The continuous fibre injection process (CFIP): A novel approach to lightweight design of multi-material structural components

Abstract. The combination of different materials enables to achieve highly efficient structures in terms of lightweight and mechanical performance, as well as in terms of manufacturing costs. However, the weakest points of these structures use to be the joints. For this reason, in the last years, many studies have dealt with joining technologies for dissimilar materials. The Reinforce3D’s Continuous Fibre Injection Process (CFIP) technology delivers a unique method to join dissimilar materials. CFIP is based on injecting continuous fibers, such as carbon fibers, simultaneously with liquid resin into tubular cavities within the part. Then the resin is cured and the final composite part is obtained. This work focuses on the characterization of the mechanical properties of CFIP-made specimens and describes the potential lightweight benefits of the technology. Mechanical tests were performed under tensile and bending conditions following standardized methods. The lightweight potential is addressed by developing a representative case study by implementing finite element and topology optimization methods. The results of this case study were finally compared with a monomaterial equivalent component (aluminium) demonstrating the improvement that CFIP provides in terms of lightweight while keeping the strength.