{"id":9083,"date":"2025-09-22T13:02:41","date_gmt":"2025-09-22T11:02:41","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/digilaughbeh-digital-design-of-a-lightweight-component\/"},"modified":"2025-09-22T15:46:34","modified_gmt":"2025-09-22T13:46:34","slug":"digilaughbeh-digital-design-of-a-lightweight-component","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/digilaughbeh-digital-design-of-a-lightweight-component\/","title":{"rendered":"DIGILaughBeh &#8211; Digital Design of a Lightweight Component"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_40919ca9b386165092d162ba03880e69 .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_40919ca9b386165092d162ba03880e69 .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_40919ca9b386165092d162ba03880e69\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                    Numerical design of a caustic tank with regard to service life under consideration of ecological aspects                <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        Long glass fibre reinforced thermoplastics (LFT) have a high potential for lightweight construction. As the tensile strength and impact strength of the material increase with increasing fibre length, significant material savings can often be achieved compared to conventional short-fibre reinforced materials. The thermoplastic foam injection moulding (TFI) with a physical blowing agent also enables a more fibre-friendly process control of LFT, which results in improved properties of the moulded parts. In addition, TSG offers greater geometrical freedom, allowing, for example, thicker rib designs and lower base wall thicknesses to achieve a load-compliant part design. These potential savings can be identified by using digital methods for a holistic view of the process.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n\n<p class=\"wp-block-paragraph\">In the public funded project <em>DIGILaugBeh<\/em>, IKV investigated the advantages of foam injection moulding with a physical blowing agent when processing LFT and developed corresponding design guidelines. In cooperation with project partners from industry and university, the simulation of foamed LFT was improved by implementing models for the calculation of fibre curvature in Moldflow. As a result, an improved moulded part design of the component could be achieved.<\/p>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/09\/03LB3044E.jpg\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/09\/03LB3044E.jpg 1338w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/09\/03LB3044E-748x602.jpg 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/09\/03LB3044E-768x618.jpg 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1338\" height=\"1077\" alt=\"03LB3044E\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; BSH Hausger\u00e4te GmbH<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: The caustic tank is connected to the oscillating system in a washing machine and subjected to a dynamic loads during operation.<\/figcaption><\/figure>\n\n\n<p class=\"wp-block-paragraph\">In the practical tests at IKV, in the first step the influence of plasticisation on the fibre length and viscosity of LFT was investigated for physical foam injection moulding. It was then compared to those of conventionally processed LFT. Longer fibres were found for TFI, particularly above the critical fibre length. The next step was to develop design guidelines for moulded parts made from foamed LFT.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Finally, these findings were transferred to the rear tray of a caustic tank in a washing machine and the guidelines were verified in scale-up tests. As part of the tests, the TFI-produced parts were compared with conventionally injection moulded and the series components. The use of TFI resulted in material savings of seven per cent with the same rigidity. At the same time, shrinkage and warpage were reduced and greater freedom in the design of the moulded part was achieved thanks to the improved dimensional accuracy.<\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the BMWE for funding the project (funding code 03LB3044E) and the project partners for their cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 01.01.2022 &#8211; 31.03.2025<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Promotion:<\/p>\n\n\n<section id=\"logo-bar-block_896e3a8bcdd688e879c381b66245e14a\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png 500w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo-335x335.png 335w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"500\" height=\"500\" alt=\"BMWE-Logo\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>In the DIGILaugBeh project, it was demonstrated how long-glass-fiber-reinforced thermoplastics can be optimized both ecologically and economically in physical foam injection molding. Using the example of a washing machine\u2019s detergent container, material savings of seven percent were achieved while simultaneously improving dimensional stability and service life.<\/p>\n","protected":false},"featured_media":9058,"parent":0,"template":"","tags":[944,921,868,845,1031,883],"research_fields":[812,809,810],"class_list":["post-9083","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-digitalisation","tag-injection-moulding","tag-leightweight-technologies","tag-long-fiber-reinforced-thermoplastics","tag-moulded-part-design","tag-thermoplastic-foam-injection-moulding","research_fields-digitalisation","research_fields-fiber-reinforced-plastics","research_fields-lightweight-technologies"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>DIGILaughBeh - Digital Design of a Lightweight Component | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"Long glass fiber reinforced thermoplastics (LFT) have a high potential for lightweight construction. As strength and impact strength increase with increasing fiber length, significant material savings can often be achieved compared to conventional short-fiber-reinforced materials. The use of thermoplastic foam injection molding (TSG) with a physical blowing agent also allows LFT to be processed in a way that is gentler on the fibers, resulting in improved properties of the molded parts. In addition, the TSG offers increased geometrical freedom, which makes it possible, for example, to design thicker ribs and thinner base wall thicknesses in order to be able to implement the molded part design in line with the load. 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The use of thermoplastic foam injection molding (TSG) with a physical blowing agent also allows LFT to be processed in a way that is gentler on the fibers, resulting in improved properties of the molded parts. In addition, the TSG offers increased geometrical freedom, which makes it possible, for example, to design thicker ribs and thinner base wall thicknesses in order to be able to implement the molded part design in line with the load. 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