Case Study-2: Composite Mold Part
MetalWorm, in collaboration with Turkish Aerospace Industry (TUSAS), achieved a significant milestone using Robotic Wire Arc Additive Manufacturing (WAAM) to create a dome-shaped aerospace industry mold part. The WAAM process involved meticulous planning, simulation, analysis, precise production, and reverse engineering. The part has a diameter of 400mm and a height of 100mm. It takes a total of 18h 24m to print. The part weighs 35.5kg and is made from Invar 36 material.
Invar is often used in composite mold applications because of its low thermal expansion coefficient.
This part is manufactured using a 6+2 axis interpolation structure with The robot arm and positioner. The robotic tool path planning utilizes the revolved surface slicing strategy.
Following production, the product successfully underwent a series of tests, including:
– Leak tightness test
– Autoclave test
After the part is produced using WAAM, the upper and lower flange surfaces are processed with a CNC machine to finalize it.
Advantages:
– The BTF ratio is 1.4
– Lead Time is reduced by 85%
– Production costs are reduced by 70%
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