AMoBaCoD – Applied model-based co-development for zeroE systems

»AMoBaCoD« is creating a distributed, model-based development environment for a flyable zeroE model aircraft. At its core is a cross-domain semantic data model that consistently links requirements, design, production, and recycling data. All specialist models access a common, maintained database via a graph database (»digital thread«). This reduces media breaks, increases data quality, and makes changes transparent and traceable throughout the entire life cycle.

Fraunhofer IAPT is developing an automated design process chain for additively manufactured structural components. Algorithms first check geometric constraints, optimize component orientation, support structures, and packing in the build space, and evaluate printability and surface quality. In addition, a generic cost model for various AM processes is being created that maps machine, material, post-processing, and QA costs. The goal is to reduce development times by up to 90% and enable reliable cost estimates early in the design phase.

Fraunhofer IGCV creates graph-based models for the manufacture and assembly of CFRP structures and for their recycling. Based on the component specifications, suitable production routes (e.g., hand lamination, automated processes) are automatically planned and evaluated in terms of costs, time, and resource utilization. An extended recycling model derives suitable process chains for fiber-matrix separation and further processing from assembly and material information and links these with material properties. Both models are linked to the other design models via the »digital thread«.

In order to validate decisions in the overall design, Fraunhofer IGCV develops mathematical metamodels that greatly accelerate the approximation of complex simulation and planning models. This enables cross-domain Monte Carlo analyses to quantitatively evaluate sensitivities and uncertainties along the model chain – from structural design to production and recycling. The model-based results are validated by building and testing a fully functional demonstrator. This creates a basis for virtual, more efficient qualification of future zero-emission aircraft systems.

»AMoBaCoD« is currently in the implementation phase: the semantic data model has been defined in basic terms, a triplestore has been set up as a digital thread, and initial domain models—including for production and recycling planning and the automated AM design workflow—have been connected in prototype form. At the same time, cost models and metamodels for uncertainty assessment are being gradually refined. By the end of the project, all models will be merged into a continuous, validated model chain and tested on the airworthy demonstrator. The results will be transferred to industrial development processes and applied to other industries such as automotive, rail, and plant engineering. In terms of content, »AMoBaCoD« ties in with other Fraunhofer IGCV projects, e.g. »COBAIN« (model-based production planning), »NewAirgility« and »NEUTRON« (recycling and life cycle assessment of CFRP structures) as well as »ODE_AM« and »HybridDigital« (semantic data models, materials and joining technology), and combines these approaches in an integrated development environment.