Smart production technology for complex carbon composites SAMBA & ARTIST STUDIO. The advanced production solution for complex fiber preforms July 2017

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1 Smart production technology for complex carbon composites SAMBA & ARTIST STUDIO The advanced production solution for complex fiber preforms July

2 The challenge in composites manufacturing Complex composites still manufactured by hand Specialists required for development and production Long production cycles No effective quality control Need for automated production solutions? 2

3 Fiber Patch Placement Additive preforming technology for complex fiber composites 3

4 The Cevotec solution Fiber Patch Placement (FPP) automated 3D preforming for complex fiber composites 4

5 SAMBA Automated 3D preforming system ARTIST STUDIO CAD-CAM software for patch technology Patch Artist CAD module Motion Artist CAM module Fiber Patch Placement additive manufacturing for complex fiber composites Innovation Additive manufacturing in sensible increments Disrupting the endless fiber paradigm Industry 4.0 powerful software enables hardware Benefits End-to-end automated process Continuous quality protocol 150% higher strength & stiffness 25% less material & weight 5

6 Main application areas Broad range of applications across industries Complex geometries Tailored reinforcements Design surfaces 6

7 The Cevotec portfolio Your one-stop partner for patch-based production technology Production systems SAMBA CAD-CAM software ARTIST STUDIO Technology services Engineering, manufacturing, consumables Automated 3D preforming system Individual configuration options Software for patch technology Perfectly matches SAMBA Product development, prototyping and manufacturing Customized fiber spread tow and patch grippers The best production solution for complex fiber composites 7

8 SAMBA Automated 3D preforming system based on Fiber Patch Placement technology System modules Patch feeding unit with laser cutter Industrial quality control cameras 4-axis pick & place robot with patch gripper 6-axis industrial robot for preform tool handling Dust and gas suction with appropriate filter Standard configuration Rofin PowerLine F50 laser Imperex Cheetah C MP cameras Ultra-fast Stäubli TP80 picker High-load and precision Stäubli TX200 manipulator Mounted on metal ground plate for safe shipping and easy set-up Technical features Tape width: mm Patch length: mm Patch areal weight: g/m² Placing accuracy: < ±0.3 mm Placing frequency: +1 Hz Fiber throughput: 2.5 kg/h Individual configurations Tailored combination of patch modules Individual patch sizes & areal weights Throughput up to 100 kg/h possible in cooperation with 8

9 ARTIST STUDIO CAD-CAM software for patch technology Standalone software platform for a continuous process from CAD to machine data. Two perfectly aligned modules: Patch Artist Generates high-performance laminates Enables complex and curvilinear fiber orientations Optimizes patch overlaps and positions Works with all CAD file formats Motion Artist Generates machine data for SAMBA Simulates the production process, incl. collision detection Optimizes robot movements Performs offline programming of SAMBA robots Outlook: Additional modules with FE-based functionalities to be added in future versions of ARTIST STUDIO 9

10 The Cevotec patch gripper Adapting to complexity Available in tailored sizes The key for automated fiber placement on complex shapes 10

11 Automated handling of SAMBA fiber preforms End-to-end automation for complex preforms 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 system 11

12 Integration of SAMBA in industrial composites lines Patch technology: decrease cost and improve product performance 12

13 milestones in composites Founded 2015 in Munich, Germany Spin-off from Institute for Carbon Composites, TU München Located on Ludwig-Bölkow Innovation Campus Strategic partners: Airbus, Baumann Automation Cevotec Founders and Management Thorsten Groene, Felix Michl, Dr. Neven Majic We enable manufacturers to produce complex composites in high volume and superior quality. For a lighter, more sustainable future. Supported by a strong network 13

14 From the press (selection) Complete press review: 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 Cevotec, Baumann announce partnership to industrialize FPP September 16, 2016 Automated production of complex carbon composites March 23, 2017 Automatisierungsgrad stark erhöht Fertigungsautomation December 16, 2016 Fiber patch placement at JEC 2016 March 9, 2016 Industrial Fibre Patch Placement machine and software Cevotec brings virtual reality to Composites Europe Fiber patch preforms help tailor kiteboard performance March July , 2017 November 22, 2016 January 28, 2016 milestones in composites 14

15 Smart production technology for complex carbon composites End-to-end automation for complex fiber composites Increase of stiffness & strength with less material & weight Production systems & software & services Cevotec milestones in composites Check with us if your product qualifies for the advantages of patch-based production. Call us at or send us an to

16 Annex

17 Bionic lightweight design Motivation for Fiber Patch Placement technology Natural Fibrous Structures Technical Structures Leaf Tree trunk Human bone Hall construction airport Stuttgart 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 patch placement on 3D geometry or along 3D load paths 17

18 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%) No optimal lightweight design 18

19 210 mm milestones in composites 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 Optimized FPP lay-up patch lay-up Source: Cevotec and Technische Universtität München 19

20 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,

21 20% weight decrease with patch reinforcements Load-path oriented reinforcements reduce material, weight and cost Quasi-isotropic lay-up Lay-up with FPP patch layers M T M T unidirectional layers FPP FPP 4 unidirectional layers with 2 FPP patch-layers M T M T 8 unidirectional layers 4 unidirectional layers + 2 FPP Lagen 20% weight reduction 21

22 Fiber Patch Placement: End-to-end automation for complex fiber composites Comparison of processing technologies by degree of automation and geometrical complexity Degree of automation Complexity with ease Autom. tape laying Automated fiber placement Fiber Patch Placement Small radii, 90 angles Strongly convex / concave Undercuts Direct 3D net shape preforming End-to-end automation Tailored fiber placement Complexity of fiber laminate Digital product development and production simulation. 10 axis robot deposition system Automated handling of preforms Highly efficient hand laminate Material savings: > 25% Scrap reduction: > 50% Short set-up times Automated quality inspection 22

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24 Local reinforcement for holes / joints Sample application Shear stress reinforcement Extreme low weight (1-3 g) Unique and attractive optic Easy to handle in automated and manual processes Sticks to preforms via binder No material scrap during manufacturing Very good load distribution in component Higher increase of bearing strengths compared to conventional reinforcements Geometry tailored to customer requirements Dry fiber reinforcement patch Application of reinforcement patch at bolt joint 24

25 Medical orthosis Sample application Medical orthosis Advanced geometry Undercuts Small radii Net-shape preforming Local thickening at critical areas Tailored stiffness by fiber design 25

26 Bicycle saddle Sample application FPP bicycle saddle Extreme low weight (<70 g) Unique and attractive optic Net shape preforming Local thickening at critical areas Stiffness tailored to customer requirements 26

27 Unique design and aesthetics Sample application FPP bicycle saddle Radially arranged, 60mm long patches with round cutting edge Scale-like pattern Tri-directional patch orientation Variable patch length with straight cutting edge 27

28 Cevotec carbon fiber tape Unidirectional, bindered carbon fiber tape produced with online quality control Technical specifications Currently available fiber material: Tenax: HTS40, HTS45, IMS65 Toray: T300, T700 additional fibers on request Areal weight: g/m2 Tape width: mm Flexibility: areal weight, tape width and thickness are coupled via the fiber material Binder material: Spunfab binder: PA1541, PA1300 powder binder on request Storage: on reel, separated with non-adhesive paper film Produced with online quality control: guaranteed low tolerances in tape width Cevotec carbon fiber tape Uniform distribution of binder material 28

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