A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

Abstract

Automated processing techniques such as automated fiber placement (AFP) or automated tape laying (ATL) are well known nowadays. However, there is still a lot of potential for these methods to achieve better results, especially for large and complex composite structures. In this experimental work, the gap effect with the Automated Fiber Placement is shown and a solution to overcome this drawback is presented. The gaps are particularly apparent on complex and/or double-curved surfaces and reduce the mechanical properties of the composite structure. In order to cover the unavoidable weak area of this effect, a plurality of fiber composite layers are laid on top of one another in order to increase the mechanical properties of components. This in turn makes the components heavier and more expensive to produce. In this new method, the gaps are detected by profile sensor after placement of the tape on the mold. The gaps are filled with the aid of a 3D printer with carbon continuous-fiber reinforced plastics. By combining the 3D printing and AFP technology, composite parts can be manufactured in a more homogeneous manner. Subsequently, the components are produced faster, cheaper and even lighter because of the avoidance of the additional layers.