Projects implemented
Ironing technology using an intelligent membrane for efficient production of composite products of high variety,
Acronym: SmartMembrane
Project objective
The aim of the project was to develop an adaptive production process, in which the production tool dedicated to the product is combined with a heated, flexible silicone membrane with integrated sensors in such a way that it is suitable for efficient forming of composite materials, based on innovative fast-cured resin systems.
The technology developed allows for significant simplification of conventional material consolidation processes, while maintaining the safety and stability of the process. The key element of the innovative form is an intelligent membrane, consisting of elastomer with integrated heating and sensory elements for process monitoring and immediate adaptation of the process parameters.
In combination with adaptive tools, based on modular or adjustable elements, a large variation in the geometry of manufactured products is possible.
In this way short series of products with geometry and properties tailored to individual customer needs and reproducible material quality at relatively low investment and production costs can be produced.
Application potential
Thanks to the developed technology, a simplified, highly flexible technology of manufacturing polymer fibre composites was created, competitive in terms of cost to classic ironing methods using metal forms.
Thanks to the versatility of the solution, it is not directly targeted at a particular industrial sector but can be implemented both in large companies and in particular in SMEs.
Key advantages of using technology:
(1) Low cost of initial investment (lower manufacturing/purchase costs of membrane compared to steel forms and their instrumentation).
(2) Lower costs of implementing the production process into the company (e.g. shorter testing time for new technology).
(3) A shorter time for the manufacture of components by using snap-cure resins with a network time of 2-6 minutes.
(4) Lower energy consumption (shorter membrane heating time compared to steel forms).
Project consortium partners
The project was carried out as part of the CORNET action – 27 in an international consortium with the participation of the Cluster of Innovative Manufacturing Technologies of CNNOMATECH (Poland) acting as coordinator and the Warsaw University of Technology (Poland), the Inotec Development Research Institute Sp. z o.o. (Poland), Forschungsinstitut für Leder und Kunsttoffbahnen (FILK) gGmbH (Germany), Technische Universität Dresden (Germany).