Descripción del proyecto
La impresión 3D da a luz a una nueva herramienta de molde para el sector aeroespacial
La fabricación por adición permite producir de forma fiable componentes con formas complejas mediante la superposición ascendente de capas de materiales guiada por un archivo de diseño digital. Ha tenido mucho éxito a la hora de reducir el tiempo y los costes de producción y mejorar la calidad de diferentes componentes. Con todo, hasta hace poco, el tamaño de estos productos estaba limitado por las dimensiones de las impresoras tridimensionales que se usaban para aplicar capas de materiales. El proyecto COMBO3D, financiado con fondos europeos, empleará impresoras nuevas de mayor tamaño para permitir la impresión tridimensional de una herramienta de molde termoplástico reforzado con fibra para el sector aeroespacial. La herramienta incorporará elementos térmicos que facilitarán el calentamiento y enfriamiento del molde y el material compuesto durante la fabricación de los componentes.
Objetivo
COMBO3D proposes to additively manufacture a short fibre reinforced thermoplastic tool with integrated active temperature control, to shorten the cure cycle time and so to focus on the objectives addressing the limitations and implementing the improvements of the state of the art project. By using a robot guided large scale short fibre reinforced plastics extrusion additive manufacturing process the tool can be produced as a single part, directly integrating the temperature control, shortening the lead-time and enabling simple and fast restoration of the tool surface to compensate for the expected lower lifespan. Using a robot-guided process also allows to print the final demonstrator tool in one piece in curved layers (real 3D printing). To ensure tool stability during the curing cycle, short carbon fibre reinforced semi-crystalline high performance thermoplastic PAEK will be used. Commercially available PAEK have a form stability of over 250°C in unreinforced grades and CF filled grades are available with heat deflection temperatures of 315°C and more.
By introducing heating elements in the tool, it can conduct heat to the parts lower surface, in combination with the autoclave or oven, heating it up from both sides. These heating elements can be electrical or fluid channels connected to an external temperature control. Electric heating elements provide higher heat up rates but fluid heating allows to change from heating to cooling mode and hence to also cool the tool. Thereby it is possible to also achieve faster cool down. COMBO3D therefore proposes to use both heating elements in the tool.
The whole development of the printed tool is supported by simulation. The design of the tool will be optimized by implementing the heating and cooling system in a thermal simulation. The manufacturing process simulation supports the printing process by generating knowledge about the temperature distribution during printing and correlating it with path planning.
Ámbito científico
Programa(s)
Régimen de financiación
CS2-RIA - Research and Innovation actionCoordinador
80333 Muenchen
Alemania