CompositesWorld
Issue link: https://cw.epubxp.com/i/891910
NEWS 33 CompositesWorld.com ADAPA's machines range in size from 1-16m 2 . e Curve Works' system, capable of parts up to 5m 2 , falls within the 4-6m 2 required by most applications, says Jepsen. "A 2m-by-3m mold is a standard size in architecture for one panel, and you install multiple panels," he adds. Geuskens notes that nonrecurring costs are reduced if the adaptive mold is used to make multiple parts per day. ADAPA's molds cost between €100,000 and €250,000 (US$118,225 and US$295,995), which includes the electromechanical control system, software and 3D laser projector. "Our molds are an open-loop system," Jepsen explains. "With the 3D laser projector, which is already used in aerospace compos- ites and is ideal for our setup, we can scan the surface of the mold, evaluate vs. the part's digital design, and reposition. We have toler- ances on the mold surface of ±1-2 mm, but," he claims, "we can actually go almost to zero." "All we need to make a part is the CAD file," says Geuskens. "If it's a large structure, we divide that into panels using the adaptive mold software, then click on each panel to generate its output file, press the shape button and the mold transforms." is ease of producing affordable, one-off shapes has been well- received in the architectural and construction industry for glass fiber-reinforced concrete façades. "We spray the mix of concrete and fibers onto the mold, similar to FRP [fiber-reinforced plastic] sprayup for boats," notes Jepsen. ADAPA recently signed an order to deliver 80 molds for construction of Kuwait International Airport's new international terminal (Fig. 2, p. 32). "It will use 40,000 unique concrete panels, all curved," says Jepsen. "Our technology offered the most cost-effective solution." ADAPA molds are also used for glass-reinforced gypsum panels, like those used in the new Mumbai airport terminal. Lufthansa Technik has also shown interest in ADAPA's adaptive molds for aircraft repair applications. "ey want to simplify their processes with respect to storing and retrieving molds," Jepsen relates. "DIAB also has interest in using our technology for cored panels. If you use pre-shaped foam instead of scored foam, the panels will decrease resin uptake, especially for 3D shapes, so the finished composites are lighter." A reconfigurable fixture "Toolbox" Historically, fixed assembly tooling/fixtures have been steel monu- ments, much larger than the part being constructed, used to locate and hold sub-assemblies and components to maintain tight FIG. 3 The Prodtex Reconfigurable Toolbox This Wingbox Demo Fixture, developed for the Lean Assembly Wing Box (LAWIB) demonstrated in the LOCOMACHS project, used Prodtex' standardized, modular and reusable components to enable a quick design and build of the fixture; e.g., for the lower cover fixture: design (20 min), reduced cost and lead time (four weeks) and quick construction (three days). Also, the wing spar and ribs were positioned with 0.1-mm accuracy, using the automated Hexapods. Source | Prodtex Reconfigurable Tooling & Fixtures BoxJoint ShimBox TFS Hexapods