The automatic preforming and lamination process involves core materials, as well as continuous AFP (automated fiber placement) and patch FPP (Fiber Patch Placement) reinforcements.
Fiber Patch Placement (FPP) is an automatic preforming and lamination technology that is mainly used in the production of aerospace and automotive parts, as well as the production of complex fiber reinforced composite parts used in medical and sports equipment. FPP cuts the reinforcement material into certain patches and automatically applies these patches to the tool. The obtained 3D complex-shaped laminate can be a dry reinforced part infused or cured with resin, or a prepreg, which can be heated and then cured into a finished part. Working closely with leading aerospace parts manufacturers, Cevotec has further developed FPP technology to meet the latest industry requirements.
Automatic aviation sandwich structure
Cevotec has developed the SAMBA Multi production system to produce complex sandwich structural components by applying complex material mixtures (such as adhesive films, fiberglass and carbon fiber layers) to commonly used sandwich cores (such as aluminum honeycombs). "The SAMBA Multi system is capable of automatically laying this multi-material mixture in a single production system," reports Felix Michl, Cevotec's chief technology officer. In addition to fiberglass wool, metal structures and wood cores (such as balsa wood), SAMBA Multi can also apply load-regulated fiber patch reinforcements to honeycombs, foams, and other core materials. According to process requirements, these processes can be produced online or in parallel with the production line, which can greatly optimize the production cycle time.
SAMBA Multi has parallel units for conveying different materials and then placing them precisely on a 3D core or pre-formed tool. By mounting the FPP unit on a linear shaft, it is also possible to produce long and wide special parts for aerospace applications. The mounting fixture is suitable for specific component sizes. The mounting fixture has been scaled to DIN-A5 and DIN-A4 sizes to meet the requirements of ordinary aircraft components. An integrated clamping station allows fixture changes during this process.
"The automated multi-material layup of complex sandwich materials has a very positive impact on processing time and throughput," explains Thorsten Groene, general manager of Cevotec. "By controlling the pressure and heat for fiber deposition, intermediate pressure can be avoided and the processing time can be greatly reduced." Groene added that FPP can continuously reduce repetitive production costs in many applications. "Saving 20-50% of materials plays a major role in reducing costs, but FPP automation technology can often further optimize the entire process."
The SAMBA Multi production line can also be expanded. Michl explained that the same process works hundreds to thousands of units each year. For example, the scenario expected in the budding "flying car" industry. "With rapid system changes and short set-up times, product changes on the system do not cause any problems, and are economical and reasonable: During the upgrade process, the capacity of the FPP system can be used for multiple components. As the number increases, the machine park Over time, the system will become more specialized. The advantage is that the production process remains the same, which means there is no need to develop new products and re-certify parts. "
Combining AFP and FPP laminates
Someone asked whether Cevotec could merge the FPP and automatic fiber placement (AFP) processes. "Yes," said Dr. Neven Majic, executive vice president of Cevotec. "We are currently expanding our ARTIST STUDIO software to accommodate the functionality of the laminate design of endless fiber tapes used in the AFP process. The new module TAPE ARTIST will be seamlessly integrated into the ARTIST STUDIO production system and will be performed using MOTION ARTIST Machine data generation and process simulation. "TAPE ARTIST can also be combined with PATCH ARTIST into a single joint module, enabling engineers to design integrated laminates based on AFP and FPP technology.
Like SAMBA Multi, TAPE ARTIST will be available this fall at Composites GoCarbon Fiber (October 9-11, Berlin, Germany), Advanced Engineering (October 31-November 1, Birmingham, UK) and Composites Europe (November 6th to 8th, Stuttgart, Germany) to the public and will be listed at the end of this year.