Smart production technology for complex fiber composites. Automated 3D fiber layup concepts for aerospace based on Fiber Patch Placement technology

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1 Smart production technology for complex fiber composites Automated 3D fiber layup concepts for aerospace based on Fiber Patch Placement technology Thorsten Groene, CEO & Co-Founder Composites Europe November 7, 2018 October

2 Complex composites still manufactured by hand! Long production cycles No effective quality control High scrap rate >30% High cost Need for automation solutions? October

3 Fiber Patch Placement Additive 3D fiber lay-up technology for complex composites SAMBA Series Automated production cells Benefits ARTIST STUDIO CAE software for part design & production Digitized, automated process chain 100% in-process raw material check Multi-material layup capability up to 50% material and cost savings October

4 October

5 The Cevotec process Fiber Patch Placement (FPP) additive manufacturing for complex fiber composites Enabling a fully automated, quality-controlled 3D layup for complex composites October

6 The Cevotec patch gripper Adapting to complexity Controlled fiber deposition on concave & convex surfaces Example: Patch Placement onto a honeycomb sandwich core Key for automated fiber placement on complex surfaces October

7 Key enabler: the Cevotec patch process Only the patch process enables high-complexity parts with cost-efficiency and volume capabilities. effort / cost Only Patch Technology enables Continuous fiber process Continuous fiber complexity barrier Automated complex direct 3D layup Processing multiple materials in parallel Discontinuous / patch process Locally load-optimized layup design part complexity 100% in-process raw material control October

8 Focus industries and applications Focus industries Primary applications Aerospace Multi-material components Automotive Medical, industrial Complex geometries Sports Additional Tailored reinforcements October

9 SAMBA Series Additive 3D fiber lay-up systems. Tailored to your requirements. Modular, scalable systems Material feeding & cutting e.g. laser, ultrasonic, mechanical Quality control cameras incl. image processing computer Robot with patch gripper e.g. 4-axis pick & place, 6-axis robot Tool manipulator e.g. 6-axis robot, tilting rotator, linear table SAMBA Pro flexible series production SAMBA Scale high-throughput production SAMBA Multi carbon, glass and other fibers SAMBA Step entry to patch technology All systems available in dry fiber and thermoset-prepreg configurations October

10 SAMBA Multi Patch-based, multi-material layup for aerospace parts. Different materials and varying gripper sizes in the same process. Ideal for sandwich structures. October

11 Industry 4.0 automation with Fiber Patch Placement Continuous process & quality control with a multitude of integrated sensors for key process parameters Real-time production data analysis and comparison with a database of previously processed patches Interfaces for integration into existing process control landscapes Controlled deposition process Temperature Pressure Compaction time Contact time from pick-up to deposition Station for in-process gripper exchange Automated detection for contamination Controlled tape feeding Temperature for material storage Controlled tape pull-off Automatic tape positioning to centricity Vision control patch Width Length Cutting edge Waviness Vision control patch position Position Orientation Self-correction process for precise deposition Global parameters: Temperature & humidity in manufacturing cell Frequency of patch deposition Cycle time Mass throughput Objective: Replace individual unit tests by continuous process monitoring October

12 Case Study: Operating box cover with Premium Aerotec Results from BMBF-supported project IMPULS Challenge: Automated layup of operating box cover Material: Results: Hexcel M21E pregtow (1/2 inch width) virgin residuals from M-Torres AFP machine Weight -70%, Cost -75% (to actual version of the part) Looking forward: Continuous, automated process blueprint for high complexity parts New options for manufacturers already using AFP / ATL systems Significant material cost savings from re-purposing AFP left overs Material cost savings Throughput AFP: 25 kg/h Volume p.a. [kg] AFP residual material Value p.a. [ ] AFP residual material Material: 100 /kg % FPP repurposing 2,5% 5,0% 7,5% 10,0% % FPP repurposing 2,5% 5,0% 7,5% 10,0% Daily production: 18 h 60% % Yearly production: 250 days 70% % OEE: 80% 80% % Note: figures only illustrative. 90% % October

13 SAMBA Series for urban air mobility Mastering production ramp-up with Fiber Patch Placement. The urban air mobility growth challenge Demand forecast highly uncertain Early decisions on part design & production process BUT: economics highly depend on volume Patch technology: scaling through ramp-up efficiently Fast & easy tool and set-up change batch production economical Flexible systems at ramp-up dedication of systems with volumes Laminate & process unchanged no costly re-qualifications Scalable production set-ups cut re-qualification efforts as build rates increase October

14 ARTIST STUDIO CAD-CAM software for patch technology Incl. export of patch laminate for FEM simulation October

15 Plug-in for commercial FE software Plug-in Enabling for HyperMesh FE analysis on sublayer & patch level, accurately predicting mechanical properties Enabling FE analysis on patch- & sublayer level October

16 Comprehensive CAE software suite for Fiber Patch Placement Enabling a continuous virtual process chain FEA Artist Studio Plug-in for commercial FE-Software CAD PATCH ARTIST Modeling & Simulation of mechanical behaviour (stiffness, strength) CAM MOTION ARTIST Patch-based laminate generation Offline robot programming October

17 The Cevotec portfolio The one-stop partner for patch-based production equipment & software Production systems SAMBA Series CAE software ARTIST STUDIO Patch technology services & products Development, production, spread tow, gripper Direct 3D fiber lay-up systems Tailored configurations Full automation incl. laminate handling CAD-CAM for patch technology Export of laminate for FEM Perfectly matches SAMBA systems Product development, prototyping & series production CAE analysis & FEM-based optimization Customized fiber spread tow and patch grippers Automation solutions for complex fiber lay-up October

18 Find us in hall 9 booth E60e Showcase parts on Lightweight Technologies Forum Fiber Patch Placement enables 100% in-process raw material input control multi-material layups complex geometry layup, also on sandwich cores re-purposing virgin left-over AFP tapes efficient and flexible scaling of production volumes Virtual process environment fully developed Cevotec is your one-stop-shop partner for Fiber Patch Placement technology contact us! Thorsten Groene CEO Phone: thorsten.groene@cevotec.com We enable manufacturers to produce complex composites in high volume and superior quality. For a lighter, more sustainable future. October

19 Annex

20 Bionic lightweight design Motivation for Fiber Patch Placement technology Natural Fibrous Structures Technical Structures Leaf Tree trunk Human bone Airport hall Curvilinear carbon fiber orientation Topology optimized chassis Fibers follow curved paths Transferring the principle to lightweight construction New curvilinear textile technologies Fiber Patch Placement Direct fiber patch placement on 3D geometry or along 3D load paths October

21 Massive drop in strength of classical laminates Average fiber-to-load deviation is significantly reduced with Fiber Patch Placement Fact Multiaxial non-crimp fabrics such as quasi-isotropic lay-ups cannot exploit the full potential of the material. Example Only 15 deviation to a tensionbased load path leads to an extremely reduced strength (>80%) Patch layup supports optimal lightweight design October

22 Rel. strength Rel. strength Patch laminate architecture for optimized strength Laminate optimization with comprehensive CAE software suite for Fiber Patch Placement Fact Composite materials have a lot of parameters which can be optimized: Fiber direction Thickness Layer order Overlap Fiber overlap Fiber direction Main performance driver FPP: load-path oriented fiber direction patch overlap pattern. Strength of continuous fiber 20 25% 75% 78% Patch layup enables high lightweight design potential >50% better mechanical properties than conventional laminates Optimized patch layup increases the strength Overlap pattern Only 15 deviation reduces >80% of fiber utilization. October

23 210 mm 2.5x stiffness increase with load-optimized patch laminate High performance lightweight design with Fiber Patch Placement Mass-specific stiffness [kn/(mm g)] F F ,3 12,35 13, % ,23 5,31 5, F 150 mm F 1 0 simulation specimen 1 specimen 2 simulation specimen 1 specimen 2 quasi Quasi-isotropic isotropic lay-up FPP lay-up Optimized patch lay-up Source: Cevotec and Technische Universität München October

24 2.2x strength increase through curvilinear fiber orientation Demonstration at an open hole specimen Biaxial non-crimp fabrics Load path oriented fibers (patch basis) F Mass-specific maximum strength +120% F F F Source: O. Meyer, Short fibre preform technology for load path aligned manufacturing of fibre reinforced plastic components, Doctoral thesis, University of Stuttgart, 2008 October

25 SAMBA Pro Thermoset prepreg configuration Application areas Mid-size to small complex components Reinforcements, also in high-volume production Replacement of manual lay-up operations Repurpose AFP virgin material left-overs October

26 SAMBA Scale Line Patch-based, high-volume 3D fiber lay-up for complex components. Throughputs of 100+ kg/h. Hybrid materials (e.g. glass & carbon fiber). October

27 Automated handling of SAMBA fiber laminates End-to-end automation for complex fiber laminates in series production Automated removal from mold Innovative tooling concept for first ply release Standard gripper equipment for lifting and transport Increase output and maximize productivity of the SAMBA systems October

28 Integration of SAMBA in industrial composites lines Patch technology: decrease cost and improve product performance October

29 From the press (selection) Complete press review: Additive Fertigung der nächsten Generation Fiber Patch Placement mit dem Roboter May 11, 2018 Direct 3D-preforming with Fiber Patch Placement May 10, 2018 (p ) Fiber Patch Placement at scale February 09, 2018 Mit Fiber Patch Placement zum komplexen 3D-Bauteil September 06, 2017 Cevotec presenta l imbuto di finestra al progetto Fiber Patch Placement del Paris Aviation Show July 05, 2017 Cevotec Samba: software en robotcel voor 3D composietdelen March 13, 2017 Industry 4.0 for carbon composites October 4, 2016 Fiber Patch Placement machine, software April 19, 2017 Exclusive preview of SAMBA preforming demo March 6, 2017 Durchbruch in der Composite-Produktion September 23, 2016 Cevotec celebrates successful market launch at JEC World 2017 March 28, 2017 A crowded house of composites March 6, 2017 Automatisierungsgrad stark erhöht Fertigungsautomation Industrial Fibre Patch Placement machine and software Fiber patch preforms help tailor kiteboard performance December 16, 2016 March 16, 2017 January 28, 2016 October

30 Cevotec GmbH Willy-Messerschmitt-Str Taufkirchen b. München Phone Fax info@cevotec.com