splineTEX  is a new process for the production of seamless 3D curved hollow fibre composite profiles, mainly CFRP tubes with high quality surface. While the process type splineTEX plast is primarily an inexpensive material substitute for steel and aluminum tubes, splineTEX  flex is used in areas where weight reduction and geometry optimization play an important role. The profiles are made of a standardized or customized semifinished from the role, which consists of a flexible inliner, the woven fibre layers and a flexible outliner.

The forming process for SplineTEX is different with conventional production methods. The technology-specific inliner/outliner concept of the semifinished enables the production of composite structural elements without costly molding and without costly post-processing such as sanding and varnishing. The shaping method depends on the required tolerance accuracy, the component geometry, the required fibre volume content and the quantity. The possible options are: free Forming, forming with holding device or forming with molds.

For low requirements on the tolerance accuracy and for large-sized components in small numbers suits the possibility of free forming, in which the semifinished product is made with only a few holding points. For large-scale components with increased demand on the tolerance accuracy and for low to medium quantity production of structural elements, the manufacturing in holding devices or templates that support the geometry linear over most of the length of the component is recommended. The holding devices and templates can be made from both rigid foams of low density as well as wood or metal. Components with high demands on precision and with complex geometries, such as deviations from the circular cross-section, are made in molds. Not in expensive metal molds, but rather in inexpensive tools of block materials (such as medium density fibreboard, high density foams)

After the Hardening Process, the strength of the material will be considerably increase. It was soft and bendable before hardened. By injecting resin into the tube, the resin will combine with the carbon fiber. The material would be hardened once the resin is dry.

 
 
 
SplineTEX Table Design

GXN have been collaborating with superTEX on designing a table using the properties of splineTEX. GXNs design philosophy is to make a design that brings together form in a unique dialogue between material potentials and possibilities in new ways of production. In the splineTEX table design the free form ability of the tubes is utilized to create a structure made of reciprocating parts that lock together to give the strength and stability needed for a table. 

Forming Process
Forming Process

Flexible

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Forming Process 2
Forming Process 2

Shape

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Forming Process 3
Forming Process 3

Harden

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Knot Table
Knot Table
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Design Proposals Phase 1
Design Proposals Phase 1
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Design Proposals Phase 2
Design Proposals Phase 2
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Form Finding From Knot Structure
Peter Guthrie Tait FRSE (28 April 1831 – 4 July 1901) was a Scottish mathematical physicist, best known for the seminal energy physics textbook Treatise on Natural Philosophy, which he co-wrote with Kelvin, and his early investigations into knot theory, which contributed to the eventual formation of topology as a mathematical discipline. His name is known in Graph theory mainly for Tait’s conjecture.


Note 3_1 from the Knot Table has the properties to uniformly load distribution. The property of radial symmetry within the shape make it convenient for both fabrication and shipping. Relatively less intersection exists in the shape compare to the derivation knots. It would make less joints due to the maximum material length.

Form Finding From Knot Structrue
 
 

Fabrication Process 1

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Fabrication Process 2

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Fabrication Process 3

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Fabrication Process 4

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The Material Potential

The freeform structural composite tubes introduce a flexible technique used to mold fiber reinforced plastic tubes. This construction method allows the realization of strong dual curved spline structures without the need for costly molding procedures. In its flexible stage the tubes can easily be free formed. In the second stage, after the tube is cured with resin, it can be used for structural purposes.

splineTEX ® is a new process for the production of seamless 3D curved hollow fiber composite profiles, mainly CFRP tubes with high quality surface. In contrast to conventional manufacturing methods of free geometric fiber composite structural elements the splineTEX ® structural elements can be produced without mold and without costly deformation processes due to the technology-specific splineTEX® outliner concept . The application areas of the splineTEX ® structural elements range from A&D to sports equipment and further to automotive and aerospace industry.

 

Project Information:

Innovative material exploration in GXN | Supervisor: Kasper Jorgensen
Manufacture: Valentine Troi, Stefan Strappler | Design: Ping Lu, Zhenyu Lai

Prototype