MC-SANDWICH - SF research project

The project funded by the Bavarian Research Foundation „MC sandwich“ focussed on the increasingly important resource-saving design of components. Lightweight structures such as sandwich composites are an ideal solution for this. However, these are only used to a limited extent due to the difficulty of modelling the curved surfaces through the shaping core structure.

The „MC-Sandwich“ research project aimed to realise the goal of producing complex curved, metallic core structures with a very low density. The main aim was to shorten the complex production chain of the sandwich composite. Additive manufacturing now enables complex and functionally integrated core structures that are customised to the application. In addition, 3D printing technologies are combined with carbon fibre-reinforced plastic (CFRP). Part of the usual heat post-treatment of additively manufactured metal structures is carried out together with the curing process of CFRP, whereby utilised synergies shorten the process chain. Surface pre-treatment is also considered, as it is crucial for optimising the bond between the core and surface layers and thus for load transfer.

In order to integrate software development into the product portfolio and create compatibility with Creo, it was the task of the Software Factory a digital analysis of the component and a preliminary definition of critical wall thicknesses and distances.

In addition to the Software Factory, the other project partners were the Fraunhofer IGCV, MT Aerospace AG, Schmelzmetall Deutschland GmbH, Hyperganic Technologies AG, Gierl DCP, EOS GmbH and Kuhn Beschichtungen GmbH. The project duration was 2.5 years.