DLR invests in automated preforming spin-off COPRO Technology GmbH
German Aerospace Center (DLR) supports reduced-cost roll-forming of composite profiles
Lightweight structures are on the rise both in aircraft and automotive manufacturing. So far, it has only been possible to mass-produce these components at great cost. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) has granted COPRO Technology GmbH the license for a new, economical manufacturing technology. By doing so, it establishes a new player that specializes in automated, continuous roll forming of CFRP preforms. DLR has in return acquired a corporate shareholding in the firm, which was founded in October 2016.
One of DLR's strategic aims is to reinforce its support for start-ups and successfully promote these by means of corporate investments. "We are delighted that our institute has spawned another new company, which takes innovations from the research stage through to cost-efficient CFRP production," says Martin Wiedemann, Director of the DLR Institute of Composite Structures and Adaptive Systems. "The plant technology developed by the COPRO Technology founders at the Institute makes it extremely economical to form profile geometries from textiles, which can be used in a wide variety of lightweight construction applications. The potential of this system technology is manifold and the Institute will continue to support its development in the future."
COPRO simplifies the manufacturing process for CFRP components
Future economical composite manufacturing is based on automated production systems with smart process control and direct quality monitoring during the production process. Highly stressed lightweight structures, such as aircraft fuselage stiffeners or car roof support, largely consist of continuous profiles. Manufacturing these from lightweight materials, such as fiber-reinforced composites, is a challenge due to their complex curvatures.
Until now, it has only been possible to automatically produce composite profiles using expensive winding, weaving and pressing processes. "Even complex, three-dimensional profile geometries can be efficiently and cost-effectively manufactured using the COPRO-Technology," says Wiedemann. "The COPRO-Technology patented at DLR uses rotating pairs of rollers. Semi-finished textiles are continuously formed into preform profiles by rollers rotating with variable speeds."
For more details on the process see CW’s two-part series on Automated Preforming and blog series:
Preforming goes industrial: Part 2 : Automated preforming isn’t only for 2D and 2.5D parts. Innovators are taking successful aim at building 3D preforms at production speeds.
Automated preforming: The numbers and landscape: CW’s multi-blog series on preforming begins with an overview and quick look at the numbers: 1-min takt time, 10-15 seconds per layer, 490-kg/hr and 3.5 million parts/yr. Are you ready for serial CFRP production?
Related Content
-
McLaren celebrates 10 years of the McLaren P1 hybrid hypercar
Lightweight carbon fiber construction, Formula 1-inspired aerodynamics and high-performance hybrid powertrain technologies hallmark this hybrid vehicle, serve as a springboard for new race cars.
-
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.
-
Carbon fiber, bionic design achieve peak performance in race-ready production vehicle
Porsche worked with Action Composites to design and manufacture an innovative carbon fiber safety cage option to lightweight one of its series race vehicles, built in a one-shot compression molding process.
