Rapid Manufacturing of a Tailored Spar by AFP and Stamp Forming

Stamp forming is a manufacturing technology used to shape flat thermoplastic composite blanks into three-dimensional components. Further cost and weight optimization can be achieved by combining stamp forming with blank manufacturing by rapid AFP. The use of AFP allows for optimized lay-ups, which improve the performance/weight ratio of the stamp formed part, and near net shape blank contours, which reduce production scrap. Subsequent stamp forming provides the final shape and consolidation quality of the part. The current work aims to demonstrate the process route of rapid AFP followed by stamp forming on a realistic component. A section of a small spar from a wingbox is designed and manufactured. 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. Good consolidation of the spar is achieved, although the process is sensitive to blank thickness.