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Item type:Publication, Access status: with files , Instant geodesic draping for optimization and path-planning and its application to incremental composite sheet formingTechnical textiles and their use in composites are crucial for many high-performance applications. Utilizing them in applications dominated by iteration and individualization requires flexible manufacturing processes. One such process is Incremental Sheet Forming (ISF), the 3D-Printing of forming processes, which is currently being adapted to composites. Enabling ISF, and other dieless processes, and leveraging their flexibility requires optimization and path-planning tools. Such tools must consider material behavior, which in turn necessitates the use of simulation. While highly sophisticated methods for increasingly accurate modeling have been developed, the speed requirements of CAM workflows and optimizations have kept simple yet efficient approximations relevant, the most prominent being kinematic draping algorithms. This work presents a novel heat-method based alternative that globally computes fabric draping under an assumption of uniform tow distances. This assumption makes it especially well-suited for the subsequently implemented drape-aware ISF paths. Additionally, the developed algorithm is highly computationally efficient, which is harnessed for visualization and optimization. While these are only explored computationally, the path-planning is employed to produce and compare a demonstrator part in a double sided ISF process. The initial results for the draping algorithm show an up to 80x speed increase compared to kinematic draping. This allows for real-time draping visualization and sub-minute optimization. The demonstrator part proves that the derived paths can counteract wrinkling, an important failure mode observed with conventional strategies. These results demonstrate the great potential of geodesic draping for ISF in particular and flexible manufacturing, optimization and visualization tasks in general.Publicationtype: Journal Article23 5 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Double-sided incremental forming of continuous fiber reinforced thermoplasticsContinuous fiber reinforced thermoplastics (CFRTP) combine excellent mechanical properties with recyclability, weldability, and reshapeability. However, their conventional processing requires part-specific tooling, imposing high initial cost and lead times. This limits their applicability to small lot sizes. A flexible alternative could be Incremental Sheet Forming (ISF), which creates parts by moving a small, part-agnostic tool along numerically controlled paths. While ISF is established for metals, its adoption for CFRTP started only recently. In particular, the Double-Sided Incremental Forming (DSIF) process, which employs a second forming tool to improve quality and flexibility, has not been investigated in detail for CFRTP. Therefore, this work presents the first extensive study into DSIF of CFRTP, with a focus on establishing a baseline process. The conducted process characterization includes temperature and force assessments. Forming strategies were compared by forming cone frusta, yielding a multi-stage strategy combining spiral and fiber-following toolpaths, which produced wrinkle-free parts with good accuracy. Micrographs indicate good consolidation for the tested material and process conditions. Furthermore, a preliminary process parameter analysis, including temperature, support force, and step size, was conducted. The results indicate that DSIF can become a viable, flexible manufacturing route for CFRTP components and provide a sound foundation for future research.Publicationtype: Journal Article49 14 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Classifying parameters and target variables in incremental sheet forming of fiber reinforced polymers(Trans Tech Publications, 2026-04-16); ; ; Incremental Sheet Forming (ISF) enables the flexible creation of shell-shaped structures. Unlike conventional forming, ISF does not require a bespoke forming tool, greatly reducing upfront costs and lead times, especially for small lot sizes. Several parameter classifications for the ISF of metals and polymers have been proposed in the past. Such classifications increase awareness of possible levers for process optimization, guide experimental analysis, and enable a holistic understanding. Lately, fiber-reinforced polymers (FRP) are of increasing interest in ISF. In previous studies, ISF systems for various kinds of FRP have been developed, and several parameters and target variables have been investigated. However, there is currently no classification that addresses the specific parameters and target variables relevant to this material class. Therefore, the goal of this work is to develop such a classification to create a comprehensive foundation for future FRP ISF investigations. This effort is undertaken by building upon existing classifications and reviews independent of the material class and synthesizing these with a systematic literature review of FRP ISF investigations. The resulting classifications cover a broad range of parameters and target variables and reveal a structure that guides a systematic understanding and ensures future expandability.Publicationtype: Journal Article58 15 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Hot double-sided incremental forming of fiber-reinforced thermoplastics: process capabilities and challengesFiber-reinforced thermoplastics (FRTP) offer high strength-to-weight ratios as well as weldability and recyclability, making them attractive for lightweight applications. Conventional thermoforming of continuous FRTP, however, requires part-specific molds, limiting economic viability for prototypes, individual parts, and small series. This study investigates a robotic hot double-sided incremental forming (DSIF) process developed for dieless, flexible forming of continuous FRTP sheets together with metal dummy sheets. Five different generic demonstrator parts with varying wall angles, degrees of symmetry, forming depths, and sizes were formed to assess process capability. Results demonstrate that typical defects such as fabric wrinkling and deconsolidation can be successfully avoided, and that the geometric accuracy achievable is comparable to that of metal DSIF. Challenges exist in forming larger parts due to the failure of the employed metal dummy sheets.Publicationtype: Journal Article12 14 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Capabilities of robot-based double-sided incremental hot-forming of fiber-reinforced thermoplastics(Soc. for the Advancement of Material and Process Engineering, 2026-04); ; ; ; Thermoplastic composites are gaining interest for their good recyclability, in addition to their mechanical performance and light weight potential. However, conventional molding processes for thermoplastic composites, such as hot pressing, require full-surface, geometry-specific molding tools and are therefore associated with high investment costs and long lead times until production can start. This is a strong drawback for manufacturing of small series, prototypes or in case of geometry changes. A promising flexible alternative is incremental forming, where geometry-agnostic tool tips exert local force to successively form the part. This allows for the economical and quick production of small part quantities. This work investigates the capabilities of a novel double sided incremental hot-forming process that employs two cooperating robots to drape a heated organosheet into the targeted shape. The process is assessed regarding mechanical performance, geometric accuracy and economic efficiency. The analysis shows that the presented process is capable of producing a wide variety of geometries with viable accuracy and good mechanical performance. The economic assessment reveals a clear advantage in both lead time as well as per part cost for small lot sizes.Publicationtype: Conference Paper40 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Assembly system modeling with SysML and AutomationML for configuration and reconfigurationProduct individualization and the need to reduce lead times put increasing pressure on production system engineering. This includes the configuration of assembly systems regarding a new product variant. Therefore, model-based engineering is increasingly applied in development and configuration tasks. To combine the two popular practices of using SysML in product development and AutomationML in assembly system development, we propose to link both in an integrated modeling approach. It aims at a seamless assembly system configuration process building upon the capabilities of AutomationML for modeling and interconnecting products, processes, and resources, including their geometries, kinematics, and behaviors.Publicationtype: Conference Paper37 22 - Some of the metrics are blocked by yourconsent settings
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); ; ; ; 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 Paper47 34 - Some of the metrics are blocked by yourconsent settings
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); ; ; 47 33 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Industry 5.0 in aircraft production and MRO: challenges and opportunitiesGlobally interconnecting machines, processes, and resources driven by exploring and advancing new technologies defined Industry 4.0 (I4.0), resulting in, e.g., Cyber-Physical Production Systems (CPPS). The aircraft industry particularly struggled with transforming production and Maintenance, Repair, and Overhaul (MRO) processes, replacing humans with machines and automating as well as digitalizing significant parts of their value- and non-value-adding activities. However, in the face of current social and environmental challenges, future industries will need to shift from purely technology-driven to value-driven, working sustainably with resources, including human capital. Together, these approaches constitute the idea of Industry 5.0 (I5.0). On the one hand, the aviation industry faces the challenge that even I4.0 concepts and technologies are not yet fully exploited or implemented. On the other hand, due to the specific characteristics of aircraft production and MRO as well as the environmental impact of the product, a tremendous potential arises regarding placing human well-being back into the center of adding value and decreasing environmental footprint while building an industry that is resilient and fortified against disruptions of this era. In line with the I5.0 terminology, in this work, we outline the challenges and opportunities of integrating I5.0 principles into the aircraft production and MRO industries, focusing specifically on the scope of selected use cases.Publicationtype: Journal Article63 41 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , A novel method for carbon fiber reinforced thermoplastics production combining single point incremental forming and 3D printing(Elsevier, 2025); ; ; ; Dieless processes such as additive manufacturing or incremental sheet forming are becoming increasingly popular in manufacturing carbon fiberreinforced components. They are a promising option for producing individual parts or small lot sizes without the need for expensive molds and can thus revolutionize the creation of patient-tailored prosthetics or high-end sports equipment. In this paper, the combination of robotic singlepoint incremental forming of carbon fiber-reinforced organo sheets with carbon fiber-reinforced 3D printing is presented. Combining those dieless processes in a novel process chain, complex parts with different geometric features could be produced without the need for adhesives or fasteners. The developed method begins with designing the desired component in CAD and its division into sections to be formed incrementally and sections to be 3D printed. For incremental forming, an organo sheet is cut to the necessary shape, sandwiched between a layup of dummy metal sheets, fixed on a clamping frame, and heated to the required forming temperature. Path planning for the robot is carried out based on a selected forming strategy, and the sheet is formed. Afterward, the part is transferred and fixed onto a robotic experimental 3D printing setup. The part\x92s surface is 3D-scanned to provide the basis for the path planning algorithm. The slicer software generates non-planar layers based on the actual shape of the formed sheet and the desired geometry of the printed part section. After slicing, the code for the robot is generated and the print job is executed. Within this paper, the conceptualized process chain is presented and basic functionality is proven by manufacturing a demonstration part. The first results are promising to enable efficient manufacturing of complex components that combine different geometric features in small batch sizes. Future research will be conducted to analyze and optimize the process chain and its capabilities, especially regarding the resulting part quality.Publicationtype: Conference Paper39 35