HIGH VOLUME AND LOW COST COMPOSITES MATERIAL AND MANUFACTURING

Purpose and goal

Via an inter-professional project team, the aim was to develop ´fast and cost-efficient manufacture of composite products´. All objectives were met: A robotic cell was developed for demonstration of manufacturing of aircraft components of 500 units/year. A vision technology was demonstrated for in-line quality assessment. A chassis component in carbon fiber was developed with potential for 100 000 details/year. A new technology for materials in aircraft engine component reduced manufacturing cost by 40%. Requirements and design concepts were developed for composite bridges.

Results and expected effects

The robotic cell showed high potential for automated manufacturing of high-performance aeronautic components. Visions based inspection during the production enables increased traceability and lower scrap cost. Manufacture of chassis component in high production volumes increased the knowledge and provides new opportunities for subcontractors. New forming technology of materials reduced manufacturing costs by up to 40%. New requirements and design concepts for composite bridges increased the purchaser competence of authorities and promotes Swedish composite industry

Approach and implementation

The project was run in parallel in three ´demo-activities´ led by the industrial problems owners, GKN Aerospace, Saab AB and Volvo Cars, with the goal to demonstrate their own technologies on TRL between 5-6. Two work packages on TRL between 3-4 were led by academic partners, KTH and Chalmers. Swerea SICOMP and KTH participated in all demos and played an important role as a knowledge transfer between industrial sectors. Three workshops and technical meetings between the partners contributed to the good contacts and exchange of experience between sectors.