Co-authors​ :

 Dominik NUSS (GERMANY), Cornelia SENNEWALD , Chokri CHERIF  

Technical woven fabrics play a pivotal role as reinforcement in plastic components across diverse applications. Traditionally, these fabrics are crafted using wide weaving machines, featuring a constant fabric width. Subsequently, the fabric is cut to attain the desired component geometry, a practice that leads to significant waste generation. To address this issue and promote more sustainable manufacturing practices, an effective approach involves utilizing woven fabrics with outer contours that align with the desired component geometry from the inception of the weaving process. However, the production of width-variable woven fabrics during the weaving process has posed a historical challenge with conventional wide weaving machines. This limitation prompts the need for innovative solutions. In response to this challenge, this work introduces a new reed design specifically tailored for wide weaving machines. The conceptualization of the new reed design, along with its successful implementation in a rapier weaving machine, is thoroughly detailed.
Delving deeper into the advancements, this work elucidates the intricate process of fabric development under the new technical specifications. The production of fabric examples serves as a tangible demonstration, showcasing the measured variables throughout the fabric production process and their consequential impact on fabric properties and geometry. With the constructed reed and the integration of advanced fabric design tools, the research successfully produces near-net-shape woven fabric embedded with carbon fibres. These woven fabrics, designed with outer contour adaptability, serve as preforms in reinforcing an exemplary Fanblade geometry designed for aero engines. The ensuing discussion not only unveils the fabric properties resulting from this innovative process but also explores the underlying textile-physical relationships governing these properties.
The final segment of this comprehensive study delves into the component manufacturing process, providing a holistic view of how the width-variable fabrics, created through this novel approach, seamlessly integrate into the manufacturing ecosystem. This section aims to bridge the gap between fabric production and the ultimate application in component manufacturing.
In summary, this presented approach, facilitated by the novel reed design and advanced fabric design tools, enlarge the production of technical fabrics. By enabling the creation of width-variable fabrics, this methodology strives to promote more sustainable manufacturing practices, ultimately contributing to the reduction of waste and the optimization of resource utilization in the realm of technical fabrics.