Carbon fiber lay-up: replacement of metal molds with composite materials

Carbon fiber lay-up with industrial 3D printing: download the document!

The use of composite materials such as carbon fibers, capable of combining chemical-physical properties typical of traditional materials like metal alloys, ceramics and polymers, is increasingly frequent in every industrial sector. This is particularly true in the aeronautical and space fields, where the need for low-weight structural components has fueled the research and development of optimized solutions since 1937.

The final properties of these materials strictly depend on the constituent phases, their relative quantities and the geometry of the dispersed phases, i.e. shape, size, distribution and orientation of the reinforcing elements. To date, the most widely used composite is carbon fiber in a resin matrix, a combination of low densities and excellent mechanical characteristics, such as stiffness and resistance to abrasion, fatigue and impact.

Carbon fiber lay-up: the traditional methods

Carbon fiber is used in laminate form in military and civilian aircraft, constituting more than 50% of the structure of the most advanced aircraft of the two main manufacturers on the market (Boeing 787 and Airbus A350).

In the manufacturing process of carbon laminates, resin-impregnated carbon sheets (pre-preg) are cut in the desired shape with the aid of one or more molds by an operator, then put into the autoclave to stimulate the polymerization of resins.

Replacement of metal molds with polymeric elements for carbon fiber lay-up

After the recent advances in additive manufacturing, a company active in the aviation industry has experimented the introduction of Roboze 3D printing technology in the carbon fiber hand lay-up for aerospace components. The investigated application concerns the replacement of traditional metal molds, often related to high costs and long processing times with CNC machines, with polymeric elements (Roboze Carbon PA PRO and Carbon PEEK) for the production of uprights and beam joints for the keel frame assembly of an airliner.

Given the artisanal nature of carbon fiber lay-up process, which necessarily involves limited production volumes, Roboze's industrial 3D printing solution has brought considerable design flexibility and cost-efficiency compared to the traditional system, reducing times and associated costs.

Both molds have been successfully used for the hot forming (Carbon PA PRO) and autoclave curing (Carbon PEEK) process, ensuring adequate mechanical, thermal and self-lubricating properties.

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