Abstract
In this study, a new automatic tape laying (ATL) method for CFRTP intermediate material was developed by using machine stitching, which can be effective to reduce material waste and production costs in automotive manufacturing. Narrow CF/PA6 semipreg tapes were stacked and fixed onto a sheet of PA6 base film by a modified embroidery sewing machine. Subsequently unidirectional laminates were fabricated and flexural specimens without fiber break were cut out from the non-stinging region of the laminates. The flexural properties of this tape lay-up laminates were examined under three-point bending condition in comparison with those of a laminate laid up with conventional wide width semipreg sheets. As a result, it was found that there is no significant difference in the flexural properties for the fiber direction between the tape lay-up laminates without fiber break and the conventional sheet lay-up laminate under the same fiber volume fraction. However, the flexural modulus and strength showed relatively low values in the tape lay-up laminates due to the decline of the fiber volume fraction because of the use of subsidiary materials of PA6 such as the base film and stitching thread.
