Mandrel Production Presentation

20160408 Aqua Mandrel Presentation_LA.pptx
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© 2016 Aero Consultants AG, LA
Lukas Atz
Product Manager
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20160408 Aqua Mandrel Presentation_LA.pptx
© 2016 Aero Consultants AG, LA
About
 Hollow parts with closed shape require
mandrel technology
 Existing mandrel or bladder techniques
show disadvantages
 New class of lost core / mandrel material
 Water soluble
 Environmentally friendly
 Processing Advantages
 Applications:
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Air- and Cable Ducts
Stiffening Structures
Pressure Vessels
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© 2016 Aero Consultants AG, LA
Highlight Features
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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
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© 2016 Aero Consultants AG, LA
Materials
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Aquacore™
Aquapour
Aquafill™
Aquaseal™
Fastcore
 Rapidcore
20160408 Aqua Mandrel Presentation_LA.pptx
wet paste
powder, castable
filler for repair
water soluble sealant
for automated
processing
rapid prototypes
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© 2016 Aero Consultants AG, LA
Materials
 Aquacore for Honeycomb Stabilisation
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© 2016 Aero Consultants AG, LA
Reasons for Mandrel Production
 Common operator problems with processing
 Service to offer ready to use water soluble mandrels
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© 2016 Aero Consultants AG, LA
Products
 AquaBlock for Prototyping
 Pressed & Sealed
 Machinable
 Machined surface must be sealed
with tape or sealer
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© 2016 Aero Consultants AG, LA
Products
 RapidCore for Prototyping
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Build volume 800 x 400 x 400mm
Silica sand with water-soluble binder
Temperature resistant 120°C
Density 1.3 gcm-3
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© 2016 Aero Consultants AG, LA
RapidCore steering wheel mounting
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© 2016 Aero Consultants AG, LA
Products
 RapidCore combining with Composites for highly intergrated
lightweight structures
 Hydraulically actuated Quadruped robot (HyQ)
 Developed at Istituto Italiano di Tecnologia IIT
www.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, submitted
Daniel Türk, dtuerk@ethz.ch, www.pdz.ethz.ch
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© 2016 Aero Consultants AG, LA
Products
 Manufactured Mandrels
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© 2016 Aero Consultants AG, LA
Applications
 Hollow Door Structures
 Door Hinges
 Airducts
 Stringers
Example: compositesworld.com 201307
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© 2016 Aero Consultants AG, LA
Aircraft Passenger Door Hinge
 Different mandrel shapes
 Wash-out station
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Door assembly
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© 2016 Aero Consultants AG, LA
Air-/Cableducts
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© 2016 Aero Consultants AG, LA
Airducts
 Different Airducts
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Missile Airduct
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© 2016 Aero Consultants AG, LA
Landing Flap
 1.5m length
 RTM Processing
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© 2016 Aero Consultants AG, LA
Reinforced Silicone Sealants
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© 2016 Aero Consultants AG, LA
Omega Stringer
 Up to 7m length
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© 2016 Aero Consultants AG, LA
Pressure Vessels
 Mandrel made from block or with mould
 Composite processing by winding or tapelaying
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© 2016 Aero Consultants AG, LA
Automotive Parts
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© 2016 Aero Consultants AG, LA
Automotive Parts
 Rear Crash Structure
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 Front Nose Section
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© 2016 Aero Consultants AG, LA
Maintenance Door
 Dimension 600x690mm
(24”x 27”)
 Volume 8.0 litre
 OEM in Germany
20160408 Aqua Mandrel Presentation_LA.pptx
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Lay-up of the SMC material
Temperature 140°C / 284°F
Pressure 40bar / 580psi
Cycle time each part 8 – 11min
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 SMC Part
 Very accurate in wall
thickness
 Weight reduction 51%
(16.5kg => 8.0kg)
 Better acoustic insulation
© 2016 Aero Consultants AG, LA
Manufacturing
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© 2016 Aero Consultants AG, LA
Production Equipment
 Hot Air Ovens
 Microwave Heating
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© 2016 Aero Consultants AG, LA
Production Equipment
 CAD/CAM Design
 CNC Milling
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© 2016 Aero Consultants AG, LA
Logistics / Serial Production
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© 2016 Aero Consultants AG, LA
Customers
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© 2016 Aero Consultants AG, LA
Aero Consultants
Your Partner in the
Aerospace
Composites
Industry
Aero Consultants AG
P.O.Box 35
Grabenstrasse 8
CH-8606 Naenikon / Switzerland
T +41 44 905 28 00 (08)
F +41 44 941 31 37
l.atz@aero-consultants.ch
www.aero-consultants.ch
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© 2016 Aero Consultants AG, LA