Significant efforts from both industry and academia are involved in developing additive technologies for improved manufacturing. A huge potential market for AM is engineering structural applications. Compared to metal AM, the use of polymer-based AM technologies has grown slowly. The main three reasons are that material properties are not strong enough to perform the necessary functions, lack of consistent material data for structural design, and availability of simulation tools for reliable automated part design. In this presentation, the AREVO Direct Energy Deposition process with continuous carbon fiber thermoplastic composites together with the software driven structural design and tool path generation for AM will be introduced. The solution developed within AREVO provides materials properties comparable or surpassing metals which opens the applications from consumer goods to aerospace industry. The software package offers reliable predictions of the mechanical performance of the structure via Additive Finite Element Analysis (AFEA) and generates tool paths and virtual process simulation in a virtual environment. To achieve this, significant material testing, structural testing and validation of the simulation has been performed. Creation of the world’s first 3D printed carbon fiber ebike will be demonstrated from development, testing to manufacturing at scale.
- Overview of current challenges for additive manufacturing for engineering applications
- Value proposition of closed loop development of material data, simulation tools and process control for automated, high-volume manufacturing
- Case study of the development and manufacturing of the first 3D printed carbon fiber ebike