination or fibre fracture when exposed to impact and resonant forces during high-pressure conditions, which could lead to catastrophic failure of parts and components
3d weaving principles of shuttle and rapier
3d woven materials have proved to be very successful due to the binding of each of the multiple-layer and the continuous fibre weft/filling during weaving of the composite material; this system is excellent for producing reinforced components where structural integrity is important at the edge of the fabric
3d fabric using shuttle weft insertion, where the weft yarn is inserted inside the shuttle forming a continuous yarn through the fabric and edges of the fabric
3d fabric using rigid rapier, where the weft is positioned outside of the fabric, the rapier picks the weft yarn, which is then cut, then transferred across the fabric where the weft yarn is released creating a fringe at each edge of the fabric
The blue multi-layer warp yarns are interlaced with the continuous black weft yarn forming multiple layers of fabric; during the formation of the layers a further yellow warp yarn binds all the multiple layers together resulting in a multi-layered fabric which is reinforced throughout the fabric structure
The number of layers depends on the yarn thickness and yarn density required for various applications
This billet of fabric is then subject to a process known as RTM (resin transfer moulding) and eventually forms a solid block of reinforced plastic which can be machined to suit the end use application
3d Weave Adaptability
The principle of multi-layer weave can be adapted to many forms of composite architectures such as 3d net shapes, seamless tubes, para-beams and multi-layer billets
Aerospace applications: 3d woven net shape – image shows a carbon fibre fan blade which has been 3d woven
Para-beam: structural beams used in aerospace and other composite engineering applications; the production of these type of architectures uses the origami technique where the 3d structure forms after weaving
Military and ballistic applications: helicopters and personnel carriers use carbon and glass fibre woven billets installed on the undercarriage for missile and shell protection
Seamless woven tubes from carbon and glass fibre for various applications
Specifications
Working width: 400mm
Jacquard brand: Staubli LX
Jacquard hooks: 1152
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