In the world of advanced materials, precision is not just an advantage – it is a necessity. This is especially true of fibre composites, which form the backbone of many advanced structures – from wind turbine blades to aircraft components.
The FiberRadar project, carried out by the Fraunhofer FHR in collaboration with the Ruhr University Bochum, Aachen University of Applied Sciences and Aeroconcept GmbH, opens a new chapter in the precision inspection of the production of these key components.
Until now, diagnostic methods in composite production – mainly based on ultrasonic testing – have detected anomalies only after the moulding process has been completed, which not only limits the possibilities for a quick reaction, but also leads to high rework costs or the complete scrapping of components. FiberRadar turns this logic 180 degrees.
Through the innovative use of high-resolution millimetre-wave radar imaging, it is possible for the first time to provide a three-dimensional representation of the fibre orientation before it is impregnated with a resin matrix.
This is a key moment in the process – it allows errors to be detected before they become irreversible. What’s more, the technology being developed not only allows the process to be monitored in real time, but can also be integrated with robotic systems to create a fully automated and monitored production chain.
The strength of the project lies in its interdisciplinarity: advanced algorithms from the Fraunhofer FHR, radar know-how from the University of Bochum, robotics competence from the Aachen University of Applied Sciences, and Aeroconcept GmbH’s practical experience in the composites industry all combine to create a system that already promises to be a milestone in quality control in composites production.
Results of initial preliminary tests at 80 GHz / © Fraunhofer FHR
