Additive Functionalisation – A concept for cost-efficient and resource-saving lightweight construction

Abstract

The concept of Additive Functionalization from the DLR Innovation Lab EmpowerAX, which was realized together with 12 partners along the industrial process chain, demonstrates this approach using a multi-curved thermoset shell that is stiffened with a topology-optimised rib structure. Here, short and continuous fiber-reinforced high-performance thermoplastics are processed using robotic 3D printing. The basic structure is produced cost-efficiently using conventional methods and then additively functionalised using fibre-reinforced 3D printing to conserve resources. Additive Functionalization ranges from the printing of local stiffening ribs and the integration of assembly and adhesive aids to the insertion of electrical conductors. The combination of manufacturing processes and materials enables the cost- and time-efficient production of resilient and individualized lightweight construction systems.