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    Integrated structural optimization and model-informed path planning of additively manufactured, continuous fiber-reinforced plastics, taking into account manufacturing restrictions and design-dependent strength
    For structures with complex fiber architecture, the transfer of a fiber composite design into the path planning of an additive manufacturing process in particular has been a mostly manual process to date. For example, the result of optimizing a fiber composite structure is available in the form of a vector field of local material orientations. Manual path planning is then used to implement a component that comes close to this design. Today, there is no approach for optimizing additively manufactured composite components made of continuous fibers in such a way that a manufacturable design is created and at the same time its full lightweight potential is exploited. The weak point here is the transition between the structural-mechanical model, path planning and the manufacturing process, which is why a continuous design chain can only be developed in close cooperation between structural optimization and manufacturing technology. The overarching aim of this application is therefore to develop a continuous process for model-informed path planning and structural optimization of additively manufactured fibre composite components. The path planning should anticipate and compensate for process-induced sources of error through simulation, control and modeling of the non-planar production and the fiber-matrix combination. In addition, the design-dependent, local strength and manufacturing restrictions are to be taken into account in the optimization. To this end, a method for error-compensating path planning with model-based process parameters is being developed and a fused filament fabrication process for the non-planar additive manufacturing of fiber-reinforced plastic composites is adapted to it. The paths determined in this way are the input for a method to be developed for the structural optimization of fiber paths while maintaining manufacturability and taking into account design-dependent strengths and stiffnesses. This overall process is to be validated by production trials and structural-mechanical tests.
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    Load-oriented additive manufacturing of optimized fiber-reinforced composites
    Due to the high achievable stiffness and strength at low weight, carbon fiber reinforced plastic (CFRP) is an attractive material for lightweight construction. Classical manufacturing processes such as hand lay-up, winding or tape laying are often limited in their applicability for complex geometric structures, such as those resulting from structural optimization. Additive manufacturing of CFRP using fused deposition modeling offers the possibility of placing individual fiber strands in the load direction to increase the effectiveness of material use. Furthermore, additive manufacturing enables accelerated development processes and the economical production of small series. The aim of the research project is to overcome this limitation through non-planar printing on machines with higher degrees of freedom. To this end, a manufacturing process for the additive manufacturing of CFRP components is to be developed, with which volumetric bodies can be produced from non-planar layers in a highly automated manner for the first time, taking load case analyses into account. The focus is on the slicing and path planning software and the necessary investigation of the manufacturing process.
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    DrumView
    Gemeinsam arbeiten die Projektpartner an einer möglichst automatisierten und vollständigen Digitalisierung der Flugzeugkabine, d. h. der Aufnahme vieler einzelner Fotos, die anschließend in einem Modell zusammengeführt werden. Hierzu gilt es geeignete Kameras und weitere benötigte Sensoren auszuwählen. Um eine hohe Aufnahmequalität zu erreichen wird eine Kinematik entwickelt, welche die systematische Führung der Sensorik durch die Flugzeugkabine gestattet. So können basierend auf den hochwertigen Daten KI-Modelle trainiert werden, die die Detektion von Anomalien erlauben. Mögliche Einsatzszenarien des Systems liegen bspw. bei den Flugzeugherstellern, die die Kabine im Montageprozess oder insbesondere vor der Übergabe an den Kunden inspizieren wollen, um etwaige Schäden frühzeitig zu erkennen und eine vollständige und nachvollziehbare Dokumentation abzuleiten. Zu möglichen Schäden, die zur Beanstandung durch den Kunden führen können, gehören bspw. Verschmutzungen, Kratzer auf Oberflächen, Spaltmaße oder falsche montierte Komponenten.
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