At the Institute of Structures and Design in Stuttgart, additive manufacturing processes and materials are investigated for their suitability for aerospace and energy applications. The IRAS (Integrated Research Platform for Affordable Satellites) project aims to produce flexible and cost-effective satellite structures. Concurrently, MuSiK (Multimaterialdruck von C/Si/SiC-Keramiken) investigates the multi-material printing of C/Si/SiC ceramics. Polymer Structures ...
World’s first prototype of a mobile, autonomous fibre layup unit The mobile layup units can move around freely and lay the fibres directly in the mould. Several small, free-moving autonomous mobile layup units are expected to respond more flexibly than was previously the case to component scaling, geometry and design changes when used in a ...
The Institute of Structures and Design (BT) has a highly-recognized and long-lasting expertise on composite technology and space applications. Across its sites in Augsburg and Stuttgart focus is laid on the entire process chain, from design and manufacturing technologies to flexible automation solutions for the production of high-performance lightweight structures. The interdisciplinary team of experts ...
Quality for production – inline, please! Focused on production-integrated real-time acquisition of process and machine data in combination with dedicated quality control sensors, the DLR Center for Lightweight-ProductionTechnology is developing systems to monitor quality ‘on the fly’. This allows processes to be adjusted and controlled almost instantaneously, thus enabling closed loop, scrap free production with ...
Transpiration Cooled Ceramic High Performance Rocket Engines Motivation and Design Improvement of high performance rocket engines Use of high temperature resistant and porous Ceramic Matrix Composites (CMC) High operation efficiency combined with transpiration cooling High operational reliability and damage tolerance Adaptation potential focussing several propulsion system cycles Light weight at high strength combined with CFRP ...
Automated process chain for manufacturing large CFRP structure parts Integrated and automated production of a dry-fibre rear pressure bulkhead In project PROTEC NSR, a concept for an integrated manufacturing process was developed and presented for full-scale structural components – for example, an A350 rear pressure bulkhead. The demonstration component under investigation is about 4.5 metres ...
Advanced thermoplastic composites are a highly promising candidate for future aerospace applications. In order to compete with metal-based solutions, highly effective and flexible production technologies are required. Weldability, in this context, is the key enabler for the successful introduction of thermoplastic composites into high-volume single-aisle programmes. This is particularly important because dustless assembly (without riveting ...
The DLR Institute of Structures and Design has highly-recognised and long-established expertise in thermoplastic composite technology. At its sites in both Augsburg and Stuttgart, focus is placed on the entire process chain – from design and manufacturing technology to flexible automation solutions for the production of carbon fibre-reinforced thermoplastics. Infrastructure for production The Institute operates ...
Efficient joining using resistance welding Fibre-reinforced thermoplastics are being increasingly qualified and used in the aviation industry. To support this increased demand, new joining technologies are required to utilise the lightweight potential of composites as structural elements. Of these joining technologies, welding processes are particularly suitable for generating material bonds between thermoplastic structural components. These ...
Automated Production of Thermoplastic Aerospace Structures Thermoplastic composite materials for structural aircraft components offer advantages in terms of performance, manufacturing processes and cost-effectiveness. During the production automated welding technologies are an enabler for a cost effective production. These could replace the classic joining methods optimized for metallic materials, such as riveting and the additionally required ...
Automated fibre placement (AFP) has been used to manufacture a sounding rocket primary structure comprised of carbon fibre-reinforced thermoplastic (CF-PEEK). Unlike many contemporary thermoplastic parts produced using AFP technology, this structure did not require a postconsolidation process to ensure its structural integrity. This single-step (in-situ) manufacturing method has long been a goal for the thermoplastic ...
Continuous Resistance Heating Technology Continuous Resistance Heating Technology (CoRe HeaT) is being developed as an alternative heating method for the Automated Fibre Placement process (AFP) at the DLR Center for Lightweight-Production-Technology in Stade. Like other heating methods – such as infrared, laser or hot gas – the technology can also be used for similar processes ...