3D-FibRe-Print Thermoplastic 3D continuous fiber-reinforced ultra-lightweight components based on a generative manufacturing process using cooperating manipulator systems
The aim of the joint project 3D-FibRe-Print is to develop a novel robot-assisted manufacturing process for the production of thermoplastic ultra-lightweight components made of continuous fiber-reinforced plastic (FRP). Through the combined use of cooperating robot systems, the fiber and thermoplastic matrix are processed simultaneously, resulting in complex, load-path-compatible 3D truss structures that are resource-efficient, recyclable and virtually free of material waste. The ITM at TU Dresden is developing simulation-based methods for topology optimization, technology and product development as well as for generating 3D robot paths. The results contribute to sustainable lightweight construction and the circular economy in Saxony.
Schematic flowchart of the development of ultralight FKV components using robot-assisted manufacturing and integrated process control
The developments described focus on revolutionizing additive manufacturing processes for thermoplastics and continuous fibre-reinforced composites. A novel hybrid process combines FDM with continuous fibre deposition, supported by the development of a special effector (also end effector) for precise fibre handling and innovative, robot-specific 3D path planning for optimized load paths.