Novel Robot-Based Process Chain for the Flexible Production of Thermoplastic Components with CFRP Tape Reinforcement Structures

Matkovic, Nikolas; Kupzik, Daniel; Steidle-Sailer, Christian; Friedmann, Marco; Fleischer, Jürgen

doi:10.1016/j.procir.2022.02.149

Cited by 2 publications

(1 citation statement)

References 10 publications

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“…Raspall et al [ 15 ] describe a facility where two cooperating robots perform the tape placement and printing simultaneously. An automated process chain for the flexible production of hybrid components using non-planar printing using industrial robots has been described by Matkovic et al [ 16 ]. This process chain offers several features to optimise the bonding conditions, such as pre-heating, substrate heating and additional consolidation pressure.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Characterisation of Bond Formation during Overprinting of PEEK Laminates

Hümbert,

Atzler,

Voggenreiter

2023

Materials

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The latest generation of high-temperature 3D printers enables the production of complex structural components from aerospace-grade thermoplastics such as PEEK (polyether ether ketone). However, adding long or continuous fibres is currently limited, and thermal stresses introduced during the process restrict the maximum part dimensions. Combining 3D-printed components with continuous fibre-reinforced components into one hybrid structure has the potential to overcome such limitations. This work aims to determine whether in situ bonding between PEEK laminates and PEEK 3D printing during overprinting is feasible and which process parameters are significantly responsible for the bonding quality. To this end, the bonding is analysed experimentally in two steps. Firstly, the influence of the process parameters on the thermal history and the strength of the bond is investigated. In the second step, a detailed investigation of the most critical parameters is carried out. The investigation showed the feasibility of overprinting with bonding strengths of up to 15 MPa. It was shown that the bonding strength depends primarily on the temperature in the interface. Additionally, the critical parameters to control the process were identified. The process influences that were displayed form the basis for future hybrid component and process designs.

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Section: Introductionmentioning

confidence: 99%

Mechanical Characterisation of Bond Formation during Overprinting of PEEK Laminates

Hümbert,

Atzler,

Voggenreiter

2023

Materials

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A Workflow for the Compensation of Substrate Defects When Overprinting in Extrusion-Based Processes

Atzler,

Hümbert,

Voggenreiter

2024

JMMP

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Fused granular fabrication (FGF) is used in industrial applications to manufacture complex parts in a short time frame and with reduced costs. Recently, the overprinting of continuous fibre-reinforced laminates has been discussed to produce high-performance, functional structures. A hybrid process combining FGF with Automated Fibre Placement (AFP) was developed to implement this approach, where an additively manufactured structure is bonded in situ onto a thermoplastic laminate. However, this combination places great demands on process control, especially in the first printing layer. When 3D printing onto a laminate, the height of the first printed layer is decisive to the shear strength of the bonding. Manufacturing-induced surface defects of a laminate, like thermal warpage, gaps, and tape overlaps, can result in deviations from the ideal geometry and thus impair the bonding strength when left uncompensated. This study, therefore, proposes a novel process flow that uses a 3D scan of a laminate to adjust the geometry of the additively manufactured structure to achieve a constant layer height in the 3D print and, thus, constant mechanical properties. For the above-listed surface defects, only thermal warpage was found to have a significant effect on the bonding strength.

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Novel Robot-Based Process Chain for the Flexible Production of Thermoplastic Components with CFRP Tape Reinforcement Structures

Cited by 2 publications

References 10 publications

Mechanical Characterisation of Bond Formation during Overprinting of PEEK Laminates

Mechanical Characterisation of Bond Formation during Overprinting of PEEK Laminates

A Workflow for the Compensation of Substrate Defects When Overprinting in Extrusion-Based Processes

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