High-Density Urethane (HDU) boards
Published

Cevotec extends Fiber Patch Placement to sandwich structures, large aerostructures and enables combining with AFP

Automated preforming and layup process addresses core materials, as well as both continuous AFP and patch FPP reinforcements.

Share

Fiber Patch Placement (FPP) is an automated preforming and layup technology for the production of complex fiber-reinforced composite parts used in aerospace and automotive applications as well as medical devices and sports equipment. FPP cuts reinforcement materials to tailored patches and robotically applies these patches to a tool. The resulting 3D, complex-shaped layup may be dry reinforcement which is then infused with resin or cured or, alternatively, may be prepreg tape which is heated and cured into a finished part. In close cooperation with leading aerospace parts manufacturers, Cevotec has further developed FPP to meet the latest industry requirements.
 

Automated aerospace sandwich structures

Cevotec has developed SAMBA Multi production systems to produce complex sandwich construction components by applying a sophisticated material mix, such as adhesive films, glass fiber and carbon fiber layers onto commonly used sandwich cores such as aluminum honeycomb. "SAMBA Multi production systems enable the automated lay-up of this type of multi-material mix in one single system," reports Cevotec CTO Felix Michl. In addition to glass fiber fleeces, metal structures and wood cores (e.g., balsa), SAMBA Multi can apply  load-adjusted fiber patch reinforcements to honeycomb, foam and other core materials. Depending on process requirements, this can be done in-line or in parallel to line production to optimize cycle times.

SAMBA Multi has parallel units for feeding different materials which are then placed precisely on 3D sandwich cores or preforming tools. By mounting the FPP unit on a linear axis, the concept also enables the production of long and wide components for aerospace applications. Adapted to specific component sizes, patch grippers have been scaled to DIN-A5 and DIN-A4 sizes to meet the requirements of common aircraft components. An integrated gripper station enables the exchange of grippers during the process.

"The automated multi-material lay-up of complex sandwich components has an extremely positive effect on process times and thus the production volume," explains Thorsten Groene, Cevotec managing director. "Fiber deposition with controlled pressure and heat enables skipping intermediate compactions and thus reduces process times significantly.” FPP sustainably reduces recurring production costs in many applications, adds Groene. "Material savings of 20-50% play a major role, but automation with FPP often enables further optimization of the overall process.”

SAMBA Multi is also readily scalable. The same process works both for a few hundred and several thousand units per year," explains Michl. These are expected scenarios in the up-and-coming “flying car” industry, for example.  “Thanks to the quick-change system and short set-up times, a product change on the system is no problem and economically reasonable: During ramp-up, an FPP system’s capacity can be used for several components. With increasing quantities, the machine park is expanded and the systems become more dedicated. The advantage: the process remains the same – no new product development and no re-qualification of parts are necessary."
 

Combining AFP and FPP laminates

Cevotec has been asked if FPP and Automated Fiber Placement (AFP) processes could be combined. “Yes,” says Cevotec executive vice president Dr. Neven Majic. “We are currently extending our ARTIST STUDIO software to accommodate the relevant features for laminate design with endless fiber tapes as used in AFP processes. The new module TAPE ARTIST will be seamlessly integrated into ARTIST STUDIO, and will also use MOTION ARTIST for machine data generation and process simulation.” TAPE ARTIST can also be combined with PATCH ARTIST into a single joint module, enabling engineers to design integrated laminates based on both AFP and FPP technology.

Like SAMBA Multi, TAPE ARTIST will be presented to the public this fall at Composites GoCarbon Fiber (Oct 9-11, Berlin, Germany), Advanced Engineering (Oct 31-Nov 1, Birmingham, UK) and Composites Europe (Nov 6-8, Stuttgart, Germany) and will be commercially available by the end of the year.

Wickert Hydraulic Presses
PRO-SET Laminating Epoxies
High-Density Urethane (HDU) boards
Composites One - distributor
Collier Aerospace's HyperX Users Conference 2025
Compsoite and Metallic tooling, parts, assemblies
Park Aerospace Corp.
Large Scale Additive Manufacturing
HEATCON Composite Systems
Airtech
Alpha’s Premier ESR®
Industrial CNC Routers

Related Content

Jeep all-composite roof receivers achieve steel performance at low mass

Ultrashort carbon fiber/PPA replaces steel on rooftop brackets to hold Jeep soft tops, hardtops.

Read More

Large-format 3D printing enables toolless, rapid production for AUVs

Dive Technologies started by 3D printing prototypes of its composite autonomous underwater vehicles, but AM became the solution for customizable, toolless production.

Read More
Epoxies

Plant tour: Joby Aviation, Marina, Calif., U.S.

As the advanced air mobility market begins to take shape, market leader Joby Aviation works to industrialize composites manufacturing for its first-generation, composites-intensive, all-electric air taxi.

Read More

TU Munich develops cuboidal conformable tanks using carbon fiber composites for increased hydrogen storage

Flat tank enabling standard platform for BEV and FCEV uses thermoplastic and thermoset composites, overwrapped skeleton design in pursuit of 25% more H2 storage.

Read More

Read Next

Compression Molding

VIDEO: High-volume processing for fiberglass components

Cannon Ergos, a company specializing in high-ton presses and equipment for composites fabrication and plastics processing, displayed automotive and industrial components at CAMX 2024.

Read More
Carbon Fibers

All-recycled, needle-punched nonwoven CFRP slashes carbon footprint of Formula 2 seat

Dallara and Tenowo collaborate to produce a race-ready Formula 2 seat using recycled carbon fiber, reducing CO2 emissions by 97.5% compared to virgin materials.

Read More
Carbon Fibers

Developing bonded composite repair for ships, offshore units

Bureau Veritas and industry partners issue guidelines and pave the way for certification via StrengthBond Offshore project.

Read More
Composites One - distributor