OPTICOMP3D | 3D printing of optimised composite structures

Region:

Wallonia

Financed by

A new generation of lightweight structures thanks to non-planar 3D printing

OPTICOMP3D meets a clear need in the industry for manufacturing of lightweight, made-to-measure parts with good mechanical performance. The project uses three powerful technological tools to achieve this: non-planar 3D printing (Freeform), continuous fibre reinforcement and topological optimisation. This approach paves the way for a new generation of composite structures that are robust, economically viable and meet the requirements of cutting-edge technology sectors.

Context

Thermoplastic composites have the advantage of being recyclable, but they require expensive moulds. While 3D printing eliminates the need for these moulds, it is often limited to building up material in a planar way. Topological optimisation is also little used in reinforced printed structures. OPTICOMP3D offers an integrated solution: an inverted printing platform with continuous fibres, controlled by advanced design tools to offer greater design freedom and improved manufacturing efficiency.

Target group

The OPTICOMP3D project is aimed primarily at sectors with stringent requirements in terms of the performance, weight and customisation of components. In particular, it is relevant to the following sectors:

Aeronautics and space: mass optimisation
Defence and UAVs: customised robust structures
Medical and orthopaedics: suitable lightweight devices
Innovative SMEs: rapid prototyping and small production runs

The project also creates opportunities in sport, design and industrial tooling.

Objectives & results

The main aim of the project is to develop a complete 3D printing solution for composites reinforced with continuous fibres, that is suitable for non-planar geometries with topological optimisation.

More specifically, the project aims to:

develop a anisotropic topological optimisation software program that is compatible with additive manufacturing (Cenaero)
design an innovative robotic platform combining a moving platform and fixed print heads (Sirris)
build complex, mechanically validated demonstrators.

The results will be promoted via webinars, scientific publications and industrial workshops.

Approach

The project is structured around eight main work packages (WPs):

WP1: Definition of the case study - Analysis of industrial needs, choice of demonstrators
WP2: Software development - Adapting Freeform tools for reverse printing.
WP3: Hardware platform - Design and manufacture of the printing system
WP4: Optimisation for support - Simulation and structural lightening
WP5: Multi-scale optimisation - Anisotropic structures via Morfeo
WP6: Software and hardware integration - Printing and characterisation of test coupons
WP7: Study of substrates - Recyclability, removal and dismantlable design
WP8: Proof-of-concepts - Manufacturing and final mechanical validation