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RESULTS1. Process parameter analysis (Markforged vs. CUAS)

2. Design study of corner jointVarious intuitive design studies have been developed andmanufactured. To verify the optimum utilization of the fiberreinforcement in the direction of load, a quasi-static test was carriedout.

3D Addtive Manufacturing ofHigh Performance Composites (AMHPC)

INTRODUCTIONGenerative manufacturing processes, such as 3D printing, areenabled of rapid prototyping of different kinds of mechanicalparts. This improvement from traditional manufacturingprocesses leads to a new design freedom and functionalities.However, open-market 3D printers for thermoplastics are black-box solutions limited to layer wise prints resulting in partssensitive to multi-dimensional stress and inhibit further code-optimization. Therefore, rapid prototyping models are mainlyused to visualize design concepts. Especially within the field oflightweight engineering the merge of manufacturingtechnologies (3D printing) and material science (continuous fiberreinforced composites) is far from tapping the full potential. Themain technological objective of the project is the developmentof a robot cell for the 3D printing of fiber reinforced lightweightmaterials such as carbon, glass, aramid and natural fibers. Thecore of innovation is characterized by the adaption of a 6-axialrobotic arm with the extrusion technology and a fibermanipulator. This novel technology provides a multi movableobject 3D printed composite material (MMO3D) with remarkablematerial properties.

OBJECTIVESThe overall objective of the project is, on the promising fields ofmechanical engineering and robotics, to connect competentR&D stakeholders and existing knowledge in the program areaand encourage the transfer of technology and expertise fordeveloping new products, technologies and services, and thuscontribute to improve economic cohesion, technologicaldevelopment, innovation and competitiveness in the field ofprogramming.• Additive production of high-performance fiber composites

components• Adaptation of a 6-axis industrial robot to align reinforced

fiber in all 3 dimensions of force flow• Show the innovative technology on a demonstrator (corner

joint of battery box for an electric car)• Portable unit design for demonstration and learning purpose

METHODS• Mechanical and microstructural material characterization• Mechanical calculation (Classical Laminate Theory)• Characterization of the layer geometry• Control of process parameters• FEA Simulation (Ansys ACP-PrePost)• Experimental validation of material properties and

component strength at multi-dimensional stress state

Conclusion and OutlookA compact overlapping printing strategy enhances the flexiblematerial properties in the transverse fiber direction. However, theflexural stress in the longitudinal direction decreases significantly,presuming the lower adhesion surface leads to delamination.

By using topology-optimized framework structures, goodmechanical properties for a specific application are achieved. Theadvantages are:

• creative design of fiber composites by using AM-systems• sustainable and resource-saving use of fiber reinforcement in the

main direction of load• weight and strength optimization.

• Analysis of AMHPC laying strategy by 6-axis technology• Development of an numerical material simulation strategy• Advanced AMHPC 6-axis printing technology with patent

application.• Comparison of printed vs. hand laminated corner joint

PROJECT: MMO3D

PROGRAM: SI-AT INTERREG

PROJECT LEADER: Oprema Ravne

DURATION: 3 years (09/2016 – 09/2019)

CONSORTIUM: 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 1, 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 2, 𝐶𝐶𝑈𝑈𝑈𝑈𝑈𝑈 3, 𝑊𝑊𝑊𝐶𝐶 4, 𝑂𝑂𝑂𝑂𝑂𝑂𝑅𝑅𝑂𝑂𝑂𝑂 𝑅𝑅𝑂𝑂𝑅𝑅𝑅𝑅𝑅𝑅 5;

LINK: https://forschung.fh-kaernten.at/mmo-3d

𝐶𝐶𝐶𝐶𝑂𝑂𝑂𝑂𝐶𝐶𝐶𝐶𝐶𝐶𝑂𝑂 𝐵𝐵𝑅𝑅𝐵𝐵𝐵𝐵𝑅𝑅𝑂𝑂1, 𝐽𝐽𝑅𝑅𝑅𝑅𝑂𝑂 𝐵𝐵𝐵𝐵𝐶𝐶𝑅𝑂𝑂𝑅𝑅𝐶𝐶1, 𝐾𝐾𝑂𝑂𝑂𝑂𝐶𝐶 𝑈𝑈𝑅𝑅𝑅𝑅𝑂𝑂𝐶𝐶1, 𝑇𝑇𝑅𝑅𝑅𝑂𝑂𝑂𝑂𝐶𝐶 𝐻𝐻𝑂𝑂𝑂𝑂𝑂𝑂𝑅𝑅𝑂𝑂𝐶𝐶𝑅𝑅𝐶𝐶𝑅𝑅𝐻𝐻𝐶𝐶1, 𝐻𝐻𝑂𝑂𝑅𝑅𝑅𝑅𝑅𝑅𝐶𝐶 𝑂𝑂𝑅𝑅𝑅𝑅𝑂𝑂𝐶𝐶𝑅𝑅𝑂𝑂𝐵𝐵𝑅𝑅𝑅𝑂𝑂1, 𝑈𝑈𝑂𝑂𝑂𝑂𝑅𝑅𝐹𝐹 𝑅𝑅𝐶𝐶𝑅𝑅𝑂𝑂𝑅𝑅𝐶𝐶𝑂𝑂𝑅𝑅𝐶𝐶𝑅𝑅𝑂𝑂1, 𝐷𝐷𝑅𝑅𝑂𝑂𝐶𝐶𝑅𝑅𝐶𝐶𝐵𝐵 𝐶𝐶𝐵𝐵𝐶𝐶𝑅𝑅𝑂𝑂1, 𝐶𝐶𝐶𝐶𝐴𝐴𝑂𝑂𝑅𝑅𝐴𝐴 𝑊𝑊𝐶𝐶𝑅𝑅𝐶𝐶𝑅𝑅𝑂𝑂1, 𝐺𝐺𝐺𝑅𝑅𝑅𝑅𝑅𝑅𝑂𝑂 𝑊𝑊𝐵𝐵𝐹𝐹𝑅𝑅𝐶𝐶𝐶𝐶𝑂𝑂4;

Abb.1) Summary of the process parameter study

Abb.2) Set-up of the flexural and flexural-torsional test

Abb.3) Evaluation of the flexural and flexural-torsional test