This approach results in a generic use case that is displayed at Formnext 2023. It consists of a carbon fibre/epoxy composite shell structure with a functional PEI layer. The latter allows for a rigid joint when printing functional elements onto the base structure using high-performance polymers. In this specific case, a short fibre-reinforced PEI is used to create a stiffening rib structure, while continuous fibre-reinforced PEEK strengthens selected load paths.
The EmpowerAX demo part shows an industrially available process chain for additive functionalisation. It does not only show the way from topology-optimised design to the physical printing process, it also establishes a digital process chain from conception to non-destructive testing.
Highlights of the demo part feature the following:
- SWMS Systemtechnik’s innovative path planning approach – integrated in the CAESA environment – which does not require repositioning and can navigate the optimised rib structure in a “House of Santa Clause” fashion.
- Hans Weber Maschinenfabrik’s highly effective additive extrusion process that can reliably deposit a high throughput of fibre-reinforced high-performance polymers
- A joint effort of SWMS and Weber’s additive team, in which the printing process has been imaged digitally and conducted physically on a double curvature shell, using full capacity of a 6-axis-robot
The EmpowerAX demo part is an excellent example of a beneficial collaboration targeting additive functionalisation by overprinting.
The speakers are:
Marc Loegel, Team leader composites and additive, SWMS Systemtechnik Ingenieurgesellschaft mbH
Erik Johannsen, Research associate, German Aerospace Center - DLR
- Aviation and aerospace