Automotive Success story

The next generation of additive manufacturing

Customer benefits
  • Fast and economical production of lightweight components
  • Exceptionally rigid components
  • Significant weight reduction
  • Process suitable for use in series production
Fiber patch placement at Cevotec
The large Stäubli TX200 is charged with the precise handling of the mold while the TP80 applies the patches.
Stäubli FAST picker TP80 and TX200 robots at Cevotec
Two Stäubli robots – a FAST picker TP80 and a six-axis TX200 – are among the key components of the Fiber Patch Placement Cell.

TASK

Efficient production of high-strength lightweight components

The Fiber Patch Placement (FPP) systems developed by a Bavarian technology company constitute a step change in additive manufacturing. Thanks to high-performance robotics, the process has the potential to revolutionize the series production of geometrically complex lightweight parts in the automotive industry.

Weight reduction is a top priority in vehicle production. Safety equipment and luxury features have been pushing unladen weights up and up in recent years. In order to reduce fuel consumption and pollutant emissions, manufacturers are now endeavoring to reverse this trend. Lightweight construction is in great demand, yet the relevant materials and manufacturing processes will only find their way into the factories if they pass the test of cost efficiency.

 

SOLUTION

Additive manufacturing Fiber Patch Placement (FPP)

The pioneering additive manufacturing process known as Fiber Patch Placement (FPP) constitutes a major breakthrough. FPP is a layering method in which a three-dimensional mold, positive or negative, is layered with carbon fiber strips, the so-called patches. The part is built up from individual adhesive fiber strips.

Just how fast, efficient and cost-effective Fiber Patch Placement can be in practice is already being shown by SAMBA Pro which has been developed by the Taufkirchen-based company Cevotec. This fully automated production line is equipped with two Stäubli robots. Between them, the ultra-nimble TP80 FAST picker and the six-axis TX200 bring a total of ten robot axes to bear on the free positioning of the patches.

And this is how Fiber Patch Placement works. Station 1 is where a continuo