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Design and manufacture of hybrid metal composite structures using functional tooling made by additive manufacturing

Türk, Daniel-Alexander and Rüegg, Fabian and Biedermann, Manuel and Meboldt, Mirko (2019) Design and manufacture of hybrid metal composite structures using functional tooling made by additive manufacturing. Design Science, 5 . Art. No. e16. ISSN 2053-4701. https://resolver.caltech.edu/CaltechAUTHORS:20201012-123637244

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Abstract

This paper presents a novel manufacturing technique for complex-shaped, hybrid metal composite structures leveraging the design freedom of additive manufacturing (AM). The key novelty of this research is an approach for an autoclave-suitable and removable tooling, which consists of a 3D-printed functional shell and a structural filler material. In this process, a layup shell is produced with AM and filled with a temperature-resistant curing support to form a removable inner tooling. The functional shell has integrated design features for the positioning and the fixation of metallic interface elements and is removed after curing through integrated breaking lines. The feasibility of this manufacturing technique is demonstrated by fabricating a novel lightweight structure for the hydraulic quadruped (HyQ) robot. Selective laser sintering (SLS) was used to produce the functional shell tooling. Titanium interface elements made via selective laser melting (SLM) were assembled to the shell and co-cured to carbon fiber using an autoclave prepreg process. The resulting multi-material structure was tested in ultimate strength and successfully operated on the HyQ robot. Weight savings of 55% compared to a reference design and the mechanical viability of the multi-material structure indicate that the proposed manufacturing technique is appropriate for individualized hybrid composite structures with complex geometries.


Item Type:Article
Related URLs:
URLURL TypeDescription
https://doi.org/10.1017/dsj.2019.16DOIArticle
ORCID:
AuthorORCID
Türk, Daniel-Alexander0000-0001-5919-3079
Additional Information:© The Author(s) 2019. Distributed as Open Access under a CC-BY-NC-ND 4.0 license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Published online by Cambridge University Press: 01 October 2019. We thank Dr. C. Semini and V. Barasuol of the Dynamic Legged Systems Lab of the Italian Institute of Technology for proposing the HyQ as a case study and for providing the experimental loads in Section 3.2. We thank Prof. P. Ermanni of ETH Zurich and Dr. M. Zogg of Inspire AG for providing access to the laboratory infrastructure. We also thank D. Fenner of ETH Zurich for his excellent craftsmanship on the milling machine. This research was supported by the Product Development Group Zurich, ETH Zurich.
Funders:
Funding AgencyGrant Number
ETH ZurichUNSPECIFIED
Subject Keywords:lightweight design, additive manufacturing,multi-material structures, carbon fiber composite
Record Number:CaltechAUTHORS:20201012-123637244
Persistent URL:https://resolver.caltech.edu/CaltechAUTHORS:20201012-123637244
Official Citation:Türk, D., Rüegg, F., Biedermann, M., & Meboldt, M. (2019). Design and manufacture of hybrid metal composite structures using functional tooling made by additive manufacturing. Design Science, 5, E16. doi:10.1017/dsj.2019.16
Usage Policy:No commercial reproduction, distribution, display or performance rights in this work are provided.
ID Code:105982
Collection:CaltechAUTHORS
Deposited By: Tony Diaz
Deposited On:12 Oct 2020 19:41
Last Modified:12 Oct 2020 19:41

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