David May received his doctorate degree in 2015 from the Technical University Kaiserslautern, where he since then lectures "integrated product development with composites". In 2021 he completed his habilitation on process engineering for composites. He currently manages an interdisciplinary research group at the Leibniz-Institut für Verbundwerkstoffe in Kaiserslautern. Manufacturing technologies for polymer composites are his main research focus.

Content I

List of used akronyms. V

List of used formula symbols (latin) IX

List of used formula symbols (greek) XIV

Preface. 1

1...... Introduction.. 3

1.1 Abstract 3

1.2 Basic mechanicle principle of Fiber-reinforced Polymers (FRP) 3

1.3 Applications of FRP.. 7

1.4 Product Development vs. Integrated Product Development (IPD) 15

1.5 Methods of IPD.. 19

1.6 Relevance of IPD for FRP.. 22

1.7 Questions. 25

1.8 References. 26

2...... Realization of an Integrated Product Development 30

2.1 Abstract 30

2.2 The development team.. 30

2.3 Procedure and division of tasks for the IPD with FRP.. 35

3...... Phase 1: Definition of the Catalogue of Requirements. 44

3.1 Abstract 44

3.2 Overview.. 44

3.3 Types and sources for requirements. 45

3.4 Risks when defining requiremtens. 47

3.5 Tools the identification and specification of requriements. 49

3.5.1 Guideline with main list of characteristics. 50

3.5.2 Szenario technique. 52

3.5.3 Identification of functions and functional structures. 53

3.6 Guidelines and requriement catalogues for FRP-components. 55

3.6.1 Guidline "Design" 55

3.6.2 Guideline "Manufacturing" 57

3.6.3 Guideline "Materials" 59

3.6.4 Full catalogue of requirements. 60

3.7 Questions. 64

3.8 References. 64

4...... Phase 2: Concept & Draft 66

4.1 Abstract 66

4.2 Overview.. 66

4.3 Basics of product development with FRP.. 67

4.3.1 Relevance of Fiber volume content 67

4.3.2 Relevance of fiber length and orientation.. 69

4.3.3 Laminate built-up. 73

4.3.4 Laminate coding. 80

4.3.5 FRP-design principles. 82

4.3.6 Advantages and disadvantages of FRP.. 86

4.4 Definition of critical load cases and derivation of requriement for geometry and material 87

4.5 Selection of fiber material and structure of fiber reinforcement 92

4.5.1 Fiber materials. 92

4.5.2 Structure of fiber reinforcement 97

4.5.3 Material properties for initial design.. 99

4.5.4 Selcetion procedure. 107

4.6 Initial design.. 115

4.7 Development of a manufacturing concept 116

4.7.1 Basics of FRP manufacturing. 117

4.7.2 Manufacturing processes. 119

4.7.3 Process selection.. 152

4.8 Decision concerning polymer class: thermoplastic or thermoset?. 157

4.9 Definition of the full draft 162

4.10 Decision about drafts to be further considered. 163

4.11 Questions. 165

4.12 References. 167

5...... Phase 3: Technical Elaboration.. 174

5.1 Abstract 174

5.2 Overview.. 174

5.3 Materials. 174

5.3.1 Selection of semi-finished products. 175

5.3.2 Selection of matrix polymer 205

5.3.3 Characterization of material properties. 212

5.4 Detailed Design.. 217

5.4.1 Design to manufacture. 218

5.4.2 Design to join.. 229

5.4.3 Design to repair 234

5.4.4 Sustainable design.. 237

5.5 Elaboration of manufacturing concept 247

5.5.1 Selection of facilities. 247

5.5.2 Process design.. 251

5.5.3 QA and damage detection.. 264

5.6 Question.. 275

5.7 Reference. 276

6...... Phase 4: Evaluation and decision.. 284

6.1 Abstract 284

6.2 Overview.. 284

6.3 Economic Evaluation.. 285

6.4 Prototyping and compontent testing. 295

6.5 Optional: Design optimization.. 296

6.6 Final comparison to catalogue of requirements. 297

6.7 Holistic techno-economic und strategic evaluation.. 298

6.8 Questions. 306

6.9 References. 306

7...... Conclusions. 308

8...... Answers to questions. 309

8.1 References 314