The culmination of a three-year project with AMRC focused on the manufacture of stable, near-net-shape preforms with variable thickness for aerospace and automotive, and efficient use of materials. #Woven

Martin Wood, the weaving director of Antich and Sons, poses with one of the single-rapier looms used to manufacture 3D woven multilayer textiles. Martin can be said to be one of the most experienced weaving experts in the country. He has devoted his entire career to weaving technology. All photos source: Antich & Sons, AMRC.

The fabric manufacturer Antich and Sons (Huddersfield, UK) passed a partnership with the University of Sheffield Advanced Manufacturing Research Center (AMRC, Cartercliffe, UK)

The advanced capabilities of Antich and Sons are the pinnacle of FABFORM. This is a three-year project in cooperation with AMRC and funded by Innovate UK. The project focuses on the development and manufacture of stable, near-net-shape variable thickness preforms. Other methods needed. According to reports, these preforms will be able to effectively use the materials in the components, ensure the correct size and shape are placed in the mold for injecting the composite matrix resin, and contribute to easier and more reliable handling and transportation.

The company’s head of research and development, Andy Smith, said that for the Huddersfield-based company, the development of stabilizing and trimming 3D woven carbon fiber preforms with uniform and variable thicknesses is one step. A major achievement that surpassed the current state-the most advanced manufacturing capabilities.

The demonstrator parts produced by Antich and Sons represent a phased change in its manufacturing capabilities.

"The variable thickness, stabilization and trimming methods developed for 3D woven materials in FABFORM allow an important step in the value chain," Smith said. "It transformed Antich from a fabric weaver to a manufacturer of advanced composite preforms, preparing for the next step in the manufacturing process."

Smith pointed out that in the UK supply chain, the development of the key processes required to transform 3D woven fabrics into "mold-ready" preforms is still immature. He said that the new development of Antich and Sons brings great value to the market by advancing manufacturing technology, improving product performance and simplifying production capacity.

“In the past, 3D woven preforms were hard work to prepare for the forming operation, and they were also prone to deterioration during handling and cutting,” Smith said. "Therefore, we believe that as a weaver, we must develop technology during and after weaving to provide finished and stable preforms that end users can easily use.

"The ability to use the AMRC's world-class facilities at the University of Sheffield is a great help in the use of scientific methods to evaluate, screen, and test the correct technology, as well as to develop industrial-scale, high-tech equipment."

Chris McHugh, dry fiber development manager of the AMRC Composites Center, said that the development achieved through FABFORM supports the creation of lighter, harder, stronger and more competitive products, and helps to diversify income sources, create new employment opportunities and Increase the skill base in composite materials.

He added: “The cooperation between AMRC and Antich and Sons utilizes advanced technology and experience to improve the 3D weaving preforming capabilities of the British manufacturing industry. The output of this project has the potential to create important new business and robustness for the UK The export involves high-value manufacturing applications across sectors, including strong automotive and aerospace export markets."

Smith said that FABFORM is an "excellent first step" that incorporates key technologies such as tapering, stabilization, and edge trimming, which mechanically convert 3D fabrics into preforms that can be used in composite molding operations.

He said that the project’s proprietary technology was developed by studying various preform stabilization technologies and quantitatively evaluating its performance through a variety of test methods (such as edge wear test and frame shear test, etc.). Subsequently, various finishing methods of preforms were compared, including laser, water jet cutting and ultrasonic methods.

"The ability to provide advanced and ready-to-use preforms opens up new avenues for the development of alternative structures and complex materials in the UK market, enabling the creation of more competitive products," Smith added. "Future opportunities in markets such as renewable energy (wind turbine blades), railways (body structure), industrial processing and defense will bring long-term benefits to the wider UK composites industry."

With more than ten years of expertise in the research and development of composite materials in the fields of polymer matrix composites (PMC) and aluminum matrix composites (AMC), Antich and Sons said it will continue to promote the development of this business to new application areas of its weaving technology .

The company has purchased a single-rapier 3D loom from Lindauer Dornier GmbH (Lindau, Germany), including a platform that is said to be the first horizontal takeoff (HTO) of its kind in the UK. The company stated that pulling the fabric out of the machine in a straight horizontal configuration, rather than around the drum, is the key to avoiding deformation of thick fabrics and forms the basis for promoting variable thickness layer separation technology. The resin transfer molding (RTM) function of the prototype has also been added to speed up the development cycle.

Antich and Sons intends to exhibit at Advanced Engineering and JEC World after the conference resumes.

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