Bachelor’s thesis or master’s thesis
© PerplexityTopic of the work:
Load-bearing structural components, such as control arms in the automotive industry, require locally tailored fiber architectures to optimize stiffness, fatigue strength, and failure behavior. However, conventional manufacturing processes allow for such local variations in fiber orientation and fiber volume fraction only with significant experimental and tooling effort. In contrast, plasticizing additive manufacturing (SEAM) offers the possibility of specifically influencing the fiber architecture during layer-by-layer deposition by actively controlling web guidance and local material flows.
This requires a model-based slicing and path planning strategy that guides fiber orientations along local load paths and varies fiber volume fractions in critical areas of a structural component. As part of this thesis, the goal is to develop such a strategy, implement it in an existing slicer prototype, and integrate it with the existing extruder control system via a suitable interface in order to experimentally demonstrate the effect of graded fiber architectures.
The work is related to this research project:
The work is part of the Collaborative Research Center TRR 402 “DediGrad”. This project investigates production methods for the optimal combination of fiber-reinforced composite and polymer technologies in order to create structural components with locally tailored properties. The focus is particularly on fiber-reinforced structural components in which fiber orientation and fiber volume fraction are varied locally to specifically adjust stiffness, energy absorption, and failure behavior, thereby reducing stress peaks.
Objective:
The goal of this work is to use model-based slicing to precisely control graded fiber architectures in load-bearing structural components.
Your task:
| For a Bachelor's thesis, you will work on the following tasks: | For a Master's thesis, you will work on the following tasks: |
| Introduction to SEAM, web design, and graded fiber architectures | In-depth training in SEAM, web design, and graded fiber architectures |
| Design and implementation of a slicing strategy for a structural demonstrator (path, TCP speed, base fiber volume content) | Design and implementation of an advanced slicing strategy, including simple 1D process model (throughput/mixing/residence time) for the same demonstrator |
| Extension of a slicer to generate suitable G-code paths and initial integration with the TwinCAT extruder controller | Extension of the slicer to include volumetric process planning and implementation of a robust interface to the TwinCAT controller |
| Manufacture and preliminary evaluation of demonstrator test specimens | Manufacture and in-depth evaluation of graded test specimens through mechanical testing |
Your profile:
- A degree in engineering or the natural sciences (e.g., mechanical engineering, industrial engineering, automation technology, CES, simulation sciences…)
- Interest in additive manufacturing
- Experience with programming languages
- A basic understanding of slicing and path planning is helpful
- Independent, structured and autonomous work
- Interest in working on pioneering research projects
If you are interested in this exciting range of topics and would like to help shape the future of additive manufacturing, we will be happy to work together to develop a topic tailored to your needs. Feel free to contact me by e-mail, phone or in person at the IKV. I look forward to your message!