The starting point for the development project was a 2D sketch of a linear structural component to be installed in an e-vehicle at two different locations and functions. The pultrusion process had been selected as the manufacturing process. The load cases of the component were known as a further framework condition.
In close coordination with both industrial partners, the work included the design of the laminate structure, the selection of a suitable fiber-matrix system with special consideration of suitable multiaxial glass-carbon fiber textiles. The materials were qualified by upstream pultrusion tests. The multi-cavity pultrusion mold with associated closed injection and impregnation chamber was developed and manufactured by KraussMaffei. A particular challenge in the design of the pultrusion process was the guidance of the more than 800 carbon rovings and the numerous hybrid multiaxial textiles to the filigree hollow chamber structure of the profile.
After demonstration of TRL 5 on the IGCV pultrusion line, the entire process setup was transferred to a supplier in South Korea. The re-commissioning and training of the local staff was carried out by colleagues from C21. The mechanical performance of the pultruded components clearly exceed the requirements and are now in commercial series use at Hyundai.
Together with SGL Carbon GmbH and Chromasens GmbH, Fraunhofer IGCV is developing an automated, inline-capable monitoring solution for carbon fibre production and related processes. A line scan camera with its own optics system and AI-supported, intelligent image processing are used.
more infoNetworked application-oriented aviation research through an agile, intelligent, networked and holistic knowledge management for lightweight construction.
The project NewAirgiLity addresses the conceptual design of a system architecture for agile knowledge management and thus sets the course for a holistic, method-based, and digitalized knowledge modeling in composite lightweight construction.
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The aim of the Saturn project (showcase for end-to-end digitalised pultrusion) is to develop digital solutions for production technology for the manufacture of fibre-reinforced plastic components. In particular, the focus is on process digitisation, production data management and intelligent fibre guidance using artificial intelligence (AI).
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The HybCar project aims to develop resource-efficient lightweight construction for the automotive industry. It involves researching and implementing innovative concepts for reducing the weight of vehicles in order to reduce CO2 emissions and increase energy efficiency. It includes both the development of new materials and the optimisation of production processes.
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"The Automated Fiber Placement (AFP) process offers enormous potential for the development of innovative solutions for CFRP components. Numerous previous research projects speak for the success of the technology: for example, the production of door frame structures for the Airbus A350. In order to make this still very expensive process more economical, possibilities for process optimisation and automation were presented in the IMPULS project."
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The sub-project "AI@FiberPlacement" focuses on tapping the potential of AI within the robot-based and material-efficient fibre placement overall process chain. For this purpose, the corresponding hardware requirements must be created in the area of plant and control technology as well as in the area of online process monitoring and in the construction of a new system architecture.
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Composite structures cannot yet compete with conventional metal construction in terms of manufacturing costs and cycle times. Therefore, the OSFIT project aims to realise a cost-efficient process chain for composite aircraft frames with short cycle times. The core competence of the Fraunhofer IGCV is the laying process of thermoplastic Automated-Fiber-Placement (T-AFP).
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In collaboration with Airbus Helicopters, a manufacturing process was developed for the production of geometrically complex shell components with sandwich cores. Automated fibre placement was used to produce two components for the RACER prototype helicopter.
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The MIKADO project is concerned with the development of lightweight structures made of composite tubes and cast nodes. It aims to research and optimise innovative joining technologies to create lightweight yet strong structures for various application areas such as automotive and mechanical engineering.
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We aim to develop high-volume production-capable CFRP structural components for the automotive industry by examining and optimizing an integrated process along the entire value chain. We strive to improve the production efficiency and economic viability of CFRP structural components.
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Fraunhofer Institute for Casting, Composite and Processing Technology IGCV