WI-IN

Implementation of an integrative winding-injection molding production cell for the resource-efficient production of hybrid thermoplastic hollow structures

American English

Within the collaborative project WI-IN, funded under the Technology Transfer Program “Leichtbau”, ILK contributed – together with its spin-off ANYBRID and further partners – to the development of the world'sfirst thermoplastic fiber-reinforced demonstrator for a high-load power tool application: a composite hybrid diamond core bit based on carbon-fiber-reinforced polypropylene. The project addressed two closely linked areas of innovation – component-level material and structural development, and the process integration of a novel hybrid manufacturing chain.
ILK was responsible for material characterization, structural analysis and component design, as well as the development of a holistic lifecycle assessment. A central focus was the design of the transition zonesbetween the wound composite tube, the injection-molded functional component, and the metallic insert – a multi-material system of considerable engineering complexity, subject to superimposed dynamic loading conditions.
Experimental validation of the demonstrator confirmed compliance with all specified mechanical requirements. The component achieved a wear rate reduction of at least 50 % compared to the steel reference, alongside a mass reduction of 65–70 %. Lifecycle assessment quantifies a CO₂ reduction of up to 40 % at extended service life. Additionally, it was demonstrated for the first time that production waste from the winding process can be recycled as injection molding feedstock within the same component – without any compromise in mechanical performance.