The German Aerospace Center (DLR) has released a new research paper validating the use of polyamide 6 (PA6) thermoplastic molds as a cost-effective alternative to traditional metal tooling in the in situ automated fiber placement (AFP) process.

With growing interest in 3D printed composite tooling for faster, more affordable production, DLR compared the mechanical and morphological characteristics of carbon fiber-reinforced LMPAEK laminates produced on both metallic and PA6-based molds. Evaluations included tensile strength, interlaminar shear strength, and detailed analysis via scanning electron microscopy (SEM) and differential scanning calorimetry (DSC).

Despite inherent material differences in stiffness and thermal conductivity, the study found no statistically significant differences in the mechanical or crystalline properties of the laminates, affirming the performance of PA6 tooling in nonheated AFP environments.

These findings demonstrate that PA6 molds offer a viable, low-cost alternative to conventional tooling, especially for non-heated applications, stated DLR researchers. We now plan to extend this work to our 3D printing efforts, unlocking greater flexibility and efficiency in composites manufacturing.

This breakthrough highlights the potential of polymer-based tools for rapid prototyping, short production runs, and lightweight tooling applications, contributing to more sustainable and agile aerospace manufacturing workflows.

Source: www.dlr.de/en