THE FORWARD ACADEMY

The demands that modern, sustainable products must meet are constantly rising. Apart from aspiring
more functionality and comfort, there are more and more legal requirements, e. g. emission limits or weight targets.
Lightweight construction is an important solution approach in meeting these challenges. Materials such as carbon
reinforced polymers (CFRPs) show higher weight specific strengths and stiffnesses compared to traditional
construction materials like aluminum and steel and have a great lightweight potential. In order to use
this potential, qualified knowledge about the properties of anisotropic composite materials, their wide variety
of production methods and their constructive design guidelines is important.

The Forward Engineering Academy passes on this knowledge to their customers, with the aim of
effectively strengthening composite technologies in the industry.


BASIC TRAINING COMPOSITE MATERIALS

Learning goal:
You will get an extensive overview on the industrial application of composite materials, especially CFRP, in automotive construction and the
industry. Practical examples and several exhibits support the interactive training. The seminar is adressed to engineers and technicians.

Programme:
Introduction: Motivation of composite lightweight construction and applied lightweight construction strategies.
Getting familiar with the raw materials of a composite material: Fiber types, textile semi-finished products and matrix systems.
Fiber-matrix-composite system: Properties and special characteristics of a customized, anisotropic composite material compared to
conventional materials.
From the fiber to the preform to the part: Basics of the various manufacturing methods of composite parts depending on part complexity and
quantity.
The right material in the right place: construction methods and strategies for implementing composites in automotive construction.
Repair and recycling: Identification and repair of defects in composite parts. Exploitation options and recycling of high value carbon fiber waste.


ADVANCED TRAINING COMPOSITE MATERIALS

Learning goal:
Enhanced knowledge in development and calculation is conveyed.
The participant learns how to design and construct a composite part in a process appropriate manner.
The two-day seminar is adressed to development engineers

Programme:
Classical laminate theory
MeChanics of composite materials
Lay-up design
Construction guidelines, process appropriate dimensioning and construction
Calculation and dimensioning of a composite part, process simulation and joining technique


FIBERSIM TRAINING

Learning goal:
Fibersim is an extensive software, taking into account the whole development process of composite materials – from the conception,
laminate definition and lay-up to simulation and documentation to manufacturing. In this user-oriented FiberSim training,
knowledge about preliminary design, detailing and manufacturing composite parts, considering production conditions, are conveyed.
Paramount is handling the software. The multi-day seminar is adressed to designers and development engineers

Programme focus points:
Introduction to Ply Based-Design:
Defining laminates and choosing the most appropriate lay-up methods, including layer based and zone based designs

Producibility:
Simulation of the manufacturability of parts based on the material and manufacturing process

Introduction to Multi Ply-Design:
Automatic generation of layer geometries by defining layer overlaps with gradual, staggered and shifted profiles

Documentation:
Assessment and transfer of development requirements by automatic generation of development documentations (e.g. Microsoft Excel charts)

Manufacturing Features:
Automatic generation of production documentation for factory instructions
Automatic generation of production data – e. g. Flat Patterns and data for automated cutting machines,
laser projection systems, fiber and tape placement systems – and company-wide exchange with subsequent positions


Academy

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