A Complex Shaped Reinforced Thermoplastic Composite Part Made of Commingled Yarns With Integrated Sensor

This paper focuses on the design and one shot manufacturing process of complex shaped composite parts based on the overbraiding of commingled yarns. The commingled yarns contain thermoplastic fibres used as the matrix and glass fibres as the reinforcement material. This technology reduces the flow path length for the melted thermoplastic and aims to improve the impregnation of materials with high viscosity. The tensile strength behaviour of the material was firstly investigated in order to evaluate the influence of the manufacturing parameters on flat structured braids that have been consolidated on a heating press. A good compatibility between the required geometry and the braiding process was observed. Additionally, piezo-resistive sensor yarns, based on glass yarns coated with PEDOT: PSS, have been successfully integrated within the composite structure. The sensor yarns have been inserted into the braided fabric, before consolidation. The inserted sensors provide the ability to monitor the structural health of the composite part in a real time. The design and manufacture of the complete complex shaped part has then been successfully achieved.