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Smart Manufacturing of Thermoplastic CFRP Skins

Schuster, Alfons and Larsen, Lars-Christian and Fischer, Frederic and Glück, Roland and Schneyer, Stefan and Kühnel, Michael and Kupke, Michael (2018) Smart Manufacturing of Thermoplastic CFRP Skins. Procedia Manufacturing, 17, pp. 935-943. Elsevier. doi: 10.1016/j.promfg.2018.10.147. ISSN 2351-9789.

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Official URL: https://doi.org/10.1016/j.promfg.2018.10.147


High performance aerospace structures often require a combination of innovative materials and new production technologies. Carbon fiber reinforced thermoplastics (CFRTP) have shown their potentials over the last decades especially due to their competitive production rates. Thermoplastic matrix systems allow joining by welding, which is a major advantage for assembly. Production systems for flat thermoplastic organic sheets are readily available on the market, as well as advanced fiber placement and tape laying machines (AFP/ATL). But there is a lack of systems capable of fabricating 3D-curved, near net shaped patch preforms that may serve for mass-customization of standard parts, e.g. for future aerospace panel production. With the composite prepregs being stacked within the mold the fibers will undergo less reshaping during consolidation (i.e. debulking) thus giving a better control over fiber angles. We describe an autonomous smart manufacturing system that is capable of handling unique parts by means of a complete digital workflow from part design over automated cut-piece fabrication, generation of system related meta-information, virtual planning of grip and drop up to the final layup. The system consists of a preprocessing and production planning apps, an industrial robot, a gripper with an ultrasonic welder, a storage system for cut-piece supply, a computer vision system, a collision avoidance app and a logging system for process relevant production parameters for inline quality control. The described system was successfully used for the production of four thermoplastic CFRP skin segments each consisting of 104 cut-pieces.

Item URL in elib:https://elib.dlr.de/123222/
Document Type:Article
Title:Smart Manufacturing of Thermoplastic CFRP Skins
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Schuster, AlfonsUNSPECIFIEDhttps://orcid.org/0000-0002-7444-366XUNSPECIFIED
Larsen, Lars-ChristianUNSPECIFIEDhttps://orcid.org/0000-0002-4450-8581UNSPECIFIED
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Glück, RolandUNSPECIFIEDhttps://orcid.org/0000-0001-7909-1942UNSPECIFIED
Schneyer, StefanUNSPECIFIEDhttps://orcid.org/0009-0004-5421-9988UNSPECIFIED
Date:15 November 2018
Journal or Publication Title:Procedia Manufacturing
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In ISI Web of Science:No
Page Range:pp. 935-943
Keywords:Innovative Manufacturing Systems Services Robotics Computer Integrated Manufacturing Production Planning Scheduling Control
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Structures and Materials (old)
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Schuster, Dr.-Ing. Alfons
Deposited On:29 Nov 2018 11:45
Last Modified:22 Nov 2023 07:37

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