Maturation of Automated Ply Placement and high-rate composite press molding processes
Customer name :
Strategic material supplier : Syensqo; Bell Textron Canada
Completion date : 2022-2026
In brief
Identification and mitigation of technological risks (de-risking) associated with the introduction of Automated Ply Placement and Press Molding processes for the high-rate production of aircraft parts with complex geometries.
Project summary
For our customers, we identified and mitigated the technological risks associated with the introduction and industrialization of the press molding process for the high-rate production of aircraft parts with complex geometries. We supported the optimization of various molding process parameters, including the choice of consumables compatible with this process. For demonstration purposes, we designed a prototype high-rate molding line around our 400-ton large-format Eagle hydraulic press, a unique CTA asset for Eastern Canada.
We also designed a customized robot end-effector solution for our customer, to handle and position the various layered materials making up the 2.5D preforms subsequently shaped by the press molding process. This original and robust solution, developed at CTA in collaboration with a university academic partner, compared favorably with commercially available solutions. Finally, we carried out a comparative study of the benefits and drawbacks of "fully automated" solutions for preparing kitting assemblies, compared with "semi-automated" solutions. We provided our customers with recommendations and specifications for the acquisition of a commercial "automated" kitting and stacking cell aligned with their needs.
The project optimized the use of the carbon-epoxy infusion system. CYCOM EP2750designed for the Double Diaphragm Forming (DDF)an automated process for shaping complex composite parts with reduced cycle times from Syensqo.
DDF technology is a proven, efficient and automatable method for the high-speed manufacture of structural composite parts, combined with fast-curing prepregs.
"As part of our R&D development for the manufacture of high-speed composite parts in the aerospace sector, Syensqo was looking for a partner capable of meeting the challenge of rapid production while ensuring the quality and reliability of the parts produced. The project carried out with the Centre technologique en aérospatiale (CTA) aimed to optimize the use of our CYCOM EP2750 carbon-epoxy prepreg, by developing an innovative adaptive manufacturing methodology.
The CTA team stood out for its cutting-edge technical expertise and its ability to propose concrete solutions tailored to our industrial needs. Their collaborative approach, combining advanced modeling and manufacturing tests, enabled us to effectively meet our expectations by integrating the specificities of the material and the requirements of the DDF process.
Thanks to this collaboration, we have been able to improve the performance of our DDF process and accelerate technology transfer to our customers. This partnership has strengthened our position in innovation and competitiveness in the aerospace sector. We are fully satisfied with this experience and look forward to future projects with the CTA."
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CTA's role
To provide expertise in the automation and robotization of the 2 processes, in the design of a prototype press molding process line, and in the development of composite manufacturing processes, thanks to in-depth knowledge of the fast-cure material system.
Results
- Production of several demonstration composite parts, with complex geometry or architecture, manufactured using this new press-molding process.
- Demonstration of the equivalence of prototype parts produced by this new process, in terms of microstructural attributes and surface quality, to those produced using legacy manufacturing processes.
- Comparative analysis of commercially available composite gripping solutions.