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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 , 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 , 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 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Industry 5.0 in aircraft production and MRO: technologies, challenges, and opportunities(2023-03); ; ; ; Globally interconnecting machines, processes, and resources driven by exploring and advancing new technologies defined Industry 4.0, 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 digitizing significant parts of their value- and non-value-adding activities. However, given current societal and environmental challenges, future industries must change from technology-driven only to value-driven, working sustainably with resources, including human capital, the idea behind Industry 5.0. On the one hand, the aircraft industry challengingly faces these demands since even Industry 4.0 concepts and technologies are not fully exploited or implemented; on the other hand, due to the specific aircraft production and MRO as well as the environmental impact characteristics of the product, tremendous potential arises regarding placing human well-being back into the core of adding value, decreasing environmental footprint, while building a resilient and fortified industry against disruptions of this era. In line with the Industry 5.0 terminology, in this work, we outline the objectives, challenges, enabling technologies, and opportunities for sustainable, resource-efficient, human-centric, and resilient concepts, systems, and procedures in aircraft production and MRO.Publicationtype: Preprint130 324