Standard Article

Filament Winding: Design, Materials, Structures and Manufacturing Processes

  1. Sotiris Koussios,
  2. A. Beukers

Published Online: 20 JUL 2012

DOI: 10.1002/9781118097298.weoc088

Wiley Encyclopedia of Composites

Wiley Encyclopedia of Composites

How to Cite

Koussios, S. and Beukers, A. 2012. Filament Winding: Design, Materials, Structures and Manufacturing Processes. Wiley Encyclopedia of Composites. 1–16.

Author Information

  1. Delft University of Technology, Delft, The Netherlands

Publication History

  1. Published Online: 20 JUL 2012

Abstract

This article provides basic information regarding the background, state of the art, process parameters, involved materials, and (possible) products of the filament winding process. This technology is the first automated procedure that is applied for the manufacturing of high performance structures. Owing to recent developments in design and analysis software, machinery, materials, and information technology, the competitiveness of the filament winding process has significantly improved. Therefore, next to the typical aerospace and low to moderate pressure energy containment applications, new markets have been entered such as preforming for the automotive and marine sectors, compressed natural gas (CNG) and H2 pressure vessels (very high pressure), and sporting goods.

The idiosyncrasies of this process, however, raise the need for a dedicated, manufacturing- driven design approach. Typical filament issues such as the dedicated mandrel geometry, the need for convex fiber bundle paths, the interaction of fiber orientations and curvatures, the sensitivity of winding patterns for the fiber bundle dimensions, and the impact of the machine configuration on the economic performance, form the main part of this article. Although a sufficient amount of (material) data is provided, the emphasis here is to outline and demonstrate the above-named interactions, rather than to create a comprehensive description of the state of the art and the available literature.

After a short history and a basic process description, the applied materials and their mechanical properties are explained. Next, the geometry of the overwound fiber bundles is considered, with particular emphasis on nongeodesics and winding patterns. The technical part is completed with a short outline of kinematics and production time minimization. Lastly, some novel developments are briefly presented to demonstrate that filament-wound products can only be successful if the designer has a full understanding of that process.

Keywords:

  • filament winding;
  • materials;
  • laminate properties;
  • (non) geodesics;
  • winding patterns;
  • kinematic model;
  • robotic winding;
  • production time minimization