JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 10

EXPERT'S DIGEST
ADDITIVE MANUFACTURING
Equipment suppliers
Filament winding can be used to produce
even very large (>10m) diameter tanks
down to small diameter pressure vessels.
The nature and requirements of the end
use will define the degree of accuracy and
control the process requires. Various suppliers have therefore focused on different
segments of the market. Table 8 shows
how the suppliers can roughly be grouped
into three categories (with some overlap
possible).
The software for both Computer Aided
Design and Manufacturing can be supplied by either the equipment suppliers
or by independent software specialist
companies.

Overview of automatic tape laying
and automatic fibre placement
Process description
Process Description
Automated tape laying (ATL) and automated fibre placement (AFP) are usually
discussed together as the processes are
similar but used for different types of
parts. Both processes are used mainly for
composites in the aircraft industry and
were needed as Boeing and Airbus moved
to greater use of composites in their new
wide-bodies jets in the early 2000's.
Both processes use a complex multi-axis
head mounted on a robot arm. The head
can move freely in any required direction
and has a tape or fibre feed system with
a roller together with a cutting system
which is computer controlled to cut the
tape or fibre at the required place on the
mould. Heating systems such as lasers can
also be incorporated in the head.
The main difference between ATL and
AFP is the width of material which the
process uses to deposit on the form or
mould. ATL uses wide (7.5 to 30mm)
tapes of unidirectional material whereas
AFP uses strands (typically 3mm to
25mm).
ATL is most efficient for large flat or gently curved parts like aircraft wing skins.
AFP is most efficient for highly curved

Tab.9: Key advantages and disadvantages of ATL and AFP in manufacturing of fibre-reinforced composites

Advantages

* Higher and more reliable material deposition rate than manual lay-up
* Savings of material and labour
* Quality improvement
* Accurate placement at any angle
* Automatic debulking

Disadvantages

* Heavy investment
* Usually with equipment manufacturers bespoke software
* Depending on the specific equipment, lack of flexibility

or complex tightly contoured parts like
aircraft fuselage sections and wing spars.
The majority of the material used by both
processes is thermoset based prepreg
tape with unidirectional, usually carbon
fibre strands but thermoplastics are now
being used more extensively as the matrix.
Consolidation of the different thermoplastic layers can take place directly on the
mould through strong localised heating
which fuses the thermoplastic matrix.
The target for this thermoplasticprocess
development is the production of aircraft
parts that do not require the extra step of
autoclaving. The key quality factor is the
need to keep voids to a very low level.
Advantages and disadvantages
of ATL and AFP
Table 9 lists the key advantages and disadvantages of ATL and AFP.
Equipment Suppliers
The suppliers of ATL and AFP equipment
are either companies heavily focused
on ATL and AFP or large composite
equipment suppliers who include ATL or
AFP machines in their offering. The main
suppliers of this type of equipment are
given in Table 10.

topics which are of interest in the refinement of these two established processes.
The articles basically cover the various
areas of process optimisation which are
being pursued to improve the process efficiency and finished product quality, which
are both key to the further development
and competitivity of automatic laying and
placement.

Overview of composite 3D printing
Reminder of fibre related factors
influencing composite properties
As stated earlier, the big challenge for any
fibre reinforced composite process is to
make optimum use of the reinforcement
properties of any particular fibre in any
particular matrix. The strength properties
of the composite part will very much
depend on multiple factors related to the
fibre, namely: fibre type, fibre length, fibre
orientation, strength of the bond between
the matrix and the fibre surface (which
can be heavily influenced by a sizing that
is applied to the fibre to enhance that
bonding).

Tab.10: Key ATL and AFP equipment suppliers (in
alphabetical order)

One of the fundamental challenges for the
3D printing of fibre-reinforced composites is how to orient the fibre and have it as
long as possible. Another major challenge
is to have good interlayer bonding and an
acceptably low level of porosities/voids. A
large number of process solutions to these
challenges have been invented and will be
presented in this section.

* Accudyne
* Automated Dynamics (Part of Trelleborg Group)
* Cincinnati
* Coriolis Composite Technologies
* Electroimpact
* Fives
* Ingersoll Machine Tools
* M.Torres
* Mikrosam

The complex, fragmented and
diversified world of 3D printing of fibre
reinforced composites
These are still early days in the world 3D
manufacturing of fibre-reinforced composites.
The AFMG Additive Manufacturing

Introduction to the digest
articles on ATL/AFP
The twelve articles in this digest cover the

Expert's digest jec

composites magazine Additive Manufacturing

10



JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020

Contents
Overview - lntroduction to the additive manufacturing of fibre-reinforced composites
Additive manufacturing
Manufacturing  - High-performance creations: additive manufacturing and composites 
Manufacturing - Additive manufacturing of high-performance composite structures 
Technology - Simulating the effects of warpage in an additively-manufactured composite layup tool 
Business insights 
AFP & ATL 
Simulation - Optimizing the key manufacturing parameters of the AFP process 
Simulation - How AFP lay-up affects a composte part’s design intent 
Measurement - Preform permeability measurement and 3D resin flow simulation for dry AFP 
Monitoring - Fibre placement in-process monitoring and solutions for quality optimisation 
Process - Repurposing residual AFP tape for complex aerospace parts 
Process - Rapid manufacturing of a tailored spar by AFP and stamp forming 
Process - PAEK composite prepreg: fast and efficient part manufacturing 
Process - Fibre patch placement: expanding the scope of additive manufacturing 
Process - Automated manufacturing of stiffened composite shells using dry fibre material 
Process - Laser-assisted tape- and fibre-placement-system «Multimaterial Head» 
Process - Economic production of load-optimized thermoplastic composites 
3D printing 
Aerospace - Full-strength 5-axis carbon fibre 3D printing revolutionizes aviation and space 
Aerospace - Successful mission of TuPOD, a TubeSats deployer manufactured via additive manufacturing 
Aerospace - lnduction welding of reinforced additive-manufactured parts 
Automotive - The Energica dashboard reinvented through professional 3D printing and composite materials 
Automotive - Transforming composite production processes with FDM additive manufacturing 
Automotive - Disrupting the composite tooling supply chain 
Marine - World’s first 3D-printed yacht with carbon fibre-reinforced thermoplastic compounds  
Sports & Leisure - Additive manaufacturing applications in sporting goods production 
Sports & Leisure - Making the first 3D-printed carbon fibre bike 
Sports & Leisure - lnnovative composite bicycle frame 
Equipment & Machining - Injection moulding: running tests earlier with 3D printing 
Equipment & Machining - Large-scalme additive manufacturing of composite thermoplastics - where are we?
Construction - 3D printing and new materials are the core of China’s smarter cities 
Construction - 3D printing technology for building and construction 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 1
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Contents
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 5
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Overview - lntroduction to the additive manufacturing of fibre-reinforced composites
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 7
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 8
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 9
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 14
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Additive manufacturing
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Manufacturing  - High-performance creations: additive manufacturing and composites 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 17
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Manufacturing - Additive manufacturing of high-performance composite structures 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 19
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Technology - Simulating the effects of warpage in an additively-manufactured composite layup tool 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 21
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 22
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Business insights 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 24
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 63
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - AFP & ATL 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Simulation - Optimizing the key manufacturing parameters of the AFP process 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 66
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 67
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Simulation - How AFP lay-up affects a composte part’s design intent 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 69
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 70
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Measurement - Preform permeability measurement and 3D resin flow simulation for dry AFP 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 72
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 73
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 74
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Monitoring - Fibre placement in-process monitoring and solutions for quality optimisation 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 76
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 77
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Repurposing residual AFP tape for complex aerospace parts 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 79
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Rapid manufacturing of a tailored spar by AFP and stamp forming 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 81
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 82
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 83
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - PAEK composite prepreg: fast and efficient part manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 85
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 86
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 87
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Fibre patch placement: expanding the scope of additive manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 89
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Automated manufacturing of stiffened composite shells using dry fibre material 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 91
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 92
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 93
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Laser-assisted tape- and fibre-placement-system «Multimaterial Head» 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 95
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Economic production of load-optimized thermoplastic composites 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 97
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 98
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 103
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 3D printing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Aerospace - Full-strength 5-axis carbon fibre 3D printing revolutionizes aviation and space 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 106
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 107
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Aerospace - Successful mission of TuPOD, a TubeSats deployer manufactured via additive manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 109
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 110
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 111
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Aerospace - lnduction welding of reinforced additive-manufactured parts 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 113
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Automotive - The Energica dashboard reinvented through professional 3D printing and composite materials 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 115
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Automotive - Transforming composite production processes with FDM additive manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 117
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Automotive - Disrupting the composite tooling supply chain 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 119
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 120
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Marine - World’s first 3D-printed yacht with carbon fibre-reinforced thermoplastic compounds  
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 122
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Sports & Leisure - Additive manaufacturing applications in sporting goods production 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 124
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Sports & Leisure - Making the first 3D-printed carbon fibre bike 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 126
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 127
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Sports & Leisure - lnnovative composite bicycle frame 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 129
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Equipment & Machining - Injection moulding: running tests earlier with 3D printing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 131
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Equipment & Machining - Large-scalme additive manufacturing of composite thermoplastics - where are we?
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 133
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 134
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Construction - 3D printing and new materials are the core of China’s smarter cities 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 136
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 137
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Construction - 3D printing technology for building and construction 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 139
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 140
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https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_134
https://www.nxtbook.fr/newpress/jeccomposites/jcm2003_133
https://www.nxtbook.fr/newpress/jeccomposites/jcm2001_132
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
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