Advanced Composites & Additive Manufacturing for Aircraft ... · laminate lay-up reference...

alu reference panel

mass [g

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CFRP & AM sandwich panel

honeycomb (Nomex)

load introduction & joining elements

CFRP facings

AM cores

metal base structure

SLM inserts

CFRP facings honeycomb (Nomex)

AM cores

rivet nuts & DZUS fasteners

rivets

metal base structure

alu reference panel

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CFRP & AM sandwich panel

design for performance tailored CFRP lay-up:

variable stiffness design of backside facing

according to local loads

determined by a novel gradient-based optimizer

(0/90/45/-45)

(0/90)

(0/90/45/-45/90)

Advanced Composites & Additive Manufacturing

for Aircraft Instrument Panels R. Kussmaul1, D. Türk2, M. Zogg1, Ch. Klahn1, A. Spierings1, H. Könen3, Prof. M. Meboldt2, Prof. K. Wegener2, Prof. P. Ermanni2, 1: Inspire AG; 2: ETH Zürich; 3: RUAG Aviation

concept sandwich structure AM core (SLS > polymer) & load introduction elements (SLM > metal)

CFRP autoclave prepreg facings

design for processing integrated positioning elements:

pockets with inserts plug & play

snap-in mounts quick positioning

tooling for laminate support strap prepreg positioning

tailored interfaces for easy assembly

manufacturing concept

highly integrated lightweight sandwich structure results in comparison to today's aluminum instrument panel (reference) in:

tailored AM core:

honeycomb core with variable density solid for high

loaded areas, lower density for lower loaded areas

core height can be adapted to laminate lay-up

to follow defined sandwich thickness

increased bonding surface to facings

integration of optimized lightweight load introduction

elements minimal stress peaks

integrated anti-telegraphing design

integrated manufacturing aids:

spacers for holes (to be machined)

honeycomb closure

panel edge protection (to be machined)

laminate lay-up reference

simple tooling lay-up (plug & play) autoclave curing post-processing

industry partner: RUAG Aviation

research partners: inspire ICS / inspire PDZ / inspire ICAMS /

reference: D. Türk, R. Kussmaul, M. Zogg, Ch. Klahn, A. Spierings, H. Könen,

P. Ermanni, M. Meboldt: Additive Manufacturing with Composites

for Integrated Aircraft Structures; SAMPE Long Beach 2016 Conf., 23-26-May-2016

contact: zogg@inspire.etzh.ch; klahn@inspire.ethz.ch; spierings@inspire.ethz.ch

the project was

supported by

SATW Transfer-

kolleg 2015

(funding by

KTI 17874.1 PFSATW-IW)