JEC COMPOSITES MAGAZINE - 2020 1st Quarter - Innovation report - 30

Multi-sector

INNOVATION REPORT
COMPACT AND ACCESSIBLE AUTOMATED FIBRE PLACEMENT

DELTA VIGO PRESENTS A NEW
AUTOMATED PREFORMING SYSTEM

Delta Vigo's Delta Carbon Fiber Technologies business
unit manufactures composite parts with its own developed
technology in out-of-autoclave processes, both impregnation
and prepregs. It developed and widely tested an automated
preforming system.
Main advantages:
Optimized fibre orientation; Minimized fibre distortion, making it
possible to manufacture CFRP parts that are not feasible using
conventional processes; No wrinkles, undulations or impregnation
Flexible configuration; Possibility of incorporating local reinforcements;
Methodic spring-back control and correction; Cost improvement;
Reduced lead times (improved reactivity).
Delta
Vigo's
press
forming
technology makes it possible to
produce carbon fibre components
with high repeatability, very good
geometry, automatic control of
pressure, temperature, etc. It is used
for the newest large aircraft and fighter planes. This unique technology
can be automated, and thus adapted to Industry 4.0 high production
rates. The company's "slipskins" are specialized composite tooling to
manufacture A220 wings; they are 18 metres long and weigh 2700 kg.
For each part, 1000 kg of resin are injected in one shot.

Aerospace

www.deltagroupspain.es

Multi-sector

Carbon Axis presents its compact and lightweight Automated Fibre Placement (AFP) solution. The XCell is a turnkey
solution that automates the preforming of small composite parts (dimensions up to 1m x 0.5m x 0.5m). It can lay fibres
from towpreg or slit tape material both on flat and complex 3D surfaces. The robotic cell includes a small-payload
six-axis robot and a dedicated AFP head attached to the robot arm in an enclosed and temperature-controlled
environment. The innovative AFP head design coupled with an ultrasonic cutter delivers net-shape preforms with
high accuracy and reduced material wastage. To control and program the machine, Carbon Axis developed a dedicated
all-in-one AFP software enabling the user to design his part, set his layup sequence, view the robot trajectories Aeronautic and, finally, export the
robot code for the machine. The main advantage of this solution is the automation of the current labour-intensive process, with an accessible
hardware and software package that will increase part quality and process repeatability while reducing raw material wastage. Typical applications
can be found, among others, in the sports and leisure, motorsports, automotive and general industry sectors. www.carbon-axis.com

50% COST SAVING USING SMART
PROCESSES AND HYBRID MATERIALS

Schuler and other partners of the iComposite 4.0 research project
achieved a 50% cost reduction compared to traditional textilebased HP-RTM process chains. An integrative and self-regulating
production system for high volumes utilizing hybrid
materials was developed for this purpose.
In the first production step, conducted by RWTH
Aachen IKV, a robot sprays the basic structure
of glass fibres. Next, an algorithm - developed
by RWTH Aachen AZL and CFRP supplier Teijin
Carbon - calculates the individual tensile strength.
Depending on this, another robot, supplied by
Siemens and Broetje Automation Composites,
then lays the fully-automatically designed carbon
fibre towpreg structure, thereby compensating for
component variations. Optical control is performed by a 3D measuring
system from Apodius. Epoxy resin is then injected into the fibre mat
using an adaptive HP-RTM process. The resin hardens under the high
pressure of the Schuler compact hydraulic press, which forms the part
at the end. The die technology from Frimo specialists also influences this
process. For the desired wall thickness, the press can directly impact
the deflection of the die. This approach makes it possible to produce
quality parts right from the start, the rejection rate is reduced to zero.
This research project is sponsored by the German Federal Ministry of
Education and Research. www.schulergroup.com

LAP'S DTEC-PRO: MORE FLEXIBLE COMPOSITE MANUFACTURING

LAP enhanced the features of the DTEC-PRO camera system to address the demands for flexible
production concepts and higher efficiency in composite manufacturing. DTEC-PRO accelerates
the calibration of the laser projection system, resulting in considerable time savings. The camera
system is intended, in particular, for manufacturing centres in the aerospace industry and other
industries that require many different tools to be handled and transported on movable carts.
Lately, LAP added new features that make it possible to open and assign calibration files and to execute
calibration nearly automatically. One feature enables automatically loading calibration files via a QR code.
As soon as a workpiece is placed in the detection range of the camera system, the camera scans the QR code linked to files such as the associated
order documentation. Upon the user's confirmation, the calibration file assigned to the tool is then opened and the calibration automatically started.
DTEC-PRO is suitable for all new or existing CAD-PRO laser projection systems. Another advantage is the system's modularity: only one camera is
required to support a number of CAD-PRO laser projectors. DTEC-PRO cuts calibration time from minutes to seconds. Together with LAP's CADPRO laser projection system and PRO-SOFT control software, companies can benefit from increased efficiency, flexibility and process reliability in
their composite manufacturing processes.
www.lap-laser.com

jec composites magazine / January-February-March 2020

http://www.carbon-axis.com http://www.deltagroupspain.es http://www.schulergroup.com http://www.lap-laser.com

JEC COMPOSITES MAGAZINE - 2020 1st Quarter - Innovation report

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