Stamp forming is a rapid manufacturing technology used to shape flat blanks of thermoplastic composite material into three-dimensional components. The combination with rapid AFP as blank manufacturing technology can further extend the applicability of stamp forming. The rapid lay-up of near net-shape tailored blanks allows for optimized structural performance while reducing weight, and reduced production scrap. Moreover, AFP offers partial preconsolidation, which makes that an expensive preconsolidation step by press or autoclave is no longer required. The current work aims to demonstrate the technical feasibility of AFP followed by stamp forming for producing high quality tailored components. For this purpose a demonstrator component is developed that resembles a small spar from a wing box. The spar includes features such as local reinforcements by tailored lay-ups in either the web, flanges or both, and joggles in order to taper the height of the spar.
Tailored Blanks, AFP, Stamp Forming, Ply Drops