The giant 6 m diameter braiding system paves the way for the development of manufacturing complex architectures and features using dry-fibre technology. As a result, the ability can be offered to tailor orientations in line with structural requirements, as well as allowing both off-axis and axial fibres to be laid simultaneously at the deposition rates required for high-volume manufacture.
A range of materials can be used with the radial braider, including carbon, thermoplastic, glass, aramid and co-mingled tows. The machine is also capable of processing ceramic fibre such as alumina and silicon carbide, which would otherwise be difficult to process on a conventional braider.
Typical applications in aerospace and automotive include the production of fuel pipes and wing spars, as well as numerous car body structure parts. The braider will also be available to support Dowty Propeller’s multi-million pound ‘Digital Propulsion’ project to develop future turbo-prop solutions.
Chris McHugh, dry-fibre development manager at the AMRC Composite Centre, says: “The radial element is a primary feature of the braider as it means less fibre damage and more complex geometry is achievable due to the fact the fibres come down in a flat disc rather than a long cone. Importantly, the machine is served by two 6-axis robots, whereas just one robot is normal with conventional braiders. Two 6-axis robots working in tandem means heavy parts and mandrels can be processed, and not just foam cores.”
The technology, which is open to research projects for AMRC members, external companies and grant-funded projects, can be combined with any of the other technologies at the AMRC, including the 1,000 ton Rhodes press and KraussMaffei resin transfer moulding equipment.
Consultant engineer at the AMRC Composite Centre, Andy Smith, says: “The advantage is it can be combined with other dry-fibre technology, as the AMRC has the full process chain to generate parts that demonstrate industrial scale, high-volume production.
“Within the set-up of this machine, the braider also has the potential to process delicate ceramic fibres for metal or ceramic matrix composites, which have higher temperature capabilities and higher stiffness – making them suitable for military applications,” he adds.
