MANZ AG FULLY AUTOMATED PREFORM PRODUCTION OF COMPLEX GEOMETRY
CFRP PARTS USING FIBER-PATCH-PREFORMING TECHNOLOGY
JUNE 25th, 2014 / MARTIN STEYER
2011-07 2
MARKET TRENDS
COST VIEW FRP-PRODUCTION
3D-FPP - FIBRE PATCH PREFORMING
FIBER-PATCH-PREFORMING
STRUCTURE
1
2011-07 3
Sports / Leisure
Indicators for a Growing FRP-Market:
BMW founds a new brand »BMW i«
and built up a carbon fiber production plant
Joint ventures between BMW-SGL Carbon,
Daimler-Toray and Audi-Voith
German government supports
FRP-development with 300 Mio. €
MARKET TRENDS
Aerospace
E-Cars
[Quelle: BMW, Madzda, Porsche, Mercedes, Fiberglastechnik]
Reasons for FRP-Use in Automotive Industry
Reducing fuel/ energy consumption (1 liter car VW)
Increasing range (electric vehicles)
Increasing crash-behavior (Audi A8 frontend)
Increasing driving dynamics (Porsche GT 3)
Design possibilities (7er BMW trunk lid)
FRP – meets serial production!?
Leaf spring Mercedes Sprinter
Cardan shaft
Monocoque Porsche GT3
FIBER-PATCH-PREFORMING
2011-07 4
Requirements on serial FRP-parts
Quality/ performance requirements
Stresses
Crash
Geometry
Surface finish
MARKET TRENDS
High load capacity
Best crash behavior
Good formability
Up to class-A finish
New cost efficient processes need to be developed
Costs
Personal costs
Material costs
Process costs
High level of manual work
High costs for carbon fiber
Long cycle times
FIBER-PATCH-PREFORMING
2011-07 5
MARKET TRENDS
COST VIEW FRP-PRODUCTION
3D-FPP - FIBER PATCH PREFORMING
STRUCTURE
2
FIBER-PATCH-PREFORMING
2011-07 6
Cost Structure of High Quantity FRP-Parts (Example Saddle)
Number of items 20.000
Write off time (5 %) 5 Year
Personal costs 40.000 €/Year
Number of shifts 1 (8 h)
Machine availability 90 %
Etc. …
1
2
3
4
Material costs Personal costs
Variable costs
(energy, maintain, etc.)
Investment costs
Shares of Production Costs
45% 28%
18% 9%
COST VIEW FRP-PRODUCTION
Material price
Material consumption
1
2
Automation 3
FIBER-PATCH-PREFORMING
2011-07 7
Cost Structure of High Quantity FRP-Parts (Example Saddle)
Number of items 100.000
Write off time (5%) 5 Year
Personal costs 40.000 €/ Year
Number of shifts 3 (8 h)
Machine availability 90 %
Etc. …
COST VIEW FRP-PRODUCTION FIBER-PATCH-PREFORMING
Shares of Production Costs
Personal costs
4 %
Variable costs
2 %
Investment costs
4 %
90 %
Material costs
Material price
Material consumption
1
2
2011-07 8
Material Efficient Reliable processes with low scrap rates
Low level of waste
Material saving processes
Material saving product design
(load optimized laminate design)
High Level of Automation Short cycle time
Cost effective systems
Cost efficient tools/ molds
Saving Variable Costs Energy effective processes
Robust systems (maintain)
Processes with low operational material consumption
Cost Effective FRP-Processes
for Serial Production
COST VIEW FRP-PRODUCTION FIBER-PATCH-PREFORMING
2011-07 9
Fiber/matrix production
Pre impregnation
Cutting
Handling
Transport/logistics
Pick and place
Automated preforming/ draping
Bindered preforming
Organo sheet preforming
Pre consolidation
Mold loading
Press/injection (RTM) (consolidation)
Tool and die manufacturing
Press production
Demolding and storing
Manz Production Systems and Processes within the FRP Manufacturing Chain:
US
P
Pre
form
ing
FRP-PROCESS CHAIN FIBER-PATCH-PREFORMING
2011-07 10
MARKET TRENDS
COST VIEW FRP-PRODUCTION
3D-FPP - FIBER PATCH PREFORMING
STRUCTURE
3
FIBER-PATCH-PREFORMING
2011-07 11
3D-FPP - Demonstrated on a Saddle
3D-FPP - NEW PREFORM TECHNOLOGY
Production process for small FRP-parts
Parts with highest light weight potential
Material efficient
Fully automated process
Short cycle time
High flexibility
Licensed by Airbus
FIBER-PATCH-PREFORMING
2011-07 12
Process
simulation
3D laminat
placement
CAD model
& load case
Resin injection
& cross linking
Load optimized
3D-FRP-part
Optimized product
design and fiber
architecture
SOWEMA- Software-, Werkzeug- und Maschinenentwicklung für eine
vollautomatische und geschlossene Leichtbau-Fertigungskette
FIBER-PATCH-PREFORMING
3D-FPP - NEW PREFORM TECHNOLOGY
Video
2011-07 13
FIBER-PATCH-PREFORMING
3D FPP - NEW PREFORM TECHNOLOGY
2011-07 15
Standard tailored fabrics More than 30% material saving against
standard processes
A A A
A-A
A B B
B-B
Material saving area
COST SAVING
Material consumption 2
FIBER-PATCH-PREFORMING
Load optimized
fiber orientation
Load optimized
laminate thickness
Undulation-free
fiber orientation
Near optimal
laminate build up
2011-07 16
Less waste than 5 % of carbon fiber More waste than 30 % of carbon fiber
Low level of waste (near-net-shape)
FIBER-PATCH-PREFORMING
COST SAVING
Material consumption 2
2011-07 17
Material Efficient Reliable processes with low scrap rates
Low level of waste
Material saving processes
Material saving product design
(load optimized laminate design)
High Level of Automation Short cycle time
Cost effective systems
Cost efficient tools/ molds
Saving Variable Costs Energy effective processes
Robust systems (maintain)
Processes with low operational material consumption
Cost Effective FRP-Processes
for Serial Production
FIBER-PATCH-PREFORMING
FPP – COST VIEW
2011-07 18
Local reinforcements
(window frame, hole reinforcements, etc.)
Shell structures
(saddles, wheels, motor cover, etc)
Sub laminates
(aircraft stringers, clips, etc.)
FPP
flexible process
FIBER-PATCH-PREFORMING
FPP - FIBER PATCH PREFORMING
2011-07 19
THANK YOU TO:
FPP - FIBER PATCH PREFORMING
Federal Ministry of
Education and
Research (BMBF)
for supporting the
»SOWEMA«
and the
»BIOTEX«
project
European Commission
for supporting the
»IMAC-PRO« project
And all project partners
FIBER-PATCH-PREFORMING
Process &
machine
development
User
Software
development
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