Airtech
Published

DYNAPIXEL: automated, reconfigurable molds

CAD-driven system cuts time for design iterations, enables cost-effective customized jigs and molded parts.

Share

 

composites

SOURCE for all images | CIKONI

CIKONI (Stuttgart, Germany) is an engineering company that specializes in composites design, simulation, automation and process innovation. CW has reported on a number of the company’s developments, including its use of 3D-printed cores and 3D filament winding to produce lightweight truss structures (see “Filament winding, reinvented”) and its work with preforming, including draping simulations and tension devices to prevent wrinkles and other defects (see “Preforming goes industrial: Part 2”). The latter is actually how DYNAPIXEL originated.

composites, filament winding, 3D printing, additive manufacturing

Examples of CIKONI’s composites developments include (top) 3D filament winding carbon fiber onto 3D-printed plastic core for a lightweight automotive truss and (bottom) draping simulation for automotive preforming. SOURCE for all images | CIKONI.

 

“We do a lot of draping simulations,” says Farbod Nezami, one of CIKONI’s co-founders. “The OEMs have good material data, but we always need a mold to validate the simulation. We wanted a system that would allow us to iterate designs on a daily basis.” The conventional process chain for molds takes weeks: part design, mold design, quotation and purchase process, machining/production of the mold, surface preparation and delivery. “With DYNAPIXEL, we simply use the CAD data to generate the mold surface,” says Nezami. “Now, if we have a draping issue, we change the CAD geometry and have the ability to produce a small prototype in a couple of hours.”

 â€‹â€‹â€‹â€‹
composites tooling

 

Automated system for reconfigurable molds

“There is no manual manipulation,” Nezami explains. “The process starts with the digital data from the part design, which is loaded into the DYNAPIXEL software. The software then generates the control array for actuating the pins and managing the parameters.”

The idea of using actuated pins to provide a reconfigurable mold has been used for decades in metalworking and recently adapted for composites by Adapa adaptive moulds (Aalborg, Denmark), discussed in CW’s 2017 feature on reconfigurable tooling. How is DYNAPIXEL different?

Nezami explains that because Adapa’s main applications are architecture and thermoforming glass, plastic and foam, they are producing bigger geometries and more continuous curves. “Compared to DYNAPIXEL, they use a smaller number of larger-sized actuators. Between these, the surface is interpolated and molded using a silicone sheet on top. Our system can produce sharp corners and more complex geometries. We also use a different estimation method. So, which technology fits depends on the application.”

Nezami points out that DYNAPIXEL also uses a silicone membrane, which can be used as a laminating surface and with molding processes up to 180°C.  For double-diaphragm forming, you would enter the CAD data, let the software actuate the mold geometry, apply vacuum to drawn down the silicone surface on top, laminate the composite plies, close the matched mold with second membrane and complete cure.

CIKONI DYNAPIXEL automated reconfigurable tooling with silicone membrane

For composite parts production, DYNAPIXEL uses a silicone membrane as a laminating surface for molding processes (e.g. double diaphragm forming) up to 180°C. 

“We have a golfball-type surface texture, but using a thicker membrane will alleviate this,” he adds. CIKONI uses three membrane thicknesses: 0.5, 1 and 3 millimeters. “The thickest gives a smoother surface but less detail,” Nezami observes, “while the 0.5-millimeter membrane gives a more accurate realization but a lower-quality surface finish.”

Surface finish has not been a driving issue because DYNAPIXEL was developed as a tool to speed R&D. “Our goal was to produce additional molds and design iterations without much additional cost,” says Nezami. “Once you freeze the part design, you would then switch to CNC-machined metal molds. You can also use this as a preforming tool.”

CIKONI DYNAPIXEL automated reconfigurable tooling

 

New applications

CIKONI is now developing additional uses for DYNAPIXEL, including flexible automotive jigs for bonding/adhesive joining and production of tailored, individualized helmets and protective apparel/structures. It also has an R&D project for customized orthotics. “We see value for this type of reconfigurable tooling where you need shapes tailored to each patient,” Nezami says. “Connection to the human body must match precisely to avoid irritation and sores. There is a lot of R&D into 3D printing for this type of application, but typically the material costs are high. Using DYNAPIXEL, you can significantly cut molding costs for individualized parts.”

To learn more about DYNAPIXEL, visit CIKONI at JEC World 2020 (Mar 3-5, Paris, France) in Hall 6, N72.

Airtech
Smart Tooling
Keyland Polymer
HEATCON Composite Systems
KraussMaffei Metering Systems
industrial CNC routers
Airtech
CAMX 2024
NewStar Adhesives - Nautical Adhesives
CW Tech Days Sustainability - Register Today!
CompositesWorld
CompositesWorld

Related Content

Molds/Tools

Nine factors to consider when designing composites cure tooling

Gary Bond discusses the common pitfalls and compromises when designing good cure tooling and their holistic significance for a robust composite production process.

Read More
Molds/Tools

Addyx carbon exoskeleton technology enables molded ribs inside hollow composite structures

Using a water-soluble mandrel, carbon exoskeleton opens paradigm for topology-optimized composites, cutting weight, manufacturing time and scrap rate.

Read More
Plant Tours

Plant tour: Airtech International, Springfield, Tenn., U.S.

Fifty years of supplying materials for composites manufacturing includes custom fabrication and now aims to advance 3D-printed tooling, parts and new resins.

Read More
Molds/Tools

3D-printed CFRP tools for serial production of composite landing flaps

GKN Aerospace Munich and CEAD develop printed tooling with short and continuous fiber that reduces cost and increases sustainability for composites production.

Read More

Read Next

Pressure Vessels

Composites end markets: Energy (2024)

Composites are used widely in oil/gas, wind and other renewable energy applications. Despite market challenges, growth potential and innovation for composites continue.

Read More
Thermoplastics

From the CW Archives: The tale of the thermoplastic cryotank

In 2006, guest columnist Bob Hartunian related the story of his efforts two decades prior, while at McDonnell Douglas, to develop a thermoplastic composite crytank for hydrogen storage. He learned a lot of lessons.

Read More
Trends

CW’s 2024 Top Shops survey offers new approach to benchmarking

Respondents that complete the survey by April 30, 2024, have the chance to be recognized as an honoree.

Read More
Airtech International Inc.