Robotic
SEAM.
Robotic Screw Extrusion Additive Manufacturing
Your contact person
Nicolas Unger
German Aerospace Center
Robotic SEAM
In the hybrid production cell Yizumi SpaceA
Robotic Screw Extrusion Additive Manufacturing (SEAM) is a new type of 3D printing process that is used in the Yizumi SpaceA hybrid manufacturing cell operated by the DLR Institute of Vehicle Concepts. The system enables the processing of cost-effective standard granulates with high build rates and is used, for example, in the production of structural parts for the DLR Next Generation Car family.
Hybrid additive manufacturing cell SpaceA
The SpaceA system combines additive manufacturing using SEAM with subtractive machining options and component handling capabilities to create a flexible unit.
At the heart of the cell are four compact single-screw extruders that allow additive manufacturing based on standard pellets and are guided by industrial robots. Here, the spatial degrees of freedom of the positioning system are combined with the flexibility of the extrusion system in the range of available and processable materials, which means that product areas not previously covered by additive manufacturing can be served. In particular, the high production speed, large component dimensions and the processing of highly filled materials, e.g. for structural components, should be mentioned.
In addition to purely additive manufacturing, hybrid manufacturing, i.e. the combination of different process types and materials in one component, is also being investigated in the project. The entire process chain, from component design, intelligent planning and generation of robot paths and the production data set through to monitoring the production process and integrated quality assurance, is being considered. In addition, materials are being qualified for the SEAM process and material combinations, e.g. for printing and functionalizing metallic structures, are being evaluated.
Additive manufacturing for industrial applications in vehicles
Additive manufacturing processes (AM) can offer the opportunity to meet future mobility requirements and the vehicles needed for this. In particular, the prospect of (partially) autonomous driving opens up new usage concepts and therefore demands for a flexible structure and a customizable interior. In addition, model and development cycles are becoming ever shorter. These developments pose a major challenge to production and, in particular, to its flexibility.
As AM processes generally do not require a component-specific tool, they can in principle produce geometrically different components one after the other without additional set-up times. The flexibility is therefore given in this respect, but most processes lack productivity and material selection. The Robotic SEAM process principle addresses these limitations and can be used in new areas that were previously served by conventional processes such as injection molding. Hybrid additive manufacturing on existing structures for functionalization and individualization is a particularly promising approach here.
The aim of this project is to identify the obstacles to this still young process and to develop appropriate solutions that enable and support its wider use. This will only work if the entire process chain, especially the digital one, is taken into account. In addition, use cases are to be developed and demonstrated together with partners inside and outside the arena in order to demonstrate the possibilities of the technology.