The world of composite manufacturing is undergoing a revolutionary transformation with the advent of additive manufacturing (AM) technologies. Two recent advancements in this field have caught the attention of industry experts: 3D-printed, thermoplastic carbon-fiber reinforced polymer (TPCFRP) tools for serial production of composite landing flaps; and the integration of composite tape laying and large-scale, thermoplastic 3D printing in a single printhead.
These developments hold immense promise for aerospace and other industries that rely on high-performance composite materials. Traditionally, the production of such tools involved time-consuming and costly processes, relying on materials such as Invar, aluminum and thermoset carbon fiber. Significant CNC machining time and waste removal from the machining process also was required.
However, with the introduction of 3D-printed TPCFRP tools, manufacturers can now slash lead times and costs while maintaining required performance characteristics. With the ability to 3D print complex geometries, manufacturers can now create intricate tool designs that were previously unachievable using traditional methods.
Thermoplastic 3D printing is rapidly becoming a mainstream manufacturing technology, with applications in a wide range of industries such as aerospace and marine. In the aerospace industry, 3D printing is being used to produce a variety of components, including composite tooling. The latter is used to manufacture composite parts, which can be expensive to produce using traditional methods. 3D printing can significantly reduce the cost and lead time of composite tooling, while also improving its quality.
In 2019, GKN Aerospace began using 3D-printed composite tooling from CEAD, a Netherlands-based pioneer in the field of large-format additive manufacturing (LFAM). With the “Flexbot” robotic 3D-printing system, intensifier tools were printed with short carbon-fiber-reinforced polymer (CFRP). CEAD also has a partnership with Belotti for applications of parts larger than what can be printed with a robot, thus requiring the system to be installed on a gantry.
The tools have been used in serial production of the Airbus A350 wide-body jet’s landing flaps, showing significant advantages over traditional aluminum tools. Using these 3D-printed tools, GKN could eliminate the use of the aluminum master tools and increase flexibility because of the completely automated printing and milling operations. This results in as much as a 50% cost reduction and an 80% cut in lead time.
However, the coefficient of thermal expansion (CTE) of larger tools became critical, limiting the size of the tools that could be printed and used for production. This led to the development of a new printhead, providing the possibility to also print larger tools. CEAD’s new printhead combines composite tape laying and large-scale thermoplastic 3D printing, incorporating continuous fibers into the thermoplastic 3D printing process, called ATLAM.
Short for Advanced Tape Layer Additive Manufacturing, ATLAM is a hybrid AM process that combines composite tape laying and large-format 3D printing in a single printhead. The process starts with the deposition of a layer placed by an extruder with short fiber-reinforced thermoplastic material. The tape is then preheated and placed into the short-fiber-reinforced layer, consolidated by a rolling mechanism after tape placement. The process is repeated to build up the part layer by layer.
The integral tape-laying head reduces CTE values in the X and Y directions, producing tools with CTE values closer to Invar tooling or CFRP prepreg, and at a fraction of the cost and time to produce. The CEAD ATLAM printhead can print parts with a wide range of short-fiber-reinforced thermoplastic materials. Carbon-reinforced PEI and PESU are materials currently tested with this technology.
CEAD has qualified Airtech Dalhtram resins for use on all its 3D-printing equipment, with a wide range of proprietary printing heads tested with Dalhtram resin, which is a family of high-performance thermoplastic resins designed for use in 3D printing. The resins are available in a variety of formulations, including high-strength, high-temperature and flame-retardant.
The qualification of Airtech Dalhtram resins for use on CEAD’s processes opens up new opportunities for the use of 3D printing in the aerospace industry. Resins can be used to produce tools for a wide range of composite parts, including landing gear, wing components and fuselage structures.
In addition, 3D printing for composite tooling enables greater design freedom, allowing for the production of composite tooling with complex geometries that are not possible with traditional manufacturing methods. This can improve the performance of the tooling and reduce the weight of the aircraft.
AM also provides enhanced flexibility, producing composite tooling in a variety of sizes and shapes. This has yielded reduced cycle times and a quick return on investment.
The use of 3D printing for the production of composite tooling is one of the most promising applications of the technology due to quality, cost and lead time advantages.
While the use of 3D printing to produce composite tooling is still in its early stages, the potential benefits of this technology are significant. As the technology continues to develop, 3D printing is likely to play an increasingly important role in the production of composite parts for aircraft.
The benefits of adopting 3D-printed CFRP tools are manifold. Reducing lead times enables manufacturers to accelerate production cycles, resulting in faster time to market. And the inherent design freedom provided by 3D printing allows for the optimization of tool geometries, leading to improved part quality and performance. Additionally, the use of CFRP materials offers high strength-to-weight ratios without compromising structural integrity. Lastly, the cost-effectiveness of 3D printing compared to traditional tooling methods makes it an attractive solution for serial production.
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