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.

Bei der Fertigung von Holzerzeugnissen entstehen Späne, die prozesssicher abgeführt werden müssen. Eine optimierte Späneerfassung führt zu einer Verbesserung der Produktivität, zur Wahrung der Gesundheit der Beschäftigten und trägt zum Explosionsschutz bei. Der Beitrag untersucht werkzeugnahe Absaugsysteme zur Späneerfassung bei der Holzbearbeitung. Mithilfe numerischer Simulationen wurde der Einfluss von fertigungs- und strömungsbedingten Eingangsgrößen auf verschiedene Zielgrößen ermittelt.   During the production of wood products, chips are produced that have to be removed in a process-safe manner. An optimised chip collection leads to an improvement of productivity, to the protection of the health of the employees and contributes to explosion protection. The article examines tool-related extraction systems for chip collection in woodworking. With the help of numerical simulations, the influence of manufacturing and flow-related input variables on various target variables was determined.

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