Carbon Fibre Composite Rim

Abstract

This report shows the intended process to automatically manufacture Carbon Fibre Reinforced Thermo Plastic (CFRTP) double bend frames. Bicycle rims were chosen as a scaled down representation for difficult to manufacture double bend products. Fuselage frames require a too large facility. The aim is to manufacture CFRTP products in an automated process, with lower cost compared to current methods. Local automated production minimizes transport costs, increases the control over the quality of the product and the production process compared to outsourcing to low income countries. This would increase the grip on quality, lower the necessary transport and create a more economical solution.
The scope of this thesis was to tackle the automation and manufacturing difficulties of double bend products. Braids were evaluated as a solution, which proved to be usable for automatic manufacturing. In order to achieve full automation, the main manufacturing issues are correlated to design details of the product. These details need proper production equipment and optimized processes in order for quality to be consistent.
Braids were tested for automation and were found to be very successful with respect to simplicity of forming. A rim was manufactured using braids only, together with a thermoset matrix. Applying a thermoplastic matrix would be a logical next step, and could mean further advancement in automation of carbon fibre products.