10:50
Session 5b: Advances in Manufacturing Automation
Chair: Sayata Ghose
10:50
20 mins
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Automated Manufacturing of Thermoplastic Composites: Technology development from manual to automated manufacturing processes of high aspect ratio parts
Guus Roosken
Abstract: With increasing rate demands in aviation, lower structural weight goals and rising labour costs, new manufacturing solutions are required to fulfil industry needs. For decades, GKN Fokker has been manufacturing primary thermoplastic aircraft structures (e.g. spars), hand lay-up and autoclave consolidation being the baseline manufacturing method. GKN Aerospace’s Global Technology Center Netherlands develops future-proof manufacturing technologies for high-rate production, with automation solutions implemented. Within the European funded Clean Sky 2 (CS2) program and the Dutch Aviation in Transition (LiT) project, Out-of-Autoclave manufacturing of high aspect ratio parts has been developed towards TRL6. Out-of-Autoclave manufacturing technology has been developed and validated on a flying application by selecting the CS2 LIFTT project tail front spar as technology demonstrator. The goals of the Out-of-Autoclave development were to reduce labour, and therefore production cost, increase part quality and prepare for high rate manufacturing for UAM applications and the Next-Gen Single Aisle (NGSA) aircraft. This presentation includes hardware and software automation solutions implemented in Out-of-Autoclave manufacturing of flying parts in a production environment representative for high-rate manufacturing of high aspect ratio parts. Also, an outlook is given on challenges and continuing developments for manufacturing of thermoplastic parts at high rate.
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11:10
20 mins
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Improving Robotic Drilling Accuracy in CFRP Structures through RTM-Embedded Reference Markers and Parallel-Kinematic End-Effectors
Maximilian Muth, Philip Carstensen, Wolfgang Hintze, Christoph Brillinger, Christian Möller, Christian Böhlmann
Abstract: Fiber-reinforced plastics (FRP) are widely established in the production of large structural components due to their lightweight properties. In the transition to CO₂ neutrality, priorities are shifting towards highly efficient and energy-optimized production methods. The demand for innovative solutions is particularly high in the aerospace industry, such as for drilling functional holes in wing structures made of carbon fiber reinforced plastics (CFRP). Characterized by small batch sizes and tight tolerance requirements, these processes are difficult to operate economically with conventional CNC gantry machines, as the small machining volume is opposed by poor utilization.
This work presents an innovative manufacturing approach combining a standard industrial robot with a specialized drilling end-effector. The end-effector integrates a parallel-kinematic compensation unit (hexapod) with a milling spindle and a laser light sectioning sensor. Its novelty lies in the use of integrated reference markers embedded directly into the component by Resin Transfer Molding (RTM), enabling repeatable and precise localization. The drilling sequence follows a two-step positioning procedure: (1) Coarse positioning - the robot places the end-effector within millimeter accuracy above the marker; (2) Fine positioning - the hexapod performs a 3D scan of the marker with the integrated sensor. A best-fit algorithm computes the marker’s center from the point cloud and determines the transformation to the tool center point (TCP). This transformation is applied through the hexapod unit, compensating for translational and rotational deviations. The subsequent drilling is executed entirely within the hexapod, ensuring superior stiffness and precision compared to the robot’s serial kinematics. Preliminary tests demonstrate a sub-millimeter positional accuracy improvement of around 50% and a reduction in standard deviation exceeding 70% compared to conventional robot drilling. Final verification will extend these findings under varied conditions and advanced strategies.
The presented method decouples positional accuracy from typical influencing sources such as insufficient robot rigidity, calibration inaccuracies, thermal effects, and part deformation by utilizing local referencing. It simplifies setup, reduces manual calibration, and increases system productivity. Using standard robots instead of CNC gantries reduces investment costs and moving masses, enhancing both economic and energy efficiency - representing a promising approach for automated CFRP machining.
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11:30
20 mins
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Robotic Large Format Additive Manufacturing for On-Demand Tooling for Composites
Michael Cargill, Patrick Bailey, Aywan Das, Wout De Backer
Abstract: The increasing adoption of carbon fiber reinforced polymers (CFRPs) in aerospace manufacturing has amplified the demand for large, high-precision tooling capable of withstanding the temperatures and pressures required for composite manufacturing. Conventional metallic tools, often fabricated from alloys like Invar, offer excellent dimensional stability but incur prohibitive costs and extended lead times, constraining rapid prototyping and low-volume production. This work investigates the application of robotic large-format additive manufacturing (LFAM) for the on-demand fabrication of composite tooling using thermoplastic polymers. Employing a custom pellet-fed, single-screw polymer extruder mounted on a KUKA KR60 robotic arm, this study evaluates the feasibility, dimensional accuracy, and durability of printed polymer tooling under composite curing conditions. Experimental comparisons between printed and conventionally machined tools assess surface quality and composite part quality through measurements of surface roughness, fiber volume fraction, and void content. Key process parameters: including print speed, bead width, and infill orientation, are analyzed to determine their influence on mechanical and dimensional tool performance. The results aim to establish validated design and process guidelines for LFAM based composite tooling and demonstrate its potential to reduce tooling costs and lead times by an order of magnitude, thereby advancing automation and sustainability in composite manufacturing.
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