composite tooling application - dsm · whether your application requires reusable layup mold...

INTRODUCTIONCOMPOSITE TOOLING

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Key drivers

▪ Weight reduction

▪ Design freedom

▪ CO2 reduction

Lightweight materials and design have always been an

important topic in product design across several industries.

The concept has been most important in aviation and also

in automotive, where driving dynamics are a major

consideration. Global trends toward CO2 reduction and

resource efficiency have significantly increased the

importance of this topic over the last years.

Fiber-reinforced plastics are a unique solution for

engineers in aerospace, automotive and sporting goods

because of their incredible strength-to-weight ratio. The

combination of fibers and polymer form a new material

with improved physical properties.

APPLICATION AREAS

COMPOSITE TOOLING

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Aerospace Automotive Marine

COMPOSITE TOOLINGINDUSTRY CHALLENGES

Whether your application requires reusable layup

mold tooling or sacrificial tooling for complex,

trapped-tool geometries, Additive Manufacturing

simplifies the fabrication of composite parts while

provided unparalleled design freedom. High

temperature, cost effective tools can be produced in

days, compared to the weeks or even months

required for traditional tooling.

Industry drivers

➢ Reduce cost and leadtime

➢ Produce (small series) functional products

➢ Respond quickly to customer demands

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HOLLOWCOMPOSITE SUB-APPLICATION

HOLLOW COMPOSITESINDUSTRY CHALLENGES

While basic shapes with constant cross sections are

easily manufactured using traditional composite

manufacturing techniques, complex composite parts

with hollow interiors present a unique manufacturing

challenge. Any configuration that traps a core or

mandrel inside requires sacrificial tooling.

Industry drivers

➢ Design freedom to create any hollow composite shape

➢ Create smooth internal and external composite surfaces

➢ Reduce turn around time from design to part

➢ Provide a cost effective solution for small series

production

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Additive manufacturing has fundamentally changed

the procedure for creating complex, hollow

composite parts.

➢ Offers significant design freedom and the ability to

quickly iterate designs

➢ Create smooth internal carbon surfaces & higher fine

feature definition

➢ Eliminates the need for additional tooling or molds for

sacrificial tool production

➢ Low initial investment required to create small series

productions

ADDITIVE MANUFACTURINGTECHNOLOGY BENEFITS

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MAKING ALL THE DIFFERENCE

HOLLOW COMPOSITE PROCESS

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DSM provides an efficient and cost-effective approach for

producing tough, complex hollow composite parts with a

superb surface finish and high feature detail compared with

competing technologies.

Using DMX/NeXt to offer a sacrificial, flexible and airtight

core which has the unique feature to be easiest and best

removed, after the autoclave process, from convoluted

shapes and voids, in the industry.

This method of using additive manufacturing to produce

sacrificial tooling is straightforward and enables multiple

iterations to be implemented quickly by the user.

HIGHLIGHTS

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SOMOS® DMX / SOMOS® NEXT

“DMX 100 OFFERS AN UNPARALLELED SOLUTION FOR COMPLEX HOLLOW COMPOSITE PARTS ACROSS A WIDE RANGE OF INDUSTRIES.“

Jonathan WarbrickGraphite AM (UK)

SMALL LAY-UPCOMPOSITE SUB-APPLICATION

Additive manufacturing has fundamentally changed

the procedure for creating small series composite

parts.

➢ Offers significant design freedom and the ability to

quickly iterate designs. Ability to deliver composite parts

faster.

➢ Fine resolution that reduces surface preparation needed

to create a smooth part.

➢ Low initial investment required to create small series

productions

➢ Increased operational safety by decreasing core weight of

mold for use in autoclave process

➢ CNC machining produces more waste when you have parts

with complex geometries

ADDITIVE MANUFACTURINGTECHNOLOGY BENEFITS

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MAKING ALL THE DIFFERENCE

LAY-UP PROCESS FOR NACA AIR DUCT

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DSM provides and has the ability to deliver, within a few days,

complex design molds with a superb surface finish and high

feature detail compared with competing technologies.

Using PerFORM to offer a high temperature resistant material

that is dimensionally stable and can withstand the stresses of

the autoclave process time and time again.

This method of using additive manufacturing to produce lay-

up tooling is straightforward and enables multiple iterations

to be implemented quickly by the user, providing flexibility

while reducing lead-time and cost for small series production

runs.

HIGHLIGHTSSOMOS® PERFORM

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“TMG’S MISSION IS TO PUSH THE BOUNDARIES OF AUTOMOTIVE TECHNOLOGY FOR MOTORSPORT AND ROAD CAR APPLICATIONS WITH DSM AS TECHNOLOGY PARTNER”

Toyota Motorsport GmbHGermany

PRODUCTTECHNICAL INFORMATION

VISUAL, OPTICAL & MECHANICAL PROPERTIES

PRODUCT DETAILS

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THERMAL PROPERTIES

PRODUCT DETAILS

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VISUAL, OPTICAL & MECHANICAL PROPERTIES

PRODUCT DETAILS SOMOS® PERFORM

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THERMAL PROPERTIES

PRODUCT DETAILS SOMOS® PERFORM

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BRIGHT SCIENCE. BRIGHTER LIVING.