Dr. B. S. Sugun is currently a Senior Principal Scientist at the Center for Societal Missions and Special Technologies (CSMST), CSIR - National Aerospace Laboratories at Bengaluru. He has an interdisciplinary background with a Bachelor's & Master's degree in Textiles Technology coupled with a Ph.D. in Mechanical Engineering. He has been working in the area of polymer matrix composites research for the past two decades. Some of his early works were on  Low velocity impact behavior of Polymer Matrix  composites, resin transfer molding, fiber metal laminates & glass-knit composites. In the last decade, he has focused on the technology of 3D weaving. His research work revolves around evolving novel concepts for indigenous 3D weaving machinery, Near-net preforming approaches and developing creative weave designs for engineering the preforms for use in composites. His recent endeavors comprises of  developing a  prototype  machine  for dual plane shedding based 3D weaving wherein basic concepts of the technology have been practically realised,  development of an automated  customised take-up-at-will 24 shaft dobby loom, utilizing pleat weaving concept for weaving T-stiffeners, development of hybrid carbon-Kevlar preform for fuselage wing joint of Micro air vehicle and weaving complex geometrical shapes using 3D noobed and angle interlock weave architectures ex., gas turbine engine nozzle flap. He was a Raman research fellow at the University of Manchester, UK in 2015, where he worked on addressing fiber lay-up schemes for rotational symmetric components using robotics approach and also worked towards the development of  specific Profiles  for applications in composites using  three dimensional braiding. He has several peer reviewed publications, conference papers & has delivered several invited talks. With participation from a private industry within the country, he is currently developing a commercially viable, production version multi weft insertion 3D weaving loom for use in textile industries. He is currently associated with the Quality Assurance and Airworthiness  activities  of NAL in addition to his research works at CSMST.

Executive Summary

List of Figures

List of Tables

1

Orthogonal Weaving

Introduction

1.2

Weave Structure details

1.3

Methods of Manufacture

1.4

Understanding the constraints of 2D weaving looms

1.5

Loom Requirements

1.6

Shape weaving methods

1.7

Preform calculations

2

Angle Interlock weaving

Introduction

2.2

Weave architecture basics, variants and weaving approach

2.3

Fibre content calculations

2.4

Combination of angle interlock and orthogonal weave architec-

tures

3

Dual plane shedding based 3D weaving

3.1

Introduction and basics

3.2

Working principle description

3.3

Previous works related to dual plane shedding based 3D weav-

ing

3.4

Theoretical information governing machine design

3.5

Design and development of prototype 3D weaving machine

3.6

Working of the machine

3.7

Photographs of machine/sub-elements and dual plane shedding
based woven preforms