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3/18/2019 | 1 MINUTE READ

3D winding enables ultralight seat for future air taxis

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Multi-company collaboration has used the xFK in 3D process to develop a 10-kg composite seat intended for hypercars or future air taxis.


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A collaboration between multiple companies has developed a prototype for an ultralight composite seat within seven months. Partner companies include:

  • Alba Tooling (Forstau, Austria)
  • Automotive Management Consulting (AMC, Penzburg, Germany)
  • Covestro (Leverkusen, Germany)
  • CSI Development Technology (CSI, Neckarsulm, Germany)
  • LBK Fertigung (Friedberg, Germany)
  • Robert Hofmann (Lichtenfels, Germany)
  • 3D Core (Herford, Germany).

The carbon fiber-reinforced seat weighs roughly 10 kilograms, a 20% weight savings compared to competitive products. The majority of this mass reduction results from a 3D fiber winding process known as xFK in 3D. Developed by Peter Fassbaender, working with AMC, this 3D fiber winding process uses a resin-impregnated continuous fiber to wind load-bearing structures with maximum efficiency. 

Fassbaender, a researcher at LBK Fertigung, worked on this seat development project which was managed by CSI. Fassbaender explains, “CSI developed the shaped concept of the seat exterior. Working with two CSI design engineers, we took this concept and developed the structure for the seat frame to be manufactured using the xFK in 3D process.” The team created details for both tooling and metal seat components. “Now it became a niche hybrid of steel, aluminum and carbon fiber composite, each placed exactly where needed,” he adds.

Fassbaender and a CSI technician produced all the xFK parts using wet winding with epoxy resin, while Alba manufactured the tools for this single-strand based carbon fiber composite. Alba also developed manufacturing and tooling technologies for ultralight polyurethane (PU) molded foam and nonwoven fabrics.


March 2019 Symposia

The developers see potential applications in seating concepts for hypercars and future air taxis. For more details on the xFK in 3D process, see: Filament winding, reinvented.

A symposium titled “STEP CHANGE IN LIGHTWEIGHT” with further discuss this seat development on Thursday, March 21, 2019 at 10 am in the Dominican winery in Kasel Trier (Trier, Germany). Presentations will be given by experts Prof. Dr.-Ing. Prof. hc Jörg Wellnitz, AIRBUS manager Peter Pirklbauer, Prof. Dr.-Ing. Markus Milwich and editor for Automotive Industries magazine Claus-Peter Köth. For more details, contact constanze.nell@automotive-management-consulting.com .

This new seat development will also be reviewed on Wednesday, March 27 at Leichtbau Gipfel 2019

This post is courtesy of the CompositesWorld and Springer lightweight.design magazine media partnership. For more information about Springer and lightweight.design, go to https://www.springerprofessional.de/en/link/12141380



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