16. September 2019
Project PROCOMP

One-step man­u­fac­tur­ing of a CFRP in­ter-stage

Flashlamp based Automated Fiber Placement (FAFP)
Flash­lamp based Au­to­mat­ed Fiber Place­ment (FAFP)
Image 1/3, Credit: DLR (CC-BY 3.0)

Flashlamp based Automated Fiber Placement (FAFP)

Flash­lamp based Au­to­mat­ed Fiber Place­ment (FAFP) at DLR Cen­ter for Lightweight-Pro­duc­tion-Tech­nol­o­gy (ZLP) in Augs­burg.
Scaled, intertank structure demonstrator (left untrimmed, right trimmed part)
Scaled, in­ter­tank struc­ture demon­stra­tor (left untrimmed, right trimmed part)
Image 2/3, Credit: DLR (CC-BY 3.0)

Scaled, intertank structure demonstrator (left untrimmed, right trimmed part)

The first one-step man­u­fac­tured in­ter­tank demon­stra­tor, that was built with the new pro­cess at the Cen­ter for Lightweight Pro­duc­tion-Tech­nol­o­gy in Augs­burg.
Detail of the anisogrid used for the intertank structure
De­tail of the aniso­grid used for the in­ter­tank struc­ture
Image 3/3, Credit: DLR (CC-BY 3.0)

Detail of the anisogrid used for the intertank structure

A node of the aniso­grid struc­ture in de­tail.
  • First use of flashlamp heating to produce aerospace component
  • Focus: Lightweight Production, Aerospace

The DLR Center for Lightweight-Production-Technology (ZLP) in Augsburg manufactured a thermoplastic carbon fiber reinforced inter-stage structure for next generation European launcher systems. Using a cutting edge flashlamp heatsource the DLR developers manufactured two scaled demonstrator of a lattice inter-stage structure using in-situ Automated Fiber Placement (AFP). The process is currently under development at the DLR-Institute of Structures and Design. The goal is to saive weight and cost for future launchers. The demonstrators are the first aerospace components that have been produced using the flashlamp technology.

The unscaled part was designed to withstand typical loads during operation. Simulation results predict that it is capable to hold a load equivalent of 7180 times its own weight. The next step is the mechanical testing of the demonstrator. The results will be used to mature the technology. Within the DLR-project PROCOMP it will be used to demonstrate the one-stage production of a cryogenic tank structure made from thermoplastic carbon fiber reinforced polymer (CFRP) for a future launcher system. The DLR experts work in cooperation with MT Aerospace AG. The project is funded by the District Government of Upper Bavaria" as part of the "Bayerisches Luftfahrtforschungs- und Technologieprogramm" and will be running until the end of 2019.

Contact
  • Bernadette Jung
    Ger­man Aerospace Cen­ter (DLR)
    Pub­lic Af­fairs and Com­mu­ni­ca­tions: Oberp­faf­fen­hofen, Augs­burg, Weil­heim
    Telephone: +49 8153 28-2251
    Fax: +49 8153 28-1243
    Münchener Straße 20
    82234 Weßling
    Contact
  • Lars Brandt
    Ger­man Aerospace En­ter (DLR)
    Cen­ter of Lightweight-Pro­duc­tion-Tech­nol­o­gy
    Pro­cess­es and Au­toma­ti­sa­tion
    Telephone: +49 821 319874 1076
    Am Technologiezentrum 4
    86159 Augsburg
    Contact
  • Dominik Deden
    Ger­man Aerospace En­ter (DLR)
    Cen­ter of Lightweight-Pro­duc­tion-Tech­nol­o­gy
    Pro­cess­es and Au­toma­ti­sa­tion
    Telephone: +49 821 319874 1081
    Am Technologiezentrum 4
    86159 Augsburg
    Contact

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