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alu reference panel
mass [g
]
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
num
be
r o
f p
art
s [-]
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: [email protected]; [email protected]; [email protected]
the project was
supported by
SATW Transfer-
kolleg 2015
(funding by
KTI 17874.1 PFSATW-IW)
