Mikrosam is proud to deliver its latest single tape placement head to the Polymer-based Lightweight Design at the Brandenburg University of Technology Cottbus – Senftenberg, Germany (BTU). This state-of-the-art equipment is specifically designed to meet the increasing demand for precision in automated composite lay-up processes of type V composite pressure vessels for hydrogen gas storage. Optimized for laboratory research and small-scale production, it offers the flexibility required for producing complex and high-performance thermoplastic composite parts.

Modular and upgradeable systems

This single-tape head system is an upgrade to the existing Robotic multi-tape AFP work cell that Mikrosam delivered to the University seven years ago. For over a decade, Mikrosam has been renowned for its upgradeable and modular AFP and ATL cells. Additionally, BTU is equipped with in-house prepreg slitting and rewinding equipment manufactured by Mikrosam. This machine is designed to work with thermoset and thermoplastic prepregs to produce spools with various sizes and re-winding styles such as 300mm wide tape down to ¼” tapes used in their existing AFP Head and now this new single-tape head. This presents a cost-effective solution for the on-demand utilization of prepreg slitting into the different AFP processes. 

Also, BTU utilizes a state-of-the-art filament winding machine capable of wet and towpreg winding processes. Mikrosam and the University have a longstanding collaboration on research and development projects, consistently delivering proven and exceptional results in the composite materials industry.

Versatility Meets Precision

The single tape placement head is engineered for automated lay-up on flat and complex, symmetrical, or non-symmetrical parts. Its innovative and compact design accommodates both open and closed mandrel surfaces, making it ideal for cylindrical structures, pressure vessels, box beams, and intricate parts with concave and convex geometries. Whether laying down thermoplastic prepreg tapes on flat surfaces or navigating the contours of small-diameter vessels (down to a 50mm radius), the equipment excels in both capability and precision.

This flexible head is compatible with existing automated fiber placement (AFP) systems, allowing seamless integration with Mikrosam’s advanced composite manufacturing solutions. The tape placement technology and thermoplastic material optimize the complete composite design because it can lay and reinforce every angle and portion of the part. This leads to efficient lightweight solutions with a remarkably improved buy-to-fly ratio, also due to the low process-related material scrap and material optimization. The future of the composite industry lies in this latest technology.

Tailored for small thermoplastic type V pressure vessels and more

Mikrosam’s head is an ideal addition to BTU’s R&D laboratory. Researchers can now produce high-performance parts using a wide variety of thermoplastic prepregs, with the system supporting tape widths of ¼” and ½”. These tapes are prepared using Mikrosam’s prepreg slitting and rewinding machine, ensuring precise material handling and preparation.

The compaction system utilizes a pneumatic roller, delivering forces from 100N to 500N, ensuring consistent pressure throughout the lay-up process. A built-in cooling system helps maintain the roller and material temperature during continuous operation, improving both product quality and equipment durability. Mikrosam has designed the system to be user-friendly, with quick and easy tape and roller replacements to minimize downtime.

“The new layup head is engineered and optimized to achieve a minimum 50mm radius at vessel domes. To accomplish this, the vessel on the tailstock side is supported by rollers rather than a chuck, with long shafts used exclusively on the headstock side. The heads itself is specially custom designed to produce type V hydrogen pressure vessels in one single and continuous process using the automated placement technology and thermoplastic prepregs. Its advanced controls enable real-time adjustments to tape placement angles and compaction forces, allowing users to optimize the process for various applications. BTU will now have the capability to develop and deliver one of the smallest type 5 pressure vessels for hydrogen in the form of a sphere“ – says Vele Samak, Vice President at Mikrosam.

Type V pressure vessels represent the cutting-edge hydrogen storage technology in specialized fields where extreme weight savings are crucial. In this development process is used thermoplastic liner that provides excellent chemical resistance and impermeability to hydrogen. This combination of thermoplastic liner and thermoplastic matrix composite allows for high strength-to-weight ratios, reduced maintenance needs, and recyclability.

The Chair of Polymer-based Lightweight Design currently researches, besides others, a technology for the efficient transport of hydrogen for the Federal Republic of Germany in the form of the lead project TransHyDE. Inside TransHyDE are several projects each aiming to address a core issue of Hydrogen transportation through Germany. One of these projects is Mukran, where the Chair creates hydrogen pressure vessels of innovative geometry to maximize transport efficiency. At the moment pressure vessels of type 4 are manufactured with various technologies supplied by Mikrosam and advanced by the knowledge of the researchers at the chair. The manufacture of these unique type 4 vessels of particular shape requires the flexibility given by the new single tow head provided by Mikrosam. Prospectively the Chair of Polymer-based Lightweight Design aims to test the capabilities of the the new AFP head in the manufacture of type 5 pressure vessels. It also shows excellent capability in the manufacture of thermoplastic carbon fiber-reinforced drive shafts (as seen in the project “AFP-Shaft”), which outperform their duroplastic counterparts.

Advanced Features for Quality Control and Efficiency

Mikrosam has equipped it with a range of features designed to enhance efficiency and quality. The latest model thermal camera continuously monitors the lay-up process, providing real-time temperature data to ensure precise quality control. Additionally, the head is integrated with a high-precision knife system that enables on-the-fly tape cutting, reducing material waste and streamlining the production workflow.

The machine’s intuitive control system, MikroAutomate, allows for continuous monitoring and real-time adjustments of key parameters such as tape tension and compaction force. Operators can easily program and modify these settings to maintain optimal process control throughout production.  

The QCS Quality Control System monitors and records all important process parameters, which can later be used for production historical overview and analysis. All recorded data is kept in a local database and can be used to recall historical part production data at any time.

Elevating Composite Manufacturing

With the introduction of the single tape placement head, Mikrosam continues to set new standards in the automated manufacturing of composite materials. By combining advanced features with user-friendly operation, this equipment is poised to become an essential tool for organizations engaged in cutting-edge research and development, as well as small-batch composite production.