Optimized and Cost-efficient Compression Molds Manufactured by Selective Laser Melting for the Production of Thermoset Fiber Reinforced Plastic Aircraft Components

Abstract

Today, innovative lightweight constructions and highly complex parts for aircraft can be realized by Additive Layer Manufacturing (ALM), also called 3D-printing, in a time-saving and cost-efficient way. However, these new production technologies are not only considered for lightweight components but also for the manufacturing of molds, tools and jigs. In this context the additive manufacturing of heated compression molds for the production of thermoset composites by using a Selective Laser Melting (SLM) or also called Laser Beam Melting (LBM) process is particularly promising. In comparison to conventional machining the additive tool manufacturing obtains shortened time for development, simplified of the production due to less process steps, reduced production lead time and a general cost reduction. By the way, less energy consumption and improved material usage for the manufacturing of composite molds are further benefits, which cause an additional increase of the cost efficiency and economical sustainability. Moreover, an optimization of the fiber reinforced plastics (FRP) part quality, an improvement of the reproducibility of manufacturing processes and a higher freedom of the part design can be realized due to a higher complexity of the mold geometry, an increased functional integration, new design approaches of heating channel systems and an improved temperature distribution of the additive manufactured compression molds. Consequently, these new composite tool manufacturing opportunities promise enormous potentials, but also several challenges for the future production of aircraft components.This paper deals with a first feasibility analysis of the Additive Layer Manufacturing of heated composite molds, jigs and tools for aerospace industries. Furthermore, the additive manufacturing of a heated research mold for a Sheet Molding Compound (SMC) aircraft component and first investigation findings of the influences on the manufacturing process parameters by using this research mold are further key aspects of the present work.