24th Month MeetingWP4 Presentation

Florence, GZE, 21 February 2013 www.3D-LightTrans.com

Benoit LAURENTFederal-Mogul Systems Protection

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

Agenda Brief overview of WP Background Structure and progress update WP4 Highlights during M18-M24 Selected exploitable results WP4 Future Planning Discussion Points

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Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP4 – Manufacturing processes of 3D TRP final compoundResearch partners1 – AIT6 – Ugent8 – TUD9 – LeitatIndustrial partners3 – CRF4 – Coatema5 – FMSP15 – Bentley17 – PromautWork Package objective WP4 develops the models, technologies and process adaptations to implement the

final part draping and thermoforming. This WP is closely linked to WP3, developing former industrial steps, and overseen by WP2.

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Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP4: Structure and progress update

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Timeline YearMonth Jul Aug Sep Oct Nov Dec Jan Feb Mar Ap May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Ap May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Ap May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

3DLT Month M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 M25 M26 M27 M28 M29 M30 M31 M32 M33 M34 M35 M36 M37 M38 M39 M40 M41 M42 M43 M44 M45 M46 M47 M48

WP4 Task 4.1a Draping Leitat-Promautb Fixation Coatemac Handling (WP5.1)d Thermo-pressing AIT-FMSP

Task 4.2Metal part integration AITClass A surface Ugent

2011 2012 2013 2014 2015

MS10

MS13

Tasks:Task 4.1: Final production of the TRTC component 50%Task 4.2: Product finishing processes and assembly of module components 20%

Deliverables:D4.10: Supervised fixated preforms process M42 – Not completeD4.11: Ready made technologies M42 – Not complete

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.1a Draping

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In coordination with TUD simulations: draping tests over a 450mm hemisphere. Manual tests simulating an automatic operation using a “push and hold” sequence.

Two hands at a time for draping.

Needles for fixing fabric around the base of the part.

Need for the usage of more or wider robot fingers for reducing space between them and prevent the wrinkling.

Design and building of passive grippers for robotic draping The Fingers: for holding, dragging and pushing the fabric.

The Jellyfish: for brushing along the surface.

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.1a Draping

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Following the same draping strategies previously tried. Tests carried out with a two arms Motoman robot. Need for increasing the number of “tentacles” and raise their rigidity. Introduction of active elements into the gripper or the tool.

Manipulation means studied in collaboration with PROMAUT, in case long displacements tasks are required during draping.

Vacuum: no affectation of A-class surfaces, high consumption, overcome porosity. Needles: hinder surface finish, low consumption, poor holding force.

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.1b Fixation

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There is a significant melting of the PET-fibers after exposition to 6-9 flashes at a frequency of 2 flashes / s.

The result looks very similar to earlier trials with PP-fibers. So the combination Glass/PET should be fixable in the same way as Glass/PP. The PET fibers

should be black, mixed with white or colorless glass fibers.

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.1d Thermopressing

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2nd Process campaign – Flat mold Glassfibre 3D-Architecture + PP-Matrix

Tests from23/24.10.2012 Procedure through: Ucsnik, Hinterberger Mat 1 = 3DLT/8/VDW-NCF -400:5-264:6Location LKR - TH3 Mat 2 = 3DLT/8/VDW-NCFV-400:6-240:5/6Press: 160t NEFF Mat 3 = 3DLT/8/VDW-NCFD-400:6-268:5/8

Rest

SamplePlatten-

NamePressure on

Stamp/Plate (bar)Press-time

(Sek)Expext.

Temp (°C) GFRP TRP in usePost-Force

after cons. (kN)Surface Quality

UGENT(50x50mm)

SVUM(230x280mm) LKR

1 V1_23_10_12 65 / 30 120 220 Mat 1 20 -- -- √

2 V2_23_10_12 65 / 30 120 220 -||- 20 -- -- √

3 V3_23_10_12 65 / 30 120 220 -||- 20 √ √ √4 V4_23_10_12 65 / 30 60 220 -||- 20 √ √ √5 V5_23_10_12 65 / 30 300 220 -||- 20 √ √ √6 V6_23_10_12 65 / 30 120 220 -||- -- √ √ √7 V7_23_10_12 65 / 30 120 220 Mat 2 20 √ √ √8 V8_23_10_12 65 / 30 120 220 -||- -- √ √ √9 V9_23_10_12 65 / 30 120 220 Mat 3 20 √ √ √10 V10_23_10_12 65 / 30 120 220 -||- -- √11 V11_24_10_12 65/30 120 250 Mat 1 20 √ √ √12 V12_24_10_12 65/30 120 250 -||- -- √ √ √13 V13_24_10_12 65/30 120 220 Mat 3 -- √ √ √14 V14_24_10_12 vacuum 0.1 mbar 240 220 Mat 1 -- √

15 V15_24_10_12 65/30 120 220 -||- -- √ √ √16 V16_24_10_12 65/30 120 220 -||- 20 √ √ √17 V17_24_10_12 vacuum 0.1 mbar 240 220 -||- -- √ √ √18 V18_24_10_12 65/30 120 220 Mat 3 -- √ √ √19 V19_24_10_12 65/30 120 200 Mat 1 20 √ √ √

investigated parameterDelivery to

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.1d Thermopressing

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Design Complex 3D-Geometry (Butter dish)

Manufacture Heated top/bottom tools

Interim process campaign Pure PET-Plate

Material issue PP/PET

process investigations on plate @ 220 C° initial U-Profile manufacture

PET process investigations on plate @ 270 C°

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.2 Product finishing, assembly

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Metal - GFRP Mold design

Mold manufacture

Top stamp Bottom Die

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Highlights M18 – M24Task 4.2 Class A Finish

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Involved parameters• Substrate quality• Paint materials• Process parameters

Testing requirement established• Important characteristics• Secondary characteristics

Processes:• Formed film (GE plastic/Azdel Inc )• Paint Coating

Literature review• Amorphous substrates have higher gloss than semicrystalline matrices• Matrix-rich layer improves gloss• Adding nano-particles (e.g. CaCO3) can enhance gloss

Patent review• Resin rich surface layer (powder or film)• Polished mould• Metal sheet on composite

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

Selected WP exploitable results

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N. Exploitable result

Exploitable result manager

Beneficiaries involved

Relevant WPs

Relevant deliverables

Progress %

Expected Date of achievement

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP Future planning WP4 meeting: 2013 March 15th in Crepy, France Milestone 10: Fixation Process (M30 - Coatema)

Process for on-line/off-line fixation of high draped multilayer textiles available and functional

WP4 / WP6 Interractions

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4.1a 4.1d4.1b

4.1c

4.2

5.2 5.3

3.2c

3.2c3.2a

3.1

2.1 2.2a 2.2b 2.2c 2.3

WP1

WP6

WP3

WP2

WP4

WP5

1.1 1.41.31.2

6.1 6.46.36.2

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP Future planning

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Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP Future planning

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Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

WP 4 Discussion points WP4 March meeting agenda discussion:

• Draping • Missing input and status• 3D textile draping• Gripping strategy

• Fixation• Strategy for fixing draped part

• Thermoforming• Lessons learned• PET process parameters acquisition• 3D textile thermoforming strategy

• Finishing• Sub-part assembly• Part integration• Class A finish

• Model and simulation process parameters (D2.6)16

Florence, GZE, 21 February 2013 WP4 | BL

A Project co-funded by the EC in the 7th Framework Program

Thank you for your attention!Questions?

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