Composites offer solutions for lighter and greener transport vehicles but also include challenges in manufacturing to avoid distortions. The DADIYSO COMP project aims to develop new methods to predict and prevent cure induced distortion with the help of advanced numerical tools for finite element analysis of the curing process.

In developing the next generation of lighter thus greener air transport, many manufacturers look towards polymer composite materials to achieve weight savings, and other possible advantages related to material design and manufacturability. 

Springback challenges

A long challenging area of design with composite materials has been the phenomena known as "spring-back", or more accurately “cure induced distortion”. It is the result of a liquid resin system being cured at high temperatures and pressures (i.e. autoclave conditions).

Differences in the coefficients of thermal expansion of the resin, fibres, and tooling, combined with chemical shrinkage due to the cross-linking process of the matrix. This can cause large and unwanted deformations to components.  These deformations cause problems in production and assembly, requiring rework, repair, or resulting in scrappage.

Layup and ply shape optimisation

Historically, design rules about laminate symmetry and tool compensation by experts in manufacturing have been the predominantly used methods of controlling distortion. Within DADIYSO COMP, optimisation methods will be developed to investigate the possibilities of instead altering layup and ply shape of components in order to eliminate the negative effects of cure induced distortion. Changes to address distortion need also take into account strict design allowable regarding stiffness and strength of the structures in question.

For more information regarding the DADIYSO COMP project, please feel free to contact us.

Clean sky 2

The DADIYSO COMP project is a part of Clean Sky 2. Clean Sky 2 is the largest European research programme developing innovative, cutting-edge technology aimed at reducing CO2, gas emissions and noise levels produced by aircraft.