|Project name||Strength and function-optimized reinforcement of thin sheet metal for use in construction; Sub-project: Object reconstruction and stiffening optimization for thin sheet metal strengthening|
|Duration||01.01.2022 – 31.12.2023|
The research project FORMlight is aiming to use Wire Arc Additive Manufacturing (WAAM) to reinforce the shape of free-formed sheet metal and ensure its load-bearing capacity for use in facade construction. Using reinforced thin sheets could significantly reduce material consumption for sheet metal facades. Wire Arc Additive Manufacturing describes 3D printing with steel. Here, a six-axis industrial robot with a welding device enables the layer-by-layer application of steel layers. The research field has become established at the IFSW at TU Darmstadt in recent years, including the world's first production of a bridge made on site.
Within FORMlight, IFSW together with ISMD has the task to develop a suitable process parameter with the welding process “CMT Cycle-Step” of the company Fronius GmbH, so that it is possible to apply several layers of weld metal on a 1.0 mm thin sheet without burn-through. In order to provide the robot with the exact path for welding on the free-formed sheets, the coordinates are scanned using a stereo camera and then sent to the robot.
Finally, two demonstrators are to be manufactured, a ventilated free-form facade sheet, and a free-form sandwich element. The industrial partners imagine computation GmbH and Dipl.-Ing. Hölscher GmbH & Co. KG support the IFSW and ISMD with know-how and material.