CFRP-AM

Carbon Fiber Reinforced Polymers and Additive Manufacturing
Individualized cost-efficient and sustainable ultra-lightweight structural components

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.

Core of an aircraft instrument panel with structural components made by AM, Source: ETH Zürich

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.

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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
  
  

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Key Technical Problems to Solve

• Fiber distribution for variable stiffness laminated structures
  
• 3D printing of complex materials
• Fracture interface mechanics of complex, inhomogeneous materials
  

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Demonstrators

• Exo-skeleton component
  
• Transcatheter heart valve
  
• Structural aircraft component
  
  

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Linked Scientific Publications

2021

• 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.

Leading Principal Investigator

Prof. Dr. Paolo Ermanni
Laboratory of Composite Materials and Adaptive Structures, ETH Zürich 

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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, EPF Lausanne
• Prof. Dr. Giovanni Terrasi, Laboratory for Mechanical Systems Engineering, Empa
• Prof. Dr. Roger Gassert, Institute of Robotics and Intelligent Systems / Rehabilitation Engineering Lab, ETH Zürich
• Dr. Markus Zogg, ics, Inspire AG
• Dr. Christoph Klahn, ipdz, Inspire AG