WindEis – Development of control arms printed with continuous fiber reinforcement including integration of sensors for online monitoring in operation
Design, topology optimization, process optimization and production of continuous fiber-reinforced and sensor-integrated suspension arms for component monitoring during operation.
Project Partners
Bright Testing GmbH
Duration
01.11.2021 – 31.03.2024
Funding authority
German Federal Ministry for Economic Affairs and Energy (BMWi)
Motivation
3D-printing is seen as a very promising key technology, especially for high-performance applications, as both low-volume products and individualized racing products cannot be produced economically with current manufacturing processes. With a newly developed printer system, which enables the processing of continuous fiber materials economically, BRIGHT Testing wants to expand the application possibilities. At the same time, the new technology takes into account the requirements for the production of automotive applications such as process and component monitoring as well as optimization of the design for further weight reduction. These project goals should facilitate further standardization and long-term licensing for automotive products.
Method
Within the scope of the project, a novel process for the additive manufacturing of topology-optimized, sensor-integrated and continuous fiber-reinforced components is to be developed. For this purpose, a printer system will be developed with which sensors and continuous fibers can be integrated automatically. Furthermore, a design tool and software is to be developed for this system. In addition, methods for topology optimization are to be researched, taking into account the process and sensor integration. Finally, a sensor readout unit must be built and the developments are to be brought together, tested, analyzed and validated within the framework of a demonstrator.
Acknowledgement
The chair would like to thank the German Federal Ministry for Economic Affairs and Energy for funding the project "WindEis" within the framework of the funding scheme „Zentrales Innovationsprogramm Mittelstand (ZIM)“ (Funding indicator: KK5135804SK0)
Contact Persons
Jan Seiffert, M.Sc.; Dr.-Ing. Swen Zaremba