20161027 aqua mandrel presentation la.pptx 1 © 2016 aero … · 2020-01-09 · © 2016 aero...

© 2016 Aero Consultants AG, LA

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20161027 Aqua Mandrel Presentation_LA.pptx

Lukas AtzProduct Manager

© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx

About Hollow parts with closed shape require

mandrel technology

Existing mandrel or bladder techniquesshow disadvantages

New class of lost core / mandrel material

Water soluble

Environmentally friendly

Processing Advantages

Applications: Air- and Cable Ducts

Stiffening Structures

Pressure Vessels

3


Highlight Features Water soluble

Leightweight 0.54 gcm-3

Low CTE 4.7 e-6

Temperature resistant 195°C

Pressure resistant 8.5 bar

Autoclave and RTM

Non corrosive

Smooth surface

Automated manufacturing, machinable

Fast wash-out

Environmentally friendly – no wastewater treatment

4

P


Materials

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Aquacore™ wet paste

Aquapour powder, castable

Aquafill™ filler for repair

Aquaseal™ water soluble sealant

Fastcore for automatedprocessing

Rapidcore rapid prototypes


Materials

6

Aquacore for Honeycomb Stabilisation


Reasons for Mandrel Production Common operator problems with processing

Service to offer ready to use water soluble mandrels

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Products AquaBlock for Prototyping

Pressed & Sealed

Machinable

Machined surface must be sealedwith tape or sealer


Products RapidCore for Prototyping

Build volume 800 x 400 x 400mm

Silica sand with water-soluble binder

Temperature resistant 120°C

Density 1.3 gcm-3


RapidCore Mandrel Steering Wheel Mounting


RapidCore Mandrel for Carbon Rim Rim size Ø 10” x 7”

Weight 1.35kg

Rim profile according DIN 7817

Made of Carbon Prepreg on a Rapidcore Mandrel with outside tool


Products RapidCore combining with Composites for highly integrated

lightweight structures

Hydraulically actuated Quadruped robot (HyQ)

Developed at Istituto Italiano di Tecnologia IITwww.iit.it Dynamic Legged Systems Lab

Türk et al. Combining Additive Manufacturing with Advanced Composites for Highly Integrated Robotic Structures, 26th CIRP Design Conference 2016, submittedDaniel Türk, [email protected], www.pdz.ethz.ch

http://www.iit.it/


RapidCore Mandrel for ANYmal Robot RapidCore Mandrel used for Carbon legs

=> lightweight, high stiffness and cable integration

www.wysszurich.ch


Products Manufactured Mandrels


Applications Hollow Door Structures

Door Hinges

Airducts

Stringers

Example: compositesworld.com 201307


Different mandrel shapes

Wash-out station Door assembly

Aircraft Passenger Door Hinge

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Air-/Cableducts

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Airducts

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Different Airducts Missile Airduct


Landing Flap 1.5m length

RTM Processing

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Reinforced Silicone Sealants

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Omega Stringer Up to 7m length


Pressure Vessels Mandrel made from block or with mould

Composite processing by winding or tapelaying

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Automotive Parts

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Automotive Parts

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Rear Crash Structure Front Nose Section


Maintenance Door

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Dimension 600x690mm (24”x 27”)

Volume 8.0 litre

OEM in Germany

Lay-up of the SMC material

Temperature 140°C / 284°F

Pressure 40bar / 580psi

Cycle time each part 8 – 11min

SMC Part

Very accurate in wall thickness

Weight reduction 51%(16.5kg => 8.0kg)

Better acoustic insulation


Manufacturing


Production Equipment

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Hot Air Ovens

Microwave Heating


CAD/CAM Design

CNC Milling

Production Equipment

28


Logistics / Serial Production


Customers

30

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20161027 aqua mandrel presentation la.pptx 1 © 2016 aero … · 2020-01-09 · © 2016 aero...

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