Our F-Scan is on the current cover page of the #lightweight.design magazine (springer Verlag). #FScan is a sensor technology that allows the accurate measurement of fibre angles on #composite parts. The technology can be used for different types of materials (carbon, glass) and also during different stages of the production process (raw material, pre-form, clear-coated part). Aside from measuring the orientation it allows the detection of typical defects such as inclusions or distorted fabric.
PROFACTOR has succesfully implemented inspection systems for metallic parts as well as composite parts in industry. Our powerful tools provide a new perspective on your production
and take you to the next level: Evolve from sorting out defective parts to avoid defects by closing the feedback loop in your production. PROFACTOR supports every step of your way, with undivided focus on your goal: Zero defects.
The JEC Innovation Awards reward composites champions, based on criteria such as partner involvement in the value chain, technicality or commercial applications of innovations. The JEC in Paris is the world’s largest composites exhibition. Ten composite innovation champions selected among 30 finalists, from more than a hundred entries, were awarded
The project ZAero coordinated by PROFACTOR won the JEC innovation award in the category aerospace processes.
The project consortium developed technologies for zero defect manufacturing of large composite parts.
Zero-defect manufacturing of composite parts
In the aerospace industry, very large components (e.g. wing covers) are made of carbon fiber composite materials. Different challenges are related to the processing of such materials. The complexity that comes with carbon fiber composites often leads to anomalies and defects during production. The EU project ZAero developed intelligent inspection technology to detect problems in production at an early stage. The ZAero project aims for 30-50% boost in productivity via inline AFP and ADMP inspection, simulated part performance and decision support tools. The technology will be showcased at the JEC (Hall 5, Booth S66).
Very high quality standards have to be met in the aerospace industry. In order to guarantee production of defect-free components, a great deal of effort needs to be put into quality control. Lightweight carbon fiber reinforced plastics (CFRP) components are nowadays largely used in the aerospace industry. Production of such parts requires multiple stages of processing, each of which needs to be done with great care.
Continuous process monitoring for zero defects
In order to avoid defects during production, the EU project ZAero developed technologies for consistent monitoring of production. This is based on sensors for fiber orientation measurement and 3D profile scanning that perform inline monitoring during the lay-up process. In addition to this, data from the following production stages (infusion, curing) is collected in a manufacturing database. This database represents a “digital twin” of the real part as manufactured. Intelligent data processing and mechanical simulation provide information about the severity of defects.Logistical simulation delivers information about the part flow and overall production performance. This enables a global view on the production and reveals how defect rates and re-work decisions affect, for example, completion time of a specific order.
Industrial reference implementation
Installation of monitoring systems into industrial environments were done at the facilities of Danobat and FIDAMC. The deployed sensor systems were demonstrated to work well in the respective environments. Data collection, simulation, and decision support modules were successfully demonstrated. Experiments showed that the future production of up to 60 passenger planes per month will be possible with the technologies developed within the project.
PROFACTOR is an Austrian research company located in Steyr and focuses on developing new methods for integrated production technologies. In the field of composite part production, the technological focus is on zero defect manufacturing. PROFACTOR offers sensor systems for fibre orientation measurements, AFP and ADMP monitoring, surface inspection and thermography. Visit us at booth S66 in hall 5.
ZAero Zero-defect manufacturing of composite parts in the aerospace industry
Coordinator PROFACTOR GmbH
Partners: Airbus Defence and Space GmbH, Dassault Systèmes SE, M Torres Diseños Industriales SA, IK4 – IDEKO S Coop, Danobat S Coop, FIDAMC
Duration: 2016 – 2019
Funding: EU Horizon 2020
Website: www.zaero-project.eu
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 721362.
The project ZAero coordinated by PROFACTOR was nominated as one of the finalists of the JEC innovation award.
The project consortium developed technologies for zero defect manufacturing of large composite parts.
Visit PROFACTOR at the JEC 2019 in Hall 5, Booth S66. The JEC takes place from March 12-14, 2019 in Paris.
Zero-defect manufacturing of composite parts
In the aerospace industry, very large components (e.g. wing covers) are made of carbon fiber composite materials. Different challenges are related to the processing of such materials. The complexity that comes with carbon fiber composites often leads to anomalies and defects during production. The EU project ZAero developed intelligent inspection technology to detect problems in production at an early stage. The ZAero project aims for 30-50% boost in productivity via inline AFP and ADMP inspection, simulated part performance and decision support tools. The technology will be showcased at the JEC (Hall 5, Booth S66).
Very high quality standards have to be met in the aerospace industry. In order to guarantee production of defect-free components, a great deal of effort needs to be put into quality control. Lightweight carbon fiber reinforced plastics (CFRP) components are nowadays largely used in the aerospace industry. Production of such parts requires multiple stages of processing, each of which needs to be done with great care.
Continuous process monitoring for zero defects
In order to avoid defects during production, the EU project ZAero developed technologies for consistent monitoring of production. This is based on sensors for fiber orientation measurement and 3D profile scanning that perform inline monitoring during the lay-up process. In addition to this, data from the following production stages (infusion, curing) is collected in a manufacturing database. This database represents a “digital twin” of the real part as manufactured. Intelligent data processing and mechanical simulation provide information about the severity of defects.Logistical simulation delivers information about the part flow and overall production performance. This enables a global view on the production and reveals how defect rates and re-work decisions affect, for example, completion time of a specific order.
Industrial reference implementation
Installation of monitoring systems into industrial environments were done at the facilities of Danobat and FIDAMC. The deployed sensor systems were demonstrated to work well in the respective environments. Data collection, simulation, and decision support modules were successfully demonstrated. Experiments showed that the future production of up to 60 passenger planes per month will be possible with the technologies developed within the project.
PROFACTOR is an Austrian research company located in Steyr and focuses on developing new methods for integrated production technologies. In the field of composite part production, the technological focus is on zero defect manufacturing. PROFACTOR offers sensor systems for fibre orientation measurements, AFP and ADMP monitoring, surface inspection and thermography. Visit us at booth S66 in hall 5.
ZAero Zero-defect manufacturing of composite parts in the aerospace industry
Coordinator PROFACTOR GmbH
Partners: Airbus Defence and Space GmbH, Dassault Systèmes SE, M Torres Diseños Industriales SA, IK4 – IDEKO S Coop, Danobat S Coop, FIDAMC
Duration: 2016 – 2019
Funding: EU Horizon 2020
Website: www.zaero-project.eu
Heimsheim. 3D-printing is everywhere. How far additive manufacturing can go this is shown in the project DIMAP. As outstanding outcome of the H2020 project DIMAP, cirp will showcase the first ever pneumatic robot in the world printed almost exclusively with PolyJetTM technology from Stratasys® at the exhibition formnext 2018.
DIMAP, standing for “Novel nanoparticle enhanced Digital Material for 3D Printing and their application shown for robotic and electronic industry”, is a multidisciplinary research project focusing on the development of novel 3D-printing materials for PolyJetTM technology.
A group of 12 partners from five different countries coordinated by PROFACTOR developed ink materials with special thermal and electrical conductive properties within the scope of the project
Due to its qualities, these ink materials can be used for selected print heads as well as be tailored to suit future industrial applications in products.
The DIMAP SCARA robot displays impressively the potential of the PolyJetTM 3D-printing technology with new developed ink materials. The robot will be presented to the public for the first time this November at the formnext exhibition. SCARA is the abbreviation for Selective Compliance Assembly Robot Arm and describes a jointed-arm robot that can operate horizontally. DIMAP stands for Novel nanoparticle enhanced Digital Materials for 3D Printing and their application shown for the robotic and electronic industry. From 2015 to 2018, Profactor has coordinated a group of 12 partners from five different countries focused on the development of novel materials for PolyJetTM printing technology. The European Union has funded this joint project within the framework of the program Horizon 2020.
PolyJetTM is a 3D-printing technique where print heads jet layers of curable liquid photopolymer materials, so called inks, onto a build tray. So layer by layer complex models get shaped. Multiple inks can be printed simultaneously in one layer to combine different characteristics or colors in one printed object. DIMAP aimed to develop ink materials with an innovative set of properties:
Electrical conductive ink with silver nanoparticles to print conductive tracks
Thermal conductive ink with ceramic nanoparticles to cool LED lights
Foamed ink for light-weight applications
Polyimide inks with excellent chemical and high temperature resistance.
A prototype PolyJetTM printer with extended processing features was created within the project to allow the printing process with the novel ink materials.
Two demonstrators were developed to test the printing suitability of the new ink formulations: a customizable luminaire and a pneumatically operated robot. Festo, a German supplier of pneumatic and electrical automation technology, was responsible for the design and startup of the DIMAP SCARA, which is a pneumatically actuated robot. Its functional plastic components have been printed with PolyJetTM additive manufacturing technology. Two movable axes display two different solutions for a printed rotary drive. Altair’s simulation software was used to optimize further structural components, such as the lightweight gripper. Additive manufacturing enabled a high functional integration with a small amount of components and a particularly light structure.
Gabriel Dämmer, Project official at Festo says: “Regardless if Additive Manufacturing is considered for prototyping or for the manufacturing of end-use products, understanding and incorporating the technological capabilities into specific design processes is essential. The development of the DIMAP SCARA gives us first hand experiences of Multi-Material Additive Manufacturing in the field of pneumatic light-weight robots.”
The German company cirp manufactured the plastic components of the robot with a modified Stratasys’ Objet260 Connex2TM printer using the newly developed inks supplied by the different partners as well as standard materials from Stratasys.
cirp will show the unique DIMAP robot in action at its exhibition stand at the formnext (hall 3.1 booth F11 + G10).
Leo Schranzhofer, project leader of DIMAP says: “DIMAP gives us a glimpse into future possibilities of PolyJetTM printing, nicely shown with the DIMAP SCARA robot, developed by FESTO and printed by cirp. The outcome of DIMAP opens the door to a new generation of highly functional products”.
cirp: The company, based in Heimsheim near Stuttgart, has been manufacturing plastic parts as prototypes and small series for a wide variety of industries with additive manufacturing and injection moulding since 1994. The processes at cirp include PolyJetTM, stereolithography, laser sintering, FDM, vacuum casting, CNC milling.
Booth number at formnext: Hall 3.1 Booth F11 + G10
Festo AG is a global player and an independent family-owned company with headquarters in Esslingen am Neckar, Germany. The company supplies pneumatic and electrical automation technology to 300,000 customers of factory and process automation in over 35 industries. The products and services are available in 176 countries. With about 20,100 employees in over 250 branch offices in 61 countries worldwide, Festo achieved a turnover of around €3.1 billion in 2017. Each year around 8 % of this turnover is invested in research and development. In this learning company, 1.5 % of turnover is invested in basic and further training. Yet training services are not only provided for Festo’s own staff – Festo Didactic SE also supplies basic and further training programmes in the field of automation technology for customers, students and trainees.
PROFACTOR: is an Austrian research company located in Steyr and focuses on developing new methods for integrated production technologies. The technological focus is on robotics, machine vision, functional surface and nanostructures. About 75 scientists of various disciplines conduct research to improve the competitiveness of the production industry and to strengthen the Austrian and European industry. PROFACTOR strives to enhance printing technologies that create solutions for functionalizing surfaces. This is the key to innovative and individual products with outstanding properties.
Stratasys is a global leader in additive manufacturing or 3D printing technology, and is the manufacturer of FDM® and PolyJet™ 3D Printers. The company’s technologies are used to create prototypes, manufacturing tools, and production parts for industries, including aerospace, automotive, healthcare, consumer products and education. For 30 years, Stratasys products have helped manufacturers reduce product-development time, cost, and time-to-market, as well as reduce or eliminate tooling costs and improve product quality. The Stratasys 3D printing ecosystem of solutions and expertise includes: 3D printers, materials, software, expert services, and on-demand parts production. Online at: www.stratasys.com, http://blog.stratasys.com and LinkedIn.
Stratasys is a registered trademark and the Stratasys signet is a trademark of Stratasys Ltd. and/or its subsidiaries or affiliates. All other trademarks are the property of their respective owners.
Die technische Speicherung oder der Zugang ist unbedingt erforderlich für den rechtmäßigen Zweck, die Nutzung eines bestimmten Dienstes zu ermöglichen, der vom Teilnehmer oder Nutzer ausdrücklich gewünscht wird, oder für den alleinigen Zweck, die Übertragung einer Nachricht über ein elektronisches Kommunikationsnetz durchzuführen.
Preferences
Die technische Speicherung oder der Zugriff ist für den rechtmäßigen Zweck der Speicherung von Präferenzen erforderlich, die nicht vom Abonnenten oder Benutzer angefordert wurden.
Statistics
Die technische Speicherung oder der Zugriff, der ausschließlich zu statistischen Zwecken erfolgt.Die technische Speicherung oder der Zugriff, der ausschließlich zu anonymen statistischen Zwecken verwendet wird. Ohne eine Vorladung, die freiwillige Zustimmung deines Internetdienstanbieters oder zusätzliche Aufzeichnungen von Dritten können die zu diesem Zweck gespeicherten oder abgerufenen Informationen allein in der Regel nicht dazu verwendet werden, dich zu identifizieren.
Marketing
Die technische Speicherung oder der Zugriff ist erforderlich, um Nutzerprofile zu erstellen, um Werbung zu versenden oder um den Nutzer auf einer Website oder über mehrere Websites hinweg zu ähnlichen Marketingzwecken zu verfolgen.
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 721362.
