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DIGITAL LIBRARY: CAMX 2023 | ATLANTA, GA | OCTOBER 30-NOVEMBER 2

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Rebar for plastics – A novel approach to part optimization with hybrid length-scale composites

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Title: Rebar for plastics – A novel approach to part optimization with hybrid length-scale composites

Authors: Christopher M. Oberste, Meghana Kamble

DOI: 10.33599/nasampe/c.23.0130

Abstract: Conventional design methodologies are divided between isotropic approaches (metals and randomly oriented discontinuous composites) and laminate-based anisotropic approaches. This bifurcation of methodologies has largely aligned with historical manufacturing processes; however, recent development of hybrid length-scale composites require a novel approach to fully unlock the capabilities of these novel materials. In hybrid length-scale composites, unidirectional tape assemblies are combined with conventional plastic molding processes such as injection molding, compression molding, or thermoforming to create a structural or semi-structural component that is more cost efficient than a pure laminate. This paper provides an overview of the Rebar for Plastics® design methodology, which leverages various micro-and macro-mechanical concepts to maximize performance and minimize cost in hybrid length-scale composites. Rather than using material properties as a fixed input in part design, stiffness, strength, and toughness can be tuned independently and in parallel with part geometry, based on overall performance targets for the component and the relative ratios of unidirectional tapes and molded plastic in the part. A representative case study will illustrate key optimization concepts associated with hybrid length-scale composites, while also providing a comparison against conventional laminate-based methodologies. This paper will also showcase a woven composite lattice structure created from unidirectional thermoplastic tapes that is suitable for high volume manufacturing.

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Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000130

Pages: 17

Price: $34.00

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