Description du projet
Un nouvel outil de moulage destiné au secteur aérospatial prend forme grâce à l’impression 3D
La fabrication additive permet de produire de manière fiable des composants aux formes complexes en superposant des matériaux de bas en haut à partir d’un fichier de conception numérique. Elle a permis de réduire le temps et le coût de production de divers composants et d’en améliorer la qualité. Toutefois, jusqu’à une date récente, la taille de ces produits était limitée par celle des imprimantes 3D utilisées pour superposer les matériaux. Le projet COMBO3D, financé par l’UE, tirera parti des nouvelles imprimantes de plus grande taille pour permettre l’impression 3D d’un outil de moulage en thermoplastique renforcé de fibres destiné au secteur aérospatial. L’outil comprendra des éléments thermiques facilitant le chauffage et le refroidissement du moule et du composite pendant la fabrication du composant.
Objectif
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.
Champ scientifique
Programme(s)
Régime de financement
CS2-RIA - Research and Innovation actionCoordinateur
80333 Muenchen
Allemagne