3D truss structures with coreless 3D filament winding technology

Abstract

A coreless manufacturing process for generic 3D rigid frame topologies will be introduced in this paper. The aim is to extend the field of filament winding from mainly 2D-shells and some exceptional cases of 3D rigid frames. This manufacturing process employs a coreless translation cross-winding method in order to continuously deposit a roving around deflection points in space. On this basis, a design methodology is being created and deductively verified by designing a beam for a three-point bending load case. The composite beam is designed on a macro level simulation approach to match the stiffness of a reference aluminum profile, which is commonly employed as structural component for robotic gripper systems in automotive assemblies. The performance of the beams is subsequently compared by three-point bending experiments. This demonstrates that the composite beam offers equivalent stiffness and strength properties with a weight-reduction potential of nearly 50% for bending loads.

Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction

“…Recent research has sought to develop manufacturing methods and verify them at building scale, utilizing technology transfer from the composite industry to construction. Interesting for our work are several academia 13,17,19 and industry [30][31][32] applications that have adopted CFW to reduce the need for formwork in AM construction elements. With the reduction of formwork come limitations in the types of producible structures.…”

“…With the reduction of formwork come limitations in the types of producible structures. Because it is dependent on the incremental deformation of free spanning fibers, CFW is currently limited to the production of lattices that approximate anticlastic surfaces, 19 3D frames, 32 or truncated cone tubes. 30 With the exception of processes described by Dawson 30 and Minsch et al, 31 CFW methods still do not provide complete design, analysis, simulation, and fabrication solutions that are adaptable for construction.…”

An overview on current manufacturing technologies: Processing continuous rovings impregnated with thermoset resin

“…The process can produce complex truss structures that cannot be manufactured via conventional wet filament winding. [ 96 ]…”

Automated Framework for the Optimisation of Spatial Layouts for Concrete Structures Reinforced with Robotic Filament Winding

“…Moreover, filaments are suitable for automated additive manufacturing [11], as commonly proven in the automotive industry to produce composite parts thanks to robotic filament winding [12]. For instance, the technology Fi-breTEC3D [13,14], developed by Daimler and CIKONI, winds spatial layouts to produce mechanically-optimised components. In the construction industry, Spadea et al [10] wound shear reinforcement for concrete beams using a rotating mandrel as core and Prado et al [15] wound filaments to form composite shells using robotic arms holding boundary frames, instead of using a core.…”