In a groundbreaking development poised to reshape the manufacturing landscape, researchers have unveiled a novel process chain that combines injection moulding with additive manufacturing to create hybrid parts with significant lightweight properties. This innovation, detailed in a recent study led by Johann Schorzmann, promises to revolutionize industries where weight reduction and structural integrity are paramount, particularly in the energy sector.
The process, as Schorzmann explains, involves the additive manufacturing of semi-finished products, or inserts, made from pre-impregnated continuous fibres. These inserts are then strategically placed within an injection mould and over-moulded with a compatible polymer matrix. “By choosing a specific positioning of the inserts, we can achieve a significant lightweight construction potential and eliminate process-related weak points such as weld lines,” Schorzmann notes. This method ensures a robust material, form, and frictional bonding between the fibres and the polymer matrix, enhancing the overall strength and durability of the final product.
The implications for the energy sector are profound. In an industry where efficiency and performance are directly tied to weight and structural integrity, this hybrid manufacturing process could lead to lighter, more durable components for everything from wind turbines to automotive parts. “The technical analysis of the hybrid part showed a weight saving of 19.5% compared with the reference part,” Schorzmann highlights. “Regarding the critical load case, a 38.1% lower deformation was achieved.” These improvements not only enhance performance but also contribute to sustainability goals by reducing material usage and energy consumption.
The research also introduces a virtual development process using digital product development tools. By combining topology optimisation and finite element analysis (FEA), the team was able to determine the load- and material-optimised design for the hybrid parts. This innovative approach to simulation and optimisation paves the way for more efficient and precise manufacturing processes, reducing waste and improving product quality.
The validation of the process chain was conducted using a test setup that mirrors real-world load situations of an automotive part. The results were impressive, with the hybrid part maintaining specified maximum load and deformation limits while avoiding malfunctions in critical areas. This success underscores the potential of the process chain to meet the demanding requirements of various industries, including energy.
Published in the ‘Proceedings of the Conference on Production Systems and Logistics’—translated to English as ‘Proceedings of the Conference on Production Systems and Logistics’—this research marks a significant step forward in the field of manufacturing. As industries continue to seek ways to improve efficiency and sustainability, the hybrid manufacturing process developed by Schorzmann and his team offers a promising solution. The future of manufacturing is here, and it is lighter, stronger, and more efficient than ever before.