Fully Automated Optimization and Manufacturing of CFRP Components

Manz AG, based in Reutlingen, Germany, is a leading high-tech engineering company that has grown in recent years from an automation specialist into a supplier of production lines. With four main business divisions in Battery/Fuel Cell, Display, Electronics, and Solar applications, Manz provides turn-key production plants for various industries. The company’s New Business division was already involved in the SOWEMA project and had experience in lightweight design and composites. The New Business division was one of the driving forces behind the collaboration with Altair to extend the process of flexible FPP manufacturing with preceded component optimization.

The production of carbon fiber reinforced plastic (CFRP) components in high volume and economically is a significant challenge due to complex design shapes and primarily manual manufacturing processes. This has limited the production of fiber composite materials to small series or single products. Despite the desirable properties of CFRP components, such as their lightweight potential and excellent mechanical properties, their complex design and cost-intensive manufacturing processes have been a disadvantage. The Fiber Patch Preforming (FPP) method, developed under the leadership of Airbus Group Innovations, enabled the automated production of composite preforms from a software lay-up plan. However, the next challenge was creating a manufacturing facility suitable for mass production and efficient processing of the fiber patches. This led to the SOWEMA research project, which aimed to develop a flexible and fully automated manufacturing process using the FPP method.

Manz AG, a leading high-tech engineering company, partnered with Altair and its engineering services division, Altair ProductDesign, to extend the process of flexible FPP manufacturing with preceded component optimization. The overall goal of the SOWEMA project was to shorten the entire development and production cycle, from CAD drawing to final product, while maintaining the flexibility and repeatability the FPP facility offers. To study the feasibility and assess the advantages and disadvantages of the entire process, including an automated optimization, the combined Manz Altair ProductDesign team used a bicycle seat as their first test object. The optimization process was completely automated, with the user only needing to insert the CAD model and the occurring loads. The result of the automated optimization was a file containing the optimized structure of the component, including load-specific fiber orientation and laminate structure. This file was subsequently complemented with process and machine data, and the Manz production machine then manufactured the part using the FPP method.

• The Manz-Altair research project demonstrated the viability of an automated FPP manufacturing process. By providing a fully optimized component as a direct input to the production facility, the ability to flexibly manufacture material-optimized and load-specific composite structures in large volume series comes within reach. The advantages of the automated process are significant. Due to the lower cutoff of the FPP process compared to traditional composite manufacturing methods and the preceded weight optimization, better cost-effectiveness and shorter cycle times can be achieved. The flexibility of the facility is another benefit. Automation and optimization also smooth the learning curve for users, allowing even inexperienced users to manufacture an optimized component. The project members are confident that a fully automated facility suitable for large-volume series production of small and mid-sized fiber composite parts can be achieved.

• The optimized and manufactured bicycle seat met all requirements regarding mass and stiffness.
• Compared to the non-optimized seat from the first phase of the SOWEMA project, the new model offered a 30 percent reduction in weight.
• The process is suitable for large volume series.