DS 80-4 Proceedings of the 20th International Conference on Engineering Design (ICED 15) Vol 4: Design for X, Design to X, Milan, Italy, 27-30.07.15

Year: 2015
Editor: Christian Weber, Stephan Husung, Marco Cantamessa, Gaetano Cascini, Dorian Marjanovic, Serena Graziosi
Author: Tuerk, Daniel-Alexander; Zueger, Andreas; Klahn, Christoph; Meboldt, Mirko
Series: ICED
Institution: 1: ETH Zuerich, Switzerland; 2: Inspire AG, Switzerland
Section: Design for X, Design to X
Page(s): 279-290
ISBN: 978-1-904670-67-4
ISSN: 2220-4334


The combination of Additive Manufacturing (AM) with Carbon-Fibre-Reinforced Polymers (CFRP) unlocks potential in the design and development of highly integrated lightweight structures. This paper introduces two different design potentials, where the combination of AM and CFRP can lead to better and lighter hybrid structures: First, Load Introductions often show complex superimposed loads and therefore lightweight metal alloys become a valuable alternative to CFRP. With AM, load-oriented designs that provide a more continuous introduction of the load into the fibers become possible. Secondly, tooling for complex composite structures is expensive and laborious. Here, inner tooling with AM can offer potentials in the design and development of complex-shaped composite parts. Within this paper, the potentials are highlighted by a case study that consists of the development of a Hydraulically actuated Quadruped robot (HyQ) leg. Based on the case study, the need for fundamental research in the design and processing of structures with AM and CFRP is pointed out in order to pave the way for its use in future high performance technological applications.

Keywords: Design For X (DfX), Additive Manufacturing, Carbon-Fiber-Reinforced Polymers, Hyq

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