Design and Manufacture of Structural Composites provides an overview of the main manufacturing challenges encountered when processing fibre-reinforced composite materials. Composites are unique in that the material is created at the same time as the structure, forming a very close link between the constituents, the manufacturing process and the resulting mechanical performance. This book takes an in-depth look at material choices and the intermediate steps required to convert different fibre and matrix combinations into finished products. It provides an insight into recent developments for each of the manufacturing processes covered, addressing design, cost, rate and mechanical performance. Topics covered include an introduction to composite materials, material preforming and conversion, moulding, digital design and sustainability, which addresses waste reduction, disassembly and fibre recovery. This book has been developed primarily as a teaching resource with contributions from leading experts in the field. The content has evolved from courses given by the authors to mechanical engineering and materials science students, at both undergraduate and postgraduate levels. It also draws upon experience gained during research projects and from leading industry experts. It therefore provides non-specialists with a valuable introduction to composite manufacturing techniques, helping to determine the most suitable manufacturing routes and to understand the challenges associated with the production of high-performance composite components. Provides an overview of the most common manufacturing routes for fibre reinforced composites, including the influence of the manufacturing route on mechanical properties, production volume and component cost Discusses recent advances in composite manufacturing, including the use of automation, process simulation, digital factories, and solutions to improve sustainability Looks at where the composites sector is heading and discusses some of the challenges faced by end-users looking to scale up production and increase the uptake of fibre-reinforced composites for structural applications

This book presents an introduction to the design and manufacture of fibre-reinforced composites. The mechanical properties of unidirectional composites are considered in a structural design context. The use of woven and random fibres is also addressed. The accuracy of design estimates for unidirectional composites is benchmarked against test data, and the relevance of a factor of safety (FoS) is established. The importance of prototype testing is emphasised. This book illustrates how to make a fibre-reinforced composite. Wet layup, vacuum bagging and prepreg moulding are covered in detail. Some guidance on mould design and construction is also provided. Finally, an introduction to the manufacture of composite tubes is presented. Wherever possible, design and make examples are used to illustrate the content. Tutorial questions and problems are included at the end of each chapter. The reader is encouraged to use these questions and problems to assess their own level of understanding of the content.

The primary objective of this book is to bridge this gap by presenting the concepts in composites in an integrated and balanced manner and expose the reader to the total gamut of activities involved in composite product development. It includes the complete know-how for development of a composite product including its design & analysis, manufacture and characterization, and testing.The book has fourteen chapters that are divided into two parts with part one describing mechanics, analytical methods in composites and basic finite element procedure, and the second part illustratesr materials, manufacturing methods, destructive and non-destructive tests and design.

A practical book of value to those in the automotive, chemical, aerospace and offshore industries. Case studies are included and as well as covering flexible manufacturing systems and non-destructive evaluation, the author looks ahead to metal matrix composites and ceramic matrix composites.

Textile composites encompass a rather narrow range of materials, based on three-dimensional reinforcements produced using specialist equipment. This book describes the design, manufacture and applications of textile composites. The intention is to describe the broad range of polymer composite materials with textile reinforcements, from woven and non-crimp commodity fabrics to 3-D textiles and their applications. The book gives particular attention to the modelling of textile structures, composites manufacturing methods, and subsequent component performance. This practical book is an invaluable guide for manufacturers of polymer composite components, end-users and designers, structural materials researchers, and textile manufacturers involved in the development of new products with textile composites.

Design and Analysis of Composite Structures enables graduate students and engineers to generate meaningful and robust designs of complex composite structures. Combining analysis and design methods for structural components, the book begins with simple topics such as skins and stiffeners and progresses through to entire components of fuselages and wings. Starting with basic mathematical derivation followed by simplifications used in real-world design, Design and Analysis of Composite Structures presents the level of accuracy and range of applicability of each method. Examples taken from actual applications are worked out in detail to show how the concepts are applied, solving the same design problem with different methods based on different drivers (e.g. cost or weight) to show how the final configuration changes as the requirements and approach change. Provides a toolkit of analysis and design methods to most situations encountered in practice, as well as analytical frameworks and the means to solving them for tackling less frequent problems. Presents solutions applicable to optimization schemes without having to run finite element models at each iteration, speeding up the design process and allowing examination of several more alternatives than traditional approaches. Includes guidelines showing how decisions based on manufacturing considerations affect weight and how weight optimization may adversely affect the cost. Accompanied by a website at www.wiley.com/go/kassapoglou hosting lecture slides and solutions to the exercises for instructors.

Design and Manufacture of Plastic Components for Multifunctionality: Structural Composites, Injection Molding, and 3D Printing presents the latest information on how plastics manufacturers are increasingly being driven towards carbon emission reduction, lightweighting, and cost savings through process integration. These technologies have the potential to revolutionize future products with built-in functionality such as sensors, smart packaging, and damage detection technology for everything from milk bottles and salad packaging to automotive bumpers and plane fuselages. This book introduces the three core manufacturing methods for multifunctional materials, composites, injection molding, and 3D printing, all processes facing challenges for the implementation of new technology. Users will find a book that brings together both process and material advances in this area, giving process engineers, designers, and manufacturers the information they need to choose the appropriate material and process for the product they are developing. Provides an introduction to the latest technologies in the area of multifunctionality, enabling engineers to implement new breakthroughs in their own businesses Gives an understanding of the processes that need to be considered in both design and manufacture of future devices, while using materials from a broader palette than used in existing manufacturing processes Includes best practice guidance and flow charts to aid in material and process selection Covers revolutionary future products with built-in functionality such as sensors, smart packaging, and damage detection technology for everything from milk bottles and salad packaging to automotive bumpers and plane fuselages