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In a recent research paper released by The German Aerospace Center — DLR (Cologne), the organization explores how thermoplastic composite (TPC) molds, specifically those made from polyamide 6 (PA6), perform compared to conventional metal tooling in the in situ automated fiber placement (AFP) process.

Traditional tooling is expensive and time-consuming, which is why the industry is increasingly looking to 3D printed tools as cost-effective and flexible alternatives. The DLR investigated the difference in mechanical and morphological characteristics of laminates produced on metallic and polymeric molds. First, carbon fiber-reinforced LMPAEK laminates for both mold types were produced and their tensile strength, interlaminar shear strength and morphological characteristics analyzed using scanning electron microscopy (SEM) and differential scanning calorimetry (DSC). Despite differences in stiffness and thermal conductivity between the materials, the DLR found no statistically significant differences in the mechanical or crystalline properties of the laminates.

Findings indicate that PA6 in its cast form is a viable, low-cost option for nonheated AFP tooling. The DLR expects to extend this research into its 3D printing activities to open up new possibilities for efficient and flexible composites manufacturing.

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