journal article·2026-01-29Open access

Rotational moulding for small diameter continuous fibre reinforced thermoplastics structures

Patrick Schaible, Jonathan Ehret, Sebastian Schabel, Jürgen Fleischer

Abstract

Continuous-reinforced thermoplastic composites are becoming increasingly important for mass production of lightweight components across various industrial sectors. This paper describes a novel process chain for the production of continuous fibre reinforced thermoplastic matrices with a rotationally symmetric cross-section, using rotational moulding technology. The process chain is based on wound and pre-consolidated preforms, which are then formed into the final geometry by rotational moulding. To support the manufacturing of smaller diameters, a composite core is used to increase the pressure during manufacture. The experimental results are examined by cross-sectional micrographs and show the approach’s feasibility.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Polymer Foaming and Composites · Epoxy Resin Curing Processes · Composite Material Mechanics

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Karlsruhe Institute of Technology (KIT)

Funding

Deutsche Forschungsgemeinschaft

References (19)

Show source-provided references
1. 10.1007/978-3-662-62833-110.1007/978-3-662-62833-1 ↗
2. 10.1016/j.cirp.2015.05.00510.1016/j.cirp.2015.05.005 ↗
3. 10.1016/j.tws.2022.10979910.1016/j.tws.2022.109799 ↗
4. Besson J-M Celli M-A Capelle N. H160 helicopter: development of a carbon thermoplastic HUB.
5. Epple S Bonten C. Production of continuous fiber thermoplastic composites by in-situ pultrusion. In: Presented at the proceedings OF PPS-29: the 29th international conference of the polymer processing society - conference papers Nuremberg Germany 15 May 2014 pp. 454–457.10.1063/1.4873820 ↗
6. Barfuss D Grützner R Garthaus C et al. Intrinsic manufacture of hollow thermoplastic composite/metal structures. In: Presented at the ESAFORM 2016: proceedings of the 19th international ESAFORM conference on material forming Nantes France 19 October 2016 p. 170024.10.1063/1.4963580 ↗
7. Mack J Schledjewski R. Filament winding process in thermoplastics. In: Suresh G. Advani Kuang-Ting Hsiao (eds) Manufacturing techniques for Polymer Matrix Composites (PMCs) Woodhead Publishing Series in Composites Science and Engineering. Woodhead Publishing 2012 pp. 182–208. doi:10.1533/9780857096258.2.182.10.1533/9780857096258.2.182 ↗
8. 10.1016/j.compscitech.2006.03.01510.1016/j.compscitech.2006.03.015 ↗
9. 10.1007/s12289-020-01584-710.1007/s12289-020-01584-7 ↗
10. Ehleben M. Herstellung von endlosfaserverstärkten Rohren mit thermoplastischer Matrix im Schleuderverfahren. Schriftenreihe konstruktiver Leichtbau mit Faser-Kunststoff-Verbunden. Shaker, 2002.
11. 10.1007/s11740-015-0620-010.1007/s11740-015-0620-0 ↗
12. Fleischer J Coutandin S Nieschlag J. Production and tensile testing of rotationally molded hybrid composite tie rods. 2020. SAMPE 2020 | Virtual Series NA SAMPE. DOI: 10.33599/nasampe/s.20.0040.10.33599/nasampe/s.20.0040 ↗
13. 10.1016/j.compstruct.2021.11468710.1016/j.compstruct.2021.114687 ↗
14. Schaible P Kuster H Rombach D et al. Production and torsion testing of rotationally moulded hybrid composites drive shafts. SAMPE conference 23 Madrid. Hrsg.: R. de Ruitjer Madrid Spanien 03 October 2023–05 October 2023.
15. 10.1016/j.procir.2024.09.00310.1016/j.procir.2024.09.003 ↗
16. 10.3390/jcs511028910.3390/jcs5110289 ↗
17. Mischorr E, Schaible P, Würfel V, et al. Advanced manufacturing of thermoplastic tape preforms: braiding simulation, curved preforming, and consolidation via rotational and bladder-assisted molding. Adv Manuf Polym Compos Sci 2025; 11(1): 2546292.
18. Celanese Corporation. Materials celanese Datenblatt CELSTRAN® CFR-TP PA6 CF60-03. https://materials.celanese.com/de/products/datasheet/SI/CELSTRAN_CFR-TP_PA6_CF60-03
19. Kunz J, Studer M. Determining the modulus of elasticity in compression via Shore-A hardness. Kunststoffe Int 2006; 96(6): 92–94.