Development of Non-Crimp Multi-Layered 3D Spacer Fabric Structures using Hybrid Yarns for Thermoplastic Composites

An innovative weaving technology for the manufacturing of 3D woven double-walled spacer fabrics from high performance hybrid yarns was developed and implemented. Based on the gained technical and technological experience the woven multi-layered structures with load-oriented non-crimp fiber arrangement are realized and improved for high preform stiffness and a reproducible manufacturing.The article provides an overview of the technology for weaving of 3D spacer preforms in one production step with the required machine modifications. Furthermore the advantages of multi-layered woven fabric as well as the development of special pattern to forming and stiffening of the critical areas (joint areas) will be presented.