TAGS: Thermoplastic Composites Part Design & Manufacturing Cost Efficiency
University of Delaware researchers have developed a new high-performance material, known as TuFF (Tailored Universal Feedstock for Forming), with properties equivalent to the best continuous fiber composites used in aerospace applications. Like sheet metal, TuFF can be stamped into complex shapes.
Tailored Universal Feedstock for Forming
The new high-performance material, known as TuFF (Tailored Universal Feedstock for Forming), can stretch up to 50 percent, achieve properties equivalent to the best continuous fiber composites used in aerospace applications and reduce part manufacturing costs. TuFF can also be produced inexpensively and sustainably from recycled composite parts or scrap carbon fiber manufacturers typically throw away and be reused to make high performance, high value materials and parts. (In the world of advanced manufacturing, “feedstock,” refers to organic materials developed and adapted in ways that serve a manufacturing process.)
TuFF represents a paradigm shift in composites design and opens the door for composites to replace metals in a variety of applications in the automotive, aerospace, infrastructure, electronics industries and more. Many common products, from kitchen appliances to smartphones and more, are now made with stamped sheet metal, and manufacturers might someday use TuFF instead.
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We are going after metals at their own game,” said Jack Gillespie, director of CCM. “
TuFF is low cost, can be made quickly, and is recyclable. Instead of expecting the metal manufacturers to redesign metal parts like airplanes, we decided to create a new material that can be designed and processed like metals using their existing manufacturing equipment – while still providing 40-70% weight savings.”
Developing Cutting-edge Methods to Manufacture Tuff
To make TuFF, the research team at CCM tried several different alignment mechanisms, the team at CCM figured out how to bring everything in line. The process can now use any type of fiber (or combinations) with nearly all polymers (thermoplastics and thermosets).
The team did not stop once they had invented the material. They are also developing cutting-edge methods to manufacture it. CCM established a semi-automated pilot plant incorporating new control systems and inline sensors for quality control.
TuFF product forms range from 20-inch wide rolls, tailored blanks for forming parts and narrow and steerable tapes for additive manufacturing processes. The team has demonstrated the feasibility and scalability of novel technologies developed through this program and are looking to supply TuFF material to designated industry partners for evaluation, prototype development and scale-up.
Researchers are now conducting additional experiments, including modeling and simulation, to further understand the behavior of TuFF so that they can tailor it for more applications.
A variety of fibers and polymers could be used to make TuFF, and the microstructure of the TuFF matrix can be tailored to each application, so there are “infinite possibilities for market growth,” but also infinite opportunities for continued basic and applied research.
Source: University of Delaware