MANZ AG
FULLY AUTOMATED PREFORM PRODUCTION OF COMPLEX GEOMETRY
CFRP PARTS USING FIBER-PATCH-PREFORMING TECHNOLOGY
JUNE 25t...
2011-07 2
 MARKET TRENDS
 COST VIEW FRP-PRODUCTION
 3D-FPP - FIBRE PATCH PREFORMING
FIBER-PATCH-PREFORMING
STRUCTURE
1
2011-07 3
Sports / Leisure
Indicators for a Growing FRP-Market:
 BMW founds a new brand »BMW i«
and built up a carbon fib...
2011-07 4
Requirements on serial FRP-parts
 Quality/ performance requirements
 Stresses
 Crash
 Geometry
 Surface fin...
2011-07 5
 MARKET TRENDS
 COST VIEW FRP-PRODUCTION
 3D-FPP - FIBER PATCH PREFORMING
STRUCTURE
2

FIBER-PATCH-PREFORMING
2011-07 6
Cost Structure of High Quantity FRP-Parts (Example Saddle)
Number of items 20.000
Write off time (5 %) 5 Year
Pe...
2011-07 7
Cost Structure of High Quantity FRP-Parts (Example Saddle)
Number of items 100.000
Write off time (5%) 5 Year
Pe...
2011-07 8
Material Efficient  Reliable processes with low scrap rates
 Low level of waste
 Material saving processes
 ...
2011-07 9
 Fiber/matrix production
 Pre impregnation
 Cutting
 Handling
 Transport/logistics
 Pick and place
 Autom...
2011-07 10
 MARKET TRENDS
 COST VIEW FRP-PRODUCTION
 3D-FPP - FIBER PATCH PREFORMING
STRUCTURE
3


FIBER-PATCH-PREFOR...
2011-07 11
3D-FPP - Demonstrated on a Saddle
3D-FPP - NEW PREFORM TECHNOLOGY
 Production process for small FRP-parts
 Pa...
2011-07 12
Process
simulation
3D laminat
placement
CAD model
& load case
Resin injection
& cross linking
Load optimized
3D...
2011-07 13
FIBER-PATCH-PREFORMING
3D FPP - NEW PREFORM TECHNOLOGY
2011-07 15
Standard tailored fabrics More than 30% material saving against
standard processes
A AA
A-A
A BB
B-B
Material s...
2011-07 16
Less waste than 5 % of carbon fiberMore waste than 30 % of carbon fiber
Low level of waste (near-net-shape)
FIB...
2011-07 17
Material Efficient  Reliable processes with low scrap rates
 Low level of waste
 Material saving processes
...
2011-07 18
Local reinforcements
(window frame, hole reinforcements, etc.)
Shell structures
(saddles, wheels, motor cover, ...
2011-07 19
THANK YOU TO:
FPP - FIBER PATCH PREFORMING
 Federal Ministry of
Education and
Research (BMBF)
for supporting t...
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Fully Automated Preform Production of Complex Geometry CFRP Parts using Fiber-Patch-Preforming Technology

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The preforming-infiltration process chain enables the use of low-cost dry fiber materials, highly automated processes and has a high potential to significantly reduce the manufacturing costs of composite structures. Fiber-Patch-Preforming (FPP) is a novel process for automated preform manufacturing of complex geometry parts. The developed preforming robot system enables the positioning of unidirectional carbon fiber patches at any position and orientation on a preforming tool. FPP enables a unique laminate design and offers the possibility to locally tailor product properties through fiber orientation and part thickness. Thereby the process aims to reduce manufacturing costs and reduce structural weight. Main applications are medical technology, aviation as well as sports and leisure industry.

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Fully Automated Preform Production of Complex Geometry CFRP Parts using Fiber-Patch-Preforming Technology

  1. 1. MANZ AG FULLY AUTOMATED PREFORM PRODUCTION OF COMPLEX GEOMETRY CFRP PARTS USING FIBER-PATCH-PREFORMING TECHNOLOGY JUNE 25th, 2014 / MARTIN STEYER
  2. 2. 2011-07 2  MARKET TRENDS  COST VIEW FRP-PRODUCTION  3D-FPP - FIBRE PATCH PREFORMING FIBER-PATCH-PREFORMING STRUCTURE 1
  3. 3. 2011-07 3 Sports / Leisure Indicators for a Growing FRP-Market:  BMW founds a new brand »BMW i« and built up a carbon fiber production plant  Joint ventures between BMW-SGL Carbon, Daimler-Toray and Audi-Voith  German government supports FRP-development with 300 Mio. € MARKET TRENDS Aerospace E-Cars [Quelle: BMW, Madzda, Porsche, Mercedes, Fiberglastechnik] Reasons for FRP-Use in Automotive Industry  Reducing fuel/ energy consumption (1 liter car VW)  Increasing range (electric vehicles)  Increasing crash-behavior (Audi A8 frontend)  Increasing driving dynamics (Porsche GT 3)  Design possibilities (7er BMW trunk lid) FRP – meets serial production!? Leaf spring Mercedes Sprinter Cardan shaft Monocoque Porsche GT3 FIBER-PATCH-PREFORMING
  4. 4. 2011-07 4 Requirements on serial FRP-parts  Quality/ performance requirements  Stresses  Crash  Geometry  Surface finish MARKET TRENDS  High load capacity  Best crash behavior  Good formability  Up to class-A finish        New cost efficient processes need to be developed  Costs  Personal costs  Material costs  Process costs  High level of manual work  High costs for carbon fiber  Long cycle times     FIBER-PATCH-PREFORMING
  5. 5. 2011-07 5  MARKET TRENDS  COST VIEW FRP-PRODUCTION  3D-FPP - FIBER PATCH PREFORMING STRUCTURE 2  FIBER-PATCH-PREFORMING
  6. 6. 2011-07 6 Cost Structure of High Quantity FRP-Parts (Example Saddle) Number of items 20.000 Write off time (5 %) 5 Year Personal costs 40.000 €/Year Number of shifts 1 (8 h) Machine availability 90 % Etc. … 1 2 3 4 Material costsPersonal costs Variable costs (energy, maintain, etc.) Investment costs Shares of Production Costs 45% 28% 18% 9% COST VIEW FRP-PRODUCTION Material price Material consumption 1 2 Automation3 FIBER-PATCH-PREFORMING
  7. 7. 2011-07 7 Cost Structure of High Quantity FRP-Parts (Example Saddle) Number of items 100.000 Write off time (5%) 5 Year Personal costs 40.000 €/ Year Number of shifts 3 (8 h) Machine availability 90 % Etc. … COST VIEW FRP-PRODUCTION FIBER-PATCH-PREFORMING Shares of Production Costs Personal costs 4 % Variable costs 2 % Investment costs 4 % 90 % Material costs Material price Material consumption 1 2
  8. 8. 2011-07 8 Material Efficient  Reliable processes with low scrap rates  Low level of waste  Material saving processes  Material saving product design (load optimized laminate design) High Level of Automation  Short cycle time  Cost effective systems  Cost efficient tools/ molds Saving Variable Costs  Energy effective processes  Robust systems (maintain)  Processes with low operational material consumption Cost Effective FRP-Processes for Serial Production COST VIEW FRP-PRODUCTION FIBER-PATCH-PREFORMING
  9. 9. 2011-07 9  Fiber/matrix production  Pre impregnation  Cutting  Handling  Transport/logistics  Pick and place  Automated preforming/ draping  Bindered preforming  Organo sheet preforming  Pre consolidation  Mold loading  Press/injection (RTM) (consolidation)  Tool and die manufacturing  Press production  Demolding and storing Manz Production Systems and Processes within the FRP Manufacturing Chain: USP PreformingFRP-PROCESS CHAIN FIBER-PATCH-PREFORMING
  10. 10. 2011-07 10  MARKET TRENDS  COST VIEW FRP-PRODUCTION  3D-FPP - FIBER PATCH PREFORMING STRUCTURE 3   FIBER-PATCH-PREFORMING
  11. 11. 2011-07 11 3D-FPP - Demonstrated on a Saddle 3D-FPP - NEW PREFORM TECHNOLOGY  Production process for small FRP-parts  Parts with highest light weight potential  Material efficient  Fully automated process  Short cycle time  High flexibility Licensed by Airbus FIBER-PATCH-PREFORMING
  12. 12. 2011-07 12 Process simulation 3D laminat placement CAD model & load case Resin injection & cross linking Load optimized 3D-FRP-part Optimized product design and fiber architecture SOWEMA- Software-, Werkzeug- und Maschinenentwicklung für eine vollautomatische und geschlossene Leichtbau-Fertigungskette FIBER-PATCH-PREFORMING 3D-FPP - NEW PREFORM TECHNOLOGY Video
  13. 13. 2011-07 13 FIBER-PATCH-PREFORMING 3D FPP - NEW PREFORM TECHNOLOGY
  14. 14. 2011-07 15 Standard tailored fabrics More than 30% material saving against standard processes A AA A-A A BB B-B Material saving area COST SAVING Material consumption2 FIBER-PATCH-PREFORMING  Load optimized fiber orientation  Load optimized laminate thickness  Undulation-free fiber orientation  Near optimal laminate build up
  15. 15. 2011-07 16 Less waste than 5 % of carbon fiberMore waste than 30 % of carbon fiber Low level of waste (near-net-shape) FIBER-PATCH-PREFORMING COST SAVING Material consumption2
  16. 16. 2011-07 17 Material Efficient  Reliable processes with low scrap rates  Low level of waste  Material saving processes  Material saving product design (load optimized laminate design) High Level of Automation  Short cycle time  Cost effective systems  Cost efficient tools/ molds Saving Variable Costs  Energy effective processes  Robust systems (maintain)  Processes with low operational material consumption Cost Effective FRP-Processes for Serial Production FIBER-PATCH-PREFORMING FPP – COST VIEW
  17. 17. 2011-07 18 Local reinforcements (window frame, hole reinforcements, etc.) Shell structures (saddles, wheels, motor cover, etc) Sub laminates (aircraft stringers, clips, etc.) FPP flexible process FIBER-PATCH-PREFORMING FPP - FIBER PATCH PREFORMING
  18. 18. 2011-07 19 THANK YOU TO: FPP - FIBER PATCH PREFORMING  Federal Ministry of Education and Research (BMBF) for supporting the »SOWEMA« and the »BIOTEX« project  European Commission for supporting the »IMAC-PRO« project  And all project partners FIBER-PATCH-PREFORMING Process & machine development User Software development

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