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Design and Development of an AM-CFRP Exoskeleton Hip Component
As part of ETH’s Strategic Focus Area: Advanced Manufacturing, CMASLab and pd|z are investigating on individualized, cost-efficient ultra-lightweight structures. These types of structures are achieved by a combination of Additive Manufacturing (AM) and Carbon Fiber Reinforced Polymers (CFRP) process
CMASLab is focusing on the optimal use of the carbon fibers and aims at individualizing the exoskeleton hip to a patient by the use of patched laminates. In a patched laminate, a CFRP layer is assembled from a (high) number of discrete fiber patches. This segmentation of a laminated structure into patches results in the following advantages:
- possibility to tailor the laminate according to the local load state
- superior mechanical properties compared to constant stiffness laminates
- reduction or recycling of preform cut-off waste
- cost reduction
Although having several advantages, the patched laminates approach poses the problem of their numerical modeling. Due to the discontinuous fibers and the multitude of gaps and overlaps in a patched laminate, classic modeling approaches fail. Therefore, a suitable mechanical model was developed by CMASLab.
In order to properly exploit the potential of the patched laminate approach, a method for the automated creation of patched laminates simulation models has to be developed as a first step. Secondly, structural designs of AM-CFRP exoskeleton hips shall be developed and assessed. Finally, the most promising design must be optimized and manufactured.
CMASLab is focusing on the optimal use of the carbon fibers and aims at individualizing the exoskeleton hip to a patient by the use of patched laminates. In a patched laminate, a CFRP layer is assembled from a (high) number of discrete fiber patches. This segmentation of a laminated structure into patches results in the following advantages: - possibility to tailor the laminate according to the local load state - superior mechanical properties compared to constant stiffness laminates - reduction or recycling of preform cut-off waste - cost reduction
Although having several advantages, the patched laminates approach poses the problem of their numerical modeling. Due to the discontinuous fibers and the multitude of gaps and overlaps in a patched laminate, classic modeling approaches fail. Therefore, a suitable mechanical model was developed by CMASLab.
In order to properly exploit the potential of the patched laminate approach, a method for the automated creation of patched laminates simulation models has to be developed as a first step. Secondly, structural designs of AM-CFRP exoskeleton hips shall be developed and assessed. Finally, the most promising design must be optimized and manufactured.
The thesis is structured into the following work packages:
• Literature research on patched laminates
• Development of a routine for the automated creation of patched laminates simulation models
• Design study on individualized exoskeleton hip
• Design and optimization of hip component
• Manufacturing of demonstrator hip
The thesis is structured into the following work packages: • Literature research on patched laminates • Development of a routine for the automated creation of patched laminates simulation models • Design study on individualized exoskeleton hip • Design and optimization of hip component • Manufacturing of demonstrator hip
ETH Zürich
Laboratory of Composite Materials and Adaptive Structures (CMAS)
Ralph Kussmaul
LEE O 224
Leonhardstrasse 21
CH-8092 Zürich
Phone: +41 44 632 37 50
Mail: kralph@ethz.ch
ETH Zürich Laboratory of Composite Materials and Adaptive Structures (CMAS)
Ralph Kussmaul LEE O 224 Leonhardstrasse 21 CH-8092 Zürich