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    Item type:Publication, Access status: with files ,
    A modular life cycle assessment framework for novel aircraft configurations and sustainable aviation fuels
    (Association of American Publishers, 2026)
    Mazur, Kristina
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    Bistreck, Katrin
    ;
    Erbskorn, Christina
    ;
    Hornung, Mirko
    This work presents a modular framework for environmental impact assessment in conceptual aircraft design, developed within the UNICADO environment. The new architecture decouples individual life cycle phases and has been extended to various Sustainable Aviation Fuel (SAF) pathways. This enhanced flexibility enables a more robust and holistic trade-off analysis of an aircraft’s environmental footprint early in the design process. The case study of UNICADO-LR-01 presents results on cumulative energy demand shares for each life cycle activity. Additional results reveal that the life cycle phases operations (62.0, 78.4, 84.6%) and energy carrier production (29.6, 14.3, 9.9%) are most dominant in terms of energy, CO2, and NOx, respectively. Results from SAF pathways suggest a shift towards the energy carrier production phase.
    Publicationtype: Conference Paper
      20  7
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    Item type:Publication, Access status: with files ,
    A preliminary study: support-free manufacturing of rotationally symmetric pipes from continuous carbon fiber reinforced polymers with multi-axis 3D printing
    (Materials Research Forum LLC, 2025-05)
    Kállai, Zsolt
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    Kipping, Johann
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    Bremer, Jan
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    Schüppstuhl, Thorsten
    This paper presents an innovative approach that combines multi-axis fused filament fabrication (FFF) with continuous carbon fiber reinforced polymers (CFRP) to evaluate the feasibility of manufacturing rotationally symmetric CFRP pipes without mandrels or support structures. Traditional methods, such as filament winding, encounter limitations with geometric complexity and require tooling that makes them unsuitable for producing complex, individual parts. The proposed process uses the manufacturing flexibility of FFF and advantageous material properties of CFRP to create rotationally symmetric pipes on-demand. In this article, the experimental setup is described, the material and process-related challenges are discussed and a preliminary study that involves the printing of rotationally symmetric pipes to verify the viability of the process is presented. The findings aim to advance additive manufacturing techniques, enabling the production of lightweight, customized pipes for various industrial applications, and establishing this method as a cost-effective and efficient alternative.
    Publicationtype: Conference Paper
      39  21
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    Item type:Publication, Access status: with files ,
    Hot double sided incremental forming of continuous fiber reinforced thermoplastics: Process analysis and system design
    (Materials Research Forum LLC, 2025-05)
    Nettig, Doran
    ;
    Rath, Jan-Erik
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    Schüppstuhl, Thorsten
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    Frank, Johannes
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    Riecken, Björn
    Interest in fiber reinforced thermoplastics (FRTP) is increasing due to their superior recyclability and processability over thermoset composites, but the need for part-specific tooling constrains their application in small-lot production. Incremental sheet forming (ISF) presents a flexible manufacturing alternative. However, existing ISF methods, predominantly developed for metals, need to be adapted to the specific process requirements of FRTP. Prior research into the ISF of FRTP has focused on single-point incremental forming (SPIF). To enable new processing strategies, this work presents the development of a robot-based hot double sided incremental forming (DSIF) setup for FRTP. A process analysis serves as the basis of the design and integration of the core system components. The setup shows great potential as a platform to explore a wide range of new ways to advance the ISF of FRTP.
    Publicationtype: Conference Paper
      50  38
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    Item type:Publication, Access status: with files ,
    Single point incremental forming of multi-matrix continuously-reinforced composites: a feasibility study
    (Materials Research Forum LLC, 2025-05)
    Rath, Jan-Erik
    ;
    Nettig, Doran
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    Palubiski, Dominic
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    Schüppstuhl, Thorsten
    ;
    Ivanov, Dmitry S.
    Fibre-reinforced plastics offer remarkable strength-to-weight ratios, making them an excellent choice for lightweight engineering solutions. However, the forming of precursor materials such as preforms or prepregs poses substantial challenges, with defects such as delaminations or fibre misalignments occurring frequently. One approach to de-risk composite parts manufacturing are Multi-Matrix Continuously-Reinforced Composites (MMCRCs), pre-structured with formable and non-formable matrix materials connected by continuous fibre reinforcement. Regions with a matrix of covalent adaptable networks (CANs, aka vitrimers) can be locally formed to the desired shape, while unformable regions with a conventional thermoset matrix restrict undesirable deformations. As targeted local forming operations are required, incremental sheet forming is proposed as a flexible forming process that does not involve expensive moulds. To evaluate the feasibility of incrementally forming MMCRCs, a simple corner geometry is formed using single point incremental forming (SPIF) in this study. The prepared sample with a formable hinge region is attached to a metal dummy sheet with a vacuum bag and heated to forming temperature. Using a specifically developed toolpath strategy, the layup is deformed in a robotic SPIF setup. Albeit revealing challenges in the simultaneous forming of metal and MMCRC sheets, results prove that the proposed approach is promising in allowing the manufacture of high-quality composite parts in decoupled production and forming processes.
    Publicationtype: Conference Paper
      47  36
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    Item type:Publication, Access status: with files ,
    Tool path strategies for single point incremental forming of fiber-reinforced thermoplastic sheets
    (Materials Research Forum LLC, 2024-05-15)
    Rath, Jan-Erik
    ;
    Schüppstuhl, Thorsten
    Continuous fiber-reinforced thermoplastics (FRTP) are gaining increasing interest as a lightweight material. However, production processes such as thermoforming rely on costly molds, making them unsuitable for individual parts or small series production. Therefore, realizing an incremental sheet forming (ISF) process for FRTP is very desirable. As direct application of ISF to FRTP is impossible, researchers placed the FRTP between two metal sheets, allowing it to slide between them during single point incremental forming (SPIF). So far, only traditional tool path strategies for metal SPIF, such as the z-level or the spiral approach, have been used, which do not consider the draping requirements of woven reinforcement fibers. To optimize the forming process and prevent the development of wrinkles or other defects in the organo sheet, we propose and test novel tool path strategies for the SPIF of an FRTP sandwiched between two metal sheets. Results show that the proposed strategies have a positive impact on part quality, as fiber orientation-based tool path approaches show less wrinkling and higher part accuracy in SPIF without support.
    Publicationtype: Conference Paper
      38  178
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    Item type:Publication, Access status: with files ,
    Die-less forming of fiber-reinforced thermoplastic sheets and metal wire mesh
    (Materials Research Forum LLC, 2023-03-17)
    Rath, Jan-Erik
    ;
    Schüppstuhl, Thorsten
    The growing market for fiber-reinforced thermoplastics (FRTP) requires new flexible production processes for prototype and small series production, as conventional forming techniques involving molds are not cost efficient in these cases. Inspired by incremental sheet metal forming (ISF), an alternative manufacturing processes for the forming of FRTP with just two robot guided standard tools is outlined. To maintain a locally formed shape in the heated, flexible fabric, auxiliary wire mesh metal is used as it has similar deformation mechanisms, especially shearability, while being sufficiently self-supporting. Feasibility of the approach is discussed and investigated in basic experiments.
    Publicationtype: Conference Paper
    Scopus© Citations 2  107  214