Additively Manufactured Roof Frame Segment with Local Carbon Fiber Reinforcement

September 30 2019

To date, polymer-based additively manufactured structures have failed to gain a foothold in vehicle bodies due to inadequate mechanical characteristics. Now, Audi and Cikoni have presented an approach combining additive manufacturing with carbon fiber reinforcement based on a concept study.

The AdditiveCarbon process presented by Cikoni represents a promising response to this type of requirements profile. The concept involves a hybrid mindset and design; uniting the advantages of additive manufacturing with the benefits of 3-D winding of continuous fibers. Additive manufacturing is used for molding with a high level of design freedom and minimizing material consumption, with carbon fibers ensuring the desired mechanical performance of the components, processed with little waste and maximum usability directly from the roll and without using any additional tools. This method was used in a concept study for a lightweight design roof frame of the Audi RS5 Coupe Fiber-reinforced Plastic (FRP) roof.

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