Load-compliant dimensioning of coreless-wound fiber skeletons for the local reinforcement of structural polymer parts

The 3D Skeleton Winding technology is a robot-based filament winding process designed for the large-scale production of skeleton-like winding structures (fiber skeletons) that can be used as local continuous fiber reinforcements within thermoplastic injection molded parts. It enables the manufacture of complex shaped fiber skeletons, as a multi-axis robot allows flexible winding movements around spatially distributed fiber deflection points (coreless filament winding).

This dissertation aims at developing a generally applicable workflow for the load-compliant dimensioning of such coreless-wound fiber skeletons prior to prototyping. Its purpose is to maximize the lightweight potential of locally continuous fiber-reinforced thermoplastic parts and to increase time- and cost-efficiency during their development.