Continuous Film Stacking and Thermoforming Process for Hybrid CFRP/aluminum Laminates

Thermoplastic-based so-called Fibre Metal Laminates, consisting of fibre reinforced plastics foils and metal sheets in an alternating structure, can be efficiently produced via a continuous film stacking process of a Fibre-Foil-Tape Unit (FFTU) and subsequently thermoforming process. These materials combine the advantages of the individual material groups and offer a great potential for lightweight structures. A construction was tested with bending and torsion tests and compared to steels. By connecting the FFTU-technology with the thermoforming process, the economical aspect can be increased considerably. The weight was reduced up to 29%, despite increasing the thickness of the hybrid laminate.