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Optimization of Materials and Manufacturing Processes

    Within EPFL-Hydros project, processing optimization of composite mate.

    The pressure exerted on a foil can be two times higher than on a fighter jet. Keeping in mind that the boat must be as light as possible and have the thinnest possible profile to meet aerodynamical constraints, one quickly sees the magnitude of the challenge. High level research on manufacturing and assembly is thus indispensable, from the microscopic scale to the overall structure of the boat. Results obtained were transferred to the design team to be used in the development and construction of l'Hydroptère.ch.

    The manner in which the various materials are combined is reflected in the name for the assembly: the composite sandwich. It's a thick honeycomb structure covered with very thin layers of reinforced carbon. Manufacturing these composite sandwiches is done in several steps. The smallest imperfection can lead to catastrophic breakage. EPFL's Laboratory of Polymer and Composite Technology (LTC) , in close collaboration with the Design Team and the shipbuilder responsible for manufacturing the components of the boat, has conducted studies to improve the reliability of components and their assemblage. The goal is to improve performance and reduce weight while avoiding breakages.

    Novel composite materials known as Thin ply technology have been applied for the very first time on boat hulls by the Hydros design team for their participation in the Little Cup in 2013. The Laboratory of Applied Mechanics and Reliability Analysis (LMAF) was involved in studies conducted with the material supplier.

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