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dTwin

DIGITAL TWINS IN ADDITIVE MANUFACTURING PROCESSES FOR CARBON FIBER COMPONENTS: TOWARDS SUSTAINABLE MOBILITY

Field
National
Date
-
Industry
Budget
96800
Funded by

STATE INVESTIGATION AGENCY

Website
Video

PROJECT INFORMATION

DESCRIPTION

This project deals with the implementation of Digital or Hybrid Twins in the manufacture of composite structures.
of high performance long fiber. New advanced manufacturing methodology for composite repair to be developed
carbon fiber reinforced plastics (CFRP) used as structural components in the aerospace industry and in vehicles.
electric. This technology is an out-of-autoclave composite forming solution based on the infiltration of liquid resins.
Its implementation is proposed both for structures manufactured with conventional technologies as well as for additive manufacturing (ALM, Additive
Layer Manufacturing) in carbon fiber with thermoplastic matrix (PEEK).
A conceptual change based on the knowledge of infusion or re-infiltration manufacturing technologies is proposed for the
repair of large composite structures. This new repair concept is associated with the development of twins.
(DT, Digital Twins) of the material, the forming process and the fracture generated by an impact. Calculation models
The new technologies developed will allow both the simulation of the reinfiltration process and the mechanical behavior of the structure before and after the reinfiltration process.
repair and estimation of resistance to possible new impacts. In the particular case of parts made up of
the lack of knowledge about its impact behavior is very low and there are no references on the techniques of additive manufacturing.
repair outside Autoclave, so the project has aroused great expectation.
In recent years, additive manufacturing processes have made it possible to reduce costs thanks to the capacity of generating
very complex geometries and above all the possibility of realizing very light structures thanks to topological optimization techniques.
These processes comply with the commitment to sustainability in manufacturing and allow for up to 90% reduction in energy savings and
only 5% of waste material. Therefore, this project is perfectly linked to the sustainable transport challenge.
We propose the study and implementation of the technique to the advanced manufacturing processes of carbon fiber with PEEK matrix by
additive manufacturing. Knowledge of 3D modeling of micro-cracks and impregnation is essential for this project,
crack growth, composite impact, quality control by non-destructive testing (ultrasonic and thermography), modeling, etc.
mechanical numerics, forming processes and material characterization. For this reason, it is necessary for the research group to
is highly multidisciplinary and well coordinated. Given the difficulty in observing the damaged area, once it has been
generated the digital twin, augmented reality techniques will be used to assist the technical personnel in charge of carrying out the
component repair.
This project is part of the research line of the Universidad Politécnica de Valencia (UPV) in the field of
composites, in which five projects of the National Plan have been developed (Ref.: DPI2001-2792, DPI2004-03152, DPI2007-66723-C02-
00, DPI 2010-20333 and DPI2013-44903-R-AR) with the same PI and research group.

This project deals with the implementation of Digital or Hybrid Twins in the fabrication of composite structures.
of high performance long fiber. New advanced manufacturing methodology for composite repair to be developed
carbon fiber reinforced plastics (CFRP) used as structural components in the aerospace industry and in vehicles.
electric. This technology is an out-of-autoclave composite forming solution based on the infiltration of liquid resins.
Its implementation is proposed for structures manufactured with conventional technologies as well as by additive manufacturing (ALM, Additive
Layer Manufacturing) in carbon fiber with thermoplastic matrix (PEEK).
A conceptual change based on the knowledge of infusion or re-infiltration manufacturing technologies is proposed for the
repair of large composite structures. This new repair concept is associated with the development of twins.
(DT, Digital Twins) of the material, the forming process and the fracture generated by an impact. Calculation models
The new technologies developed will allow both the simulation of the reinfiltration process and the mechanical behavior of the structure before and after the reinfiltration process.
repair and estimation of resistance to possible new impacts. In the particular case of parts made up of
the lack of knowledge about its impact behavior is very low and there are no references on the techniques of additive manufacturing.
repair outside Autoclave, so the project has aroused great expectation.
In recent years, additive manufacturing processes have made it possible to reduce costs thanks to the capacity of generating
very complex geometries and above all the possibility of realizing very light structures thanks to topological optimization techniques.
These processes comply with the commitment to sustainability in manufacturing and allow for up to 90% reduction in energy savings and
only 5% of waste material. Therefore, this project is perfectly linked to the sustainable transport challenge.
We propose the study and implementation of the technique to the advanced manufacturing processes of carbon fiber with PEEK matrix by
additive manufacturing. Knowledge of 3D modeling of micro cracks, impregnation, etc. is essential for this project,
crack growth, composite impact, quality control by non-destructive testing (ultrasound and thermography), modeling, etc.
mechanical numerics, forming processes and material characterization. For this reason, it is necessary for the research group to
is highly multidisciplinary and well coordinated. Given the difficulty of observing the damaged area, once it has been
generated the digital twin, augmented reality techniques will be used to assist the technical personnel in charge of carrying out the
component repair.
This project is part of the research line of the Universidad Politécnica de Valencia (UPV) in the field of
composites, in which five projects of the National Plan have been developed (Ref.: DPI2001-2792, DPI2004-03152, DPI2007-66723-C02-
00, DPI 2010-20333 and DPI2013-44903-R-AR) with the same PI and research group.

Entities

UPV

Contact information

Juan Antonio García Manrique
IDF Member

IDF

Technological capabilities

Robotics
Industrial robotics