Material Selection and Process Configuration for Free-Form, Voluminous and Textile-Based Multi-Material-Design by the Example of a Bucket Seat

Hybrid textile-based composites possess an enormous potential for energy and resource efficient large-scale production, with freedom in and high specific mechanical properties. This paper covers the connection of available and established production processes for textiles in a differential process chain for the manufacturing of complex shaped and elastic sandwich components. The technology enables both stiffness and comfort through elasticity.OLU-Preg®-organic sheets, polyurethane foam cores and 3D-spacer fabrics form the targeted properties of demonstrator models. This article refers to the demonstrator part “bucket seat”. To show the benefit of complex composite material, the lightweight and mechanical properties of the sandwich structures are tested in several variations of core and comfort shapes. Absolute and specific improvements of performance are shown in static and dynamic examinations. An Analysis of coupling effects, deformation and failure behavior of the multi-material design (MMD) complete the scientific approach of the structure-property relationships of hybrid composites.