Induction Melt Incremental Thermoforming of Advanced Thermoplastic Composites (iMeltComposites)

Typically, to achieve optimum mechanical properties in composite structures, placement of fibres in multiple directions is required to accommodate complex loading conditions. Despite the development of sheet forming processes for advanced composites dating back over 30 years, questions regarding the production of defects, such as wrinkles, during the forming of multi-axial sheets have yet to be satisfactorily answered.

The idea of the project is to develop a novel sheet forming process for advanced thermoplastic composites designed to mitigate defects when thermoforming multi-axial laminates into complex geometries. This will be achieved through the creation of wrinkle-resistant 'lubricated-blanks' using a combination of robotically controlled induction heating and incremental forming.

What We Do

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Robotic Assisted Thermoforming

In this cutting-edge process, we utilise advanced robotics to automate the thermoforming process. This precision-driven technique enhances efficiency and accuracy, allowing us to create complex shapes and structures with exceptional consistency and reduced wrinkles.

Mechanical Testing Experiments

Our mechanical testing experiments include both destructive and non-destructive testing (NDT) methods to evaluate the mechanical performance of the manufactured parts. By rigorously testing these materials, we ensure they meet the highest standards of quality and reliability for their intended applications.

Finite Element Analysis

Using state-of-the-art finite element analysis (FEA) software, we simulate and analyse the behaviour of materials and structures under different stresses and loads. This powerful computational tool helps us predict performance, optimise designs, and identify potential issues before they arise in real-world applications.

Project Publications

Tabatabaeian, A., Ambuehl, K., Blair, C., Kahavitage Dona, H.N.K. & Harrison, P. (2026). Wrinkle Mitigation via Pre-Tensioned and Lubricated Double-Diaphragm Press-Forming of Woven Fabric. Composites Part B: Engineering. https://doi.org/10.1016/j.compositesb.2026.114178

Tabatabaeian, A., Blair, C., Ambuehl, K. & Harrison, P. (2026). Wrinkling Behaviour of Engineering Fabrics in Diaphragm-Assisted Deep Drawing. Solid State Phenomena, 387, 43–51. https://doi.org/10.4028/p-mkod5g

Campbell, Iain, Mulvihill, Daniel M. and Harrison, Philip (2023) The influence of residual tin following induction melt thermoforming of composite parts. Composites Part A: Applied Science and Manufacturing, 164, 107286. (doi: 10.1016/j.compositesa.2022.107286)

Harrison, P. & Gonzalez Camacho, L.F. (2021). Deep draw induced wrinkling of engineering fabrics. International Journal of Solids and Structures, 212, 220–236. https://doi.org/10.1016/j.ijsolstr.2020.12.003

Harrison, P., Campbell, I., Guliyev, E., McLelland, B., Gomes, R., Curado-Correia, N., McGookin, E. & Mulvihill, D.M. (2020). Induction melt thermoforming of advanced multi-axial thermoplastic composite laminates. Journal of Manufacturing Processes, 60, 673–683. https://doi.org/10.1016/j.jmapro.2020.10.026

Our Team

This ambitious and adventurous project requires a team of investigators and partners with a broad mix of expertise, technical capabilities and connections to maximise the chance of success. The academic team includes Dr. Harrison and Prof. Mulvihill who bring research experience in Composites Manufacturing, and Dr. McGookin, who brings expertise in Robotic Control. Supporting our PIs is Dr. Himanthi Nimrekha Kahavita, our dedicated postdoctoral research associate, whose innovative research in Mechanics of Composite Materials connects our multidisciplinary approaches.