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Composite Material Optimization

    Within EPFL-Alinghi project, processing optimization of composite materials.

    The yachts in a race such as the America’s Cup pose great technological challenges. Top performance on water to leave competitors behind requires, among other things, cutting-edge technology to push current limits. Alinghi’s hulls and various structures are made of a rigid, strong and incredibly light composite material. These parts must be reliable to withstand the merciless duels between competing yachts in extreme sailing conditions.

    The way in which the various materials interact is referred to as a “composite sandwich” because it is made up of two thin and stiff fiber-reinforced faces with a thick and very light honeycomb core. The production process for this composite sandwich involves several steps. Over the years, the Laboratory of Polymer and Composite Technology (LTC) has developed the process in close cooperation with Decision SA so as to optimize material performance.

    One of these stages was the integration of fiber optics into the sandwich structure to produce “intelligent” materials, able to provide data on the yacht’s performance. This is all the more essential since the huge dimensions of the new yacht will have to withstand great strains - which must be measured in real time. Due to the yacht’s unusual size, EPFL provided Alinghi with the required equipment and skills to test large structures. In parallel, non-destructive testing techniques were developed in collaboration with the Haute Ecole d'Ingénierie et de Gestion du Canton de Vaud (HEIG-VD) to assess the “health” of the composite sandwich over time.

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