Generative manufacturing processes, such as 3D printing, are enabled of rapid prototyping of different kinds of mechanical parts. This improvement from traditional manufacturing process leads to a new design freedom and functionalities. However, open-market 3D printers for thermoplastics are black-box solutions, limited to layer wise prints resulting in parts sensitive to multi-dimensional stress and inhibit further codeoptimization. Therefore rapid prototyping models are mainly used to visualize design concepts. Especially within the field of lightweight engineering the merge of manufacturing technologies (3D printing) and material science (continuous fiber reinforced composites) is far from tapping the full potential. The main technological objective of the project is the development of a robot cell for the 3D printing of fiber reinforced lightweight materials such as carbon, glass, aramid and natural fibers. The core of innovation is characterized by the adaption of a 6-axial robotic arm with the extrusion technology and a fiber manipulator. This novel technology provides a multi movable object 3D printed composite material (MMO3D) with remarkable material properties.
• Additive production of high-performance fiber composites components
• Adaptation of a 6-axis industrial robot to align reinforced fiber in all 3 dimensions of force flow
• Show the innovative technology on a demonstrator (Corner Joint of battery box for an electric car)
• Portable unit design for demonstration and learning purpose
The overall objective of the project is, on the promising fields of mechanical engineering and robotics, to connect competent R&D stakeholders and existing knowledge in the program area and encourage the transfer of technology and expertise for developing new products, technologies and services, and thus contribute to improving economic cohesion, technological development, innovation and competitiveness in the programming area.
• Mechanical and microstructural material characterization
• Mechanical calculation (Classical Laminate Theory, CLT)
• Characterization of the layer geometry
• Control of process parameters
• FEA Simulation (AnsysACP-PrePost)
• Experimental validation of material properties and component strength at multi-dimensional stress state