CFRP-AM
Carbon Fiber Reinforced Polymers and Additive Manufacturing
Main Achievement? - PLACEHOLDER
Placeholder Text - To be replaced Suggestion: One of three demonstrators?
project
Background and Main Goal
The main task of any natural and technical structure is to guarantee functionality and integrity and to be light in order to minimize material and energy consumption over the entire lifetime. Considering that material, function and form are intimately related to one another, structural efficiency can be improved by multi-material approaches, optimal design topology in terms of material orientation and distribution, and integration of functions.
A key challenge is the realization of individualized lightweight solutions with high customer value. The project consortium aims to push the potential of lightweight through the combination of Carbon Fiber Reinforced Polymers (CFRPs) and Additive Manufacturing (AM) technologies.
Scope of Research Activities
Optimal use of carbon fibers: ➜ Development of a flexible, cost-efficient, and sustainable design and manufacturing route for variable stiffness laminated structures Efficient design processes for Additive Manufacturing (AM): ➜ Development of methods and tools for an efficient design process, including a design tool for the parametrical CAD modeling of functional and load-bearing elements in target applications 3D printing of soft/hard complex materials: ➜ Formulation of printable inks with varied mechanical properties to enable fabrication of graded parts and interfaces and development of an additive manufacturing platform for DIW on non-planar surfaces Fracture and interface mechanics of interfaces/interphases: ➜ Characterize the durability (load transfer, stiffness) and fracture of the interfaces/interphases between the different scaffolds, produced by the 3D printing, and polymer composite, steel and/or aluminum, or other chosen appropriate materials Structural Mechanics & Design: ➜ Development of robust and integrated component-level testing and simulation environment based on in-service loading conditions to provide: (i) initial input conditions for implementing and optimizing component designs, and (ii) experimental validation of prototypes Key Challenges and Technical Problems to Solve
➜ Fiber distribution for variable stiffness laminated structures ➜ 3D printing of complex materials ➜ Fracture interface mechanics of complex, inhomogeneous materials Achievements
Manufacturing route for lightweight AM-CFRP parts
The production of parts from carbon fiber reinforced polymers (CFRP) requires the use of cores, molds, and tools. However, conventional manufacturing methods, such as milling, often restrict the geometric complexity of such tools. In contrast, additive manufacturing (AM) offers the possibility to fabricate complex-shaped tools at reduced manufacturing costs and time. Within the project, we explored AM cores for the production of lightweight composite structures. For example, this novel manufacturing route was applied for the fabrication of components of the VARILEG exoskeleton for the CYBATHLON competition.
Contact: Dr. Manuel Biedermann Involved Research Groups
Related Publications
Digital design process of costumized AM-CFRP parts
For biomedical applications, such as orthoses, prostheses, and exoskeletons, the combination of additive manufacturing (AM) and carbon fiber reinforced polymers (CFRP) offers the potential to fabricate novel lightweight structures that are customized to specific shape and body weight of patients. In the project, we demonstrate this potential using the example of an exoskeleton component. The developed digital process chain includes the 3D scanning of the body shape, automated design customization, and load-bearing optimization of the composite layup using patched laminates as a reinforcement.
Contact: Dr. Manuel Biedermann Involved Research Groups
Related Publications
6 Axis Multi-Material 3D Printing system
The additive manufacturing system developed and built during the course of the project was designed to extrude soft and elastomeric materials over the surface of non-planar objects. Utilizing a laser measurement device, the work-piece position and shape could be ascertained before printing. Deposition of materials was achieved either by atomising spray (creating layers as thin as 5 micrometers) or by extrusion (with layers down to 200 micrometers). Demonstrators included a carbon-fiber and PEEK stent reinforced heart valve, and also a self-healing silicone based aortic model.
Contact: Prof. Dr. André Studart Involved Research Groups
Related Publications
Characterization and optimization of bi-material interfaces
Identification of the effects of service loads and residual stresses in an in-situ cured CFRP-Alumimun interface. Direct implementation of the concept leads to high residual stresses, highly affected by curing temperature and stiffness gradient on the bonded components. When dealing with thin-walled FRP-metallic interfaces, elimination of highly stressed interface domains allows for design feasibility with efficient load transfer. Soft-stiff material interface behavior is highly affected by the compliance of the soft substance given that the tractions are resulting from the local strains.
Contact: Dr. Georgios Pappas Involved Research Groups
Related Publications
In-situ load assessment for exo-skeleton
A next generation exo-skeleton was developed using Carbon Fiber Reinforced Polymers (CFRPs) and Additive Manufacturing (AM) technologies. Load monitoring on a conventional system during different activities of daily life (level walking, sit down, ramp up/down, Stairs up/down, etc.) was performed. The measured loads were used to design a new hip frame component of the exo-skeleton. Static tests on a manufactured prototype of the device including strain gauge based measurements were carried out to validate the computational models and to assess the mechanical integrity of the developed demonstrator.
Contact: Dr. Bernhard Weisse and Prof. Dr. Giovanni Terrasi Involved Research Groups
Related Publications
Demonstrators
Individualized lightweight exoskeleton hip-pelvis component
Individualized lightweight exoskeleton hip-pelvis was developed & manufactured, comprising of hybrid material domains. A lightweight composite hollow section connects the two metallic, motion introduction supports, while carrying the electrical and electronic devices. The component is manufactured via an innovative approach from 3D body scanning to additively manufactured (AM) inner mold-scaffold, which is partially integrated in the final structure. The composite part is cured directly on the AM scaffold as well as the metallic connection, providing manufacturing efficiency and durability.
Contact: Prof. Dr. Paolo Ermanni & Dr. Georgios Pappas Involved Research Groups
Related Publications
Heart valve implant by composite stent & deposited leaflets
Innovative heart valve implant inspired by aerospace adaptive structures is being developed, comprising of packageable stent made of carbon fiber reinforced PEEK, with soft, direct ink deposited, silicone leaflets. Advanced thin-composite shell mechanics provide framework for robust folding and deployment step. Novel manufacturing techniques allow for thin-ply hemocompatible thermoplastic stent, while advanced self calibrating multi-axis 3D printer allow for robust direct leaflet print on the stent. Soft-stiff material interface characterization and optimization proves concept feasibility.
Contact: Prof. Dr. Paolo Ermanni & Dr. Georgios Pappas Involved Research Groups
Related Publications
Publications
2022
Vidrih, T., P. Winiger, Z. Triantafyllidis, V. Ott and G. P. Terrasi (2022) "Investigations on the Fatigue Behaviour of 3D-Printed Continuous Carbon Fibre-Reinforced Polymer Tension Straps." Polymers 14(20). 2021
Biedermann, M., M. Widmer and M. Meboldt (2021). "Additive Manufactured Break-Out Cores for Composite Production: A Case Study with Motorcycle Parts." Proceedings of the Munich Symposium on Lightweight Design 2020, Berlin, Heidelberg, Springer Berlin Heidelberg. Biedermann, M., P. Beutler and M. Meboldt (2021). "Automated design of additive manufactured flow components with consideration of overhang constraint." Additive Manufacturing 46: 102119. Pappas, G. A., A. Schlothauer and P. Ermanni (2021). "Bending failure analysis and modeling of thin fiber reinforced shells." Composites Science and Technology 216: 108979. 2020
Biedermann, M. and M. Meboldt (2020). "Computational design synthesis of additive manufactured multi-flow nozzles." Additive Manufacturing 35: 101231. Pappas, G. A. and J. Botsis (2020). "Variations on R-curves and traction-separation relations in DCB specimens loaded under end opening forces or pure moments." International Journal of Solids and Structures 191-192: 42-55. Schlothauer, A., G. A. Pappas and P. Ermanni (2020). "Material response and failure of highly deformable carbon fiber composite shells." Composites Science and Technology 199: 108378. 2019
Kussmaul, R., M. Biedermann, G. A. Pappas, J. G. Jónasson, P. Winiger, M. Zogg, D.-A. Türk, M. Meboldt and P. Ermanni (2019). "Individualized lightweight structures for biomedical applications using additive manufacturing and carbon fiber patched composites." Design Science 5: e20. Kussmaul, R., J. G. Jónasson, M. Zogg and P. Ermanni (2019). "A novel computational framework for structural optimization with patched laminates." Structural and Multidisciplinary Optimization 60(5): 2073-2091. Kussmaul, R., M. Zogg and P. Ermanni (2019). "A failure mechanics and strength optimization study for patched laminates." Composite Structures 226: 111165. Pappas, G. A. and J. Botsis (2019). "Design optimization of a CFRP–aluminum joint for a bioengineering application." Design Science 5: e14. Schlothauer, A. and P. Ermanni (2019). "Stiff Composite Cylinders for Extremely Expandable Structures." Scientific Reports 9(1): 15955. Türk, D.-A., F. Rüegg, M. Biedermann and M. Meboldt (2019). "Design and manufacture of hybrid metal composite structures using functional tooling made by additive manufacturing." Design Science 5: e16. 2018
Kussmaul, R., M. Zogg and P. Ermanni (2018). "An optimality criteria-based algorithm for efficient design optimization of laminated composites using concurrent resizing and scaling." Structural and Multidisciplinary Optimization 58(2): 735-750. Kussmaul, R., M. Zogg and P. Ermanni (2018). "An efficient two-dimensional shear-lag model for the analysis of patched laminates." Composite Structures 206: 288-300. Team and partners
Project Consortium
Prof. Dr. Mirko Meboldt Product Development Group Zürich (pd|z), ETH Zürich Prof. Dr. André Studart Complex Materials, ETH Zürich Prof. Dr. John Botsis Laboratory of Applied Mechanics and Reliability Analysis, EPFL Prof. Dr. Giovanni Terrasi Laboratory for Mechanical Systems Engineering, Empa Prof. Dr. Roger GassertInstitute of Robotics and Intelligent Systems / Rehabilitation Engineering Lab, ETH Zürich Dr. Markus Zogg ics, Inspire AG Dr. Christoph Klahn ipdz, Inspire AG Leading Principal Investigator
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