Assessment of the measurements contribution on composites thermoforming processes: a case study of an automotive component

The thermoforming manufacturing process appears as one of most promising for obtaining high quality components made of thermoplastic based composites. Many industrial sectors are keen on implementing this method on the production of primary or secondary structures of their products. Nevertheless, a significant number of problems are risen due to the complexity of the process and the materials themselves. Some of them are related to the correct thermoforming conditions, which are difficult to be monitored, while others to the materials architecture. In the present work, presented is a case study of an automotive part made of thermoplastic composites and manufactured via thermoforming. A priori, numerical analysis of the component is conducted to identify fabrication defects and to optimize the stamping and material configuration respectively. After the production of the component, measurements are conducted to identify the variations in several parameters that may influence the product both on its structural integrity as well as its esthetic characteristics.