FuPul

The increasing demand for resource-efficient lightweight solutions promotes the use of bio-based materials such as wood veneers, which offer high application potential in laminated structures due to their mechanical properties while also providing an appealing appearance and tactile quality. However, the economical production of complex, laminate structures remains challenging, as current manufacturing processes are typically discontinuous and cost-intensive.
Veneer profile pultrusion represents a novel approach for the continuous production of laminated veneer profiles. Similar to the pultrusion process, multiple pre-coated veneers are pulled through a shaping tool. The objective of the project is to develop this process, in which the veneers are continuously formed and bonded in multiple layers, comparable to a plywood structure.
In addition to material-related questions regarding adhesive selection and component aging, open manufacturing challenges include continuous forming, pressing, and consolidation of the component, which are investigated at laboratory scale. Based on experimental friction-tension tests and statistical design of experiments, friction coefficients for various material and process parameter combinations were modeled and serve as key input for process design. In the next phase of the project, the overall process will be implemented and the mechanical properties of the produced profiles will be compared with those of conventionally pressed profiles.