Mikrosam unveils multi-robot system for tool-less thermoplastics layup

The company says it has developed an automated process for fabrication of thermoplastic composites without the use of any moulds or tools. A result of a research cooperation project between Mikrosam, General Atomics Aeronautical Systems Inc., and Composite Automation, has turned the idea of tool-less in-situ consolidation for thermoplastics into reality.

Mikrosam used its advanced AFP and ATL systems to create an integrated manufacturing cell with dual robots working in tandem: one robot lays up thermoplastic UD tape, another robot acts as a tool.

The movements of the robots are precise and coordinated to obtain spatial 3D in-situ consolidation. The integration is controlled using Mikrosam's advanced simulation, control and automation software MikroPlace and MikroAutomate which allows for coordination of multiple robots in a single cell to produce a composite part.

The Multi-Robot system – a patent-pending innovation – produced 3D composite parts – flat, spherical and bathtub shapes – in-situ consolidated without an autoclave. The systems use laser with precise temperature and angle control, and a closed-loop feedback with custom thermal models for thermoplastic samples with better mechanical properties. It leverages the advances in Mikrosam’s thermoplastics layup from many development projects with Tier 1 aerospace suppliers over the past couple of years. This application of thermoplastic carbon fibre 3D printing presents new opportunities for composites manufacturing where building a new tool isn't always feasible or requires flexibility, in industries, such as aerospace, space, marine, automotive.

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