Process of making a plastic component (1), in particular luggage shell, from self-reinforced thermoplastic material, to a plastic component (1) made of self-reinforced thermoplastic material and an apparatus for making such a plastic component, in particular luggage shell (7). The invention provides a new product and process for manufacturing same on the basis of self-reinforced thermoplastic material by means of the step of tensioning said material (lamina), at least partially tensioning said lamina during all follow-up component shaping and/or molding steps up to a release of a component pre-form shape from the remainder lamina, to form the component. The present invention allow the manufacturing of an ultra-light weight luggage shell (7) on the basis of using self-reinforced thermoplastic material, the manufacturing of same can be further enhanced by permanently tensioning said material during all manufacturing steps up to the final finishing of the product.

Process of making a plastic component (1), in particular luggage shell, from self-reinforced thermoplastic material, to a plastic component (1) made of self-reinforced thermoplastic material and an apparatus for making such a plastic component, in particular luggage shell (7). The invention provides a new product and process for manufacturing same on the basis of self-reinforced thermoplastic material by means of the step of tensioning said material (lamina), at least partially tensioning said lamina during all follow-up component shaping and/or molding steps up to a release of a component pre-form shape from the remainder lamina, to form the component. The present invention allow the manufacturing of an ultra-light weight luggage shell (7) on the basis of using self-reinforced thermoplastic material, the manufacturing of same can be further enhanced by permanently tensioning said material during all manufacturing steps up to the final finishing of the product.

There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange.

A method for producing a three-dimensional construction material component preferably having at least one curved surface. A plurality of spacers are arranged in a formwork. A textile reinforcement is supported on the spacers, such that the textile reinforcement has a defined position within a formwork interior of the formwork. A tensile force is applied via a tensioning device to the textile reinforcement in at least one tension direction. Construction material is introduced into the formwork interior and surrounds the textile reinforcement. The construction material is then hardened, wherein the tensile force is maintained during the hardening. During this process, the spacers are integrated into the construction material component. The tensioning device has at least one clamping unit for clamping an end portion of the textile reinforcement between two clamping surfaces. The clamping surfaces are provided on clamping insert bodies, which are of a plastic material of a defined hardness.

A method for producing a three-dimensional construction material component preferably having at least one curved surface. A plurality of spacers are arranged in a formwork. A textile reinforcement is supported on the spacers, such that the textile reinforcement has a defined position within a formwork interior of the formwork. A tensile force is applied via a tensioning device to the textile reinforcement in at least one tension direction. Construction material is introduced into the formwork interior and surrounds the textile reinforcement. The construction material is then hardened, wherein the tensile force is maintained during the hardening. During this process, the spacers are integrated into the construction material component. The tensioning device has at least one clamping unit for clamping an end portion of the textile reinforcement between two clamping surfaces. The clamping surfaces are provided on clamping insert bodies, which are of a plastic material of a defined hardness.

A lamination head for laying up a composite laminate includes a material supply drum supporting roll of layup material backed by a backing layer, a first and second separation device respectively having a first and second horn, and a first and second compaction device. When the first separation device is extended, the first horn is in close proximity to the first compaction device, causing a layup material to separate from the backing layer and move underneath the first compaction device as the lamination head moves along a first direction of travel. When the second separation device is extended, the second horn is in close proximity to the second compaction device, causing the layup material to separate from the backing layer and move underneath the second compaction device as the lamination head moves along a second direction of travel opposite the first direction of travel.

A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.

The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

There is provided a forming apparatus for constraining a composite charge and forming the composite charge into a highly contoured composite structure. The forming apparatus includes a first die and a second die between which the composite charge is formed. The first die has pairs of first die portions spaced apart to define a die cavity into which the composite charge is formed into a contoured hat section having a cap. The forming apparatus includes a constraining assembly having a constraining device positioned in the die cavity. The constraining device is designed to constrain a cap portion, and to apply an upward resistive force against the cap portion, and against a downward compressive force applied by the second die, to provide wrinkle prevention in the cap as the contoured hat section is formed. The constraining assembly has a retaining element to retain the constraining device.