An innovative Flexible Hybrid solution will be developed by MOLDAM for the production of moulds for big composite components. A Robotic Hybrid Manufacturing System will be used to create the preforms of the moulds. In addition, it will be able to execute a variety of other operations, allowing for more production flexibility. A combination of an already existing Additive Manufacturing (AM) technology with the necessary post-processes (compacting, machining, and surface coating) and additional modules, such as scalable Measuring modules, Easy and Flexible Programming Tools, CAD libraries for Hybrid Design and Manufacturing, and parametrized CAM will be used to create the system. Its adaptability will be further enhanced by its inclusion in remanufacturing and repair operations.
Replacement of moulds currently used, generally in metallic materials such as INVAR, by manufacturing moulds in mixed thermoplastic and composite materials using Additive Manufacturing technologies, in order to reduce costs, manufacturing times and weight.
Integration of the extrusion system (of high productivity) in a robotic cell for Additive Manufacturing of large moulds of thermoplastic and composite materials.
Optimisation and selection of mould materials and of the Direct extrusion process for the selected material and for the manufacture of large parts.
Design of the moulds for their production using this additive technology and providing them with high thermo-mechanical performance. Important: include heating/cooling ducts.
Process monitoring and control.
Manufacture of a 1000 mm length mould scale demonstrator
Verification of dimensional, metallurgical, mechanical, wear and thermal properties of the produced mould.
Validation of MOLDAM technology and definition of future lines of action.