Novel Field-Manufacturing Methods for Long-Fiber Thermoplastic Composites

Continuous fiber reinforced thermoplastics (CFRTPs) are valued for their high strength-to-weight ratios, corrosion resistance, and recyclability over traditional structural materials. However, CFRTPs are difficult to fabricate compared to thermoset composites, a significant barrier to their adoption in construction and infrastructure. The University of Maine’s Advanced Structures and Composites Center has developed several innovative manufacturing and post-processing techniques to address fabrication challenges. The Continuous Forming Machine (CFM) is a processing device for non-reactive thermoplastic pultrusion, efficiently producing structural profiles like rods, plates, and channels. The CFM platform can be expanded with co-processes to create parts such as field-bendable concrete reinforcing bar. Further, effective post-forming processes will be crucial for adapting CFRTP components to on-site infrastructure applications. Localized thermoforming targets specific bending regions within a CFRTP component, offering a field-friendly approach over stamp thermoforming. Using localized heating methods, such as embedded heating elements, CFRTP panels can be locally thermoformed into three-dimensional components. Additional work has been performed to mitigate wrinkle formation in the bending of thick-gauge CFRTP laminates by implementing modifications to component architecture. This research presents significant advancements towards the widespread adoption of CFRTPs for infrastructure, demonstrating the technology's adaptability for onsite manufacturing and its future impact on sustainable construction practices.