Additive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and materials. This hybrid approach can merge the different benefits to realize mass savings in load-bearing structures with high mass-specific stiffnesses, strict geometrical tolerances, and machinability. In this study, a digital tool for coreless filament winding was developed to support all project phases by natively capturing the process-specific characteristics. As a demonstration, an aluminum base plate was stiffened by a coreless wound fiber-composite structure, which was attached by additively manufactured metallic winding pins. The geometrical deviations and surface roughness of the pins were investigated to describe the interface. The concept of multi-stage winding was introduced to reduce fiber–fiber interaction. The demonstration example exhibited an increase in mass-specific component stiffness by a factor of 2.5 with only 1/5 of the mass of a state-of-the-art reference. The hybrid design approach holds great potential to increase performance if process-specific features, interfaces, material interaction, and processes interdependencies are aligned during the digitized design phase.

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A detailed experimental study on the aerodynamic performance and noise emission of airfoils and fan blades with permeable leading edges under disturbed inflow conditions was performed. The airfoils and fan blades with permeable leading edges were made of an aluminum alloy using a powder bed fusion-based additive manufacturing process. In a first step, a wind-tunnel study was carried out. This consisted of detailed aerodynamic and aeroacoustic measurements on 16 airfoils with different permeable leading-edge designs that were performed for various flow speeds and geometric angles of attack. Based on the results from that study, unskewed fan blades with four different permeable leading-edge designs were manufactured in a second step. With the aim of reducing turbulence interaction noise of axial fans, the fans were examined with regard to their aerodynamic and acoustic properties under grid-generated turbulent inflow conditions. In a third step, a possible transfer of the observed noise emission from airfoils with permeable leading edge to that of fan blades was investigated. It was found that a notable broadband noise reduction can be transferred from airfoil applications to the sound spectra of axial fans. At the same time, the porous modifications can reduce the aerodynamic performance, and hence the fan efficiency.

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