A two-year initiative, the OverHiPP project, funded by Innovate UK, is aiming to change the landscape of additive manufacturing with high-performance polymers. Led by GRM, a TriMech Group entity, in collaboration with five partners and an advisory board, the project is planning to pioneer a novel hybrid manufacturing technique.
This new approach combines overprinting 3D materials onto composite sheets, blending the strengths of over-molding, resin transfer molding (RTM), and 3D printing. It promises reduced tooling costs, enhanced flexibility, swift material changeover, and minimized material wastage.
Recent advancements in five-axis 3D printing hardware have expanded technological possibilities, enabling the creation of complex shapes without support structures. Overprinting materials onto existing components marks a significant milestone in additive manufacturing.
However, challenges persist, particularly in the development of simulation techniques for intricate 3D printed structures. Addressing this gap, GRM Consulting has developed cutting-edge software tailored for the OverHiPP project. Leveraging expertise in Finite Element Analysis (FEA), the software enhances the accuracy of digital twins, providing valuable insights into structural integrity.
GRM’s solution includes software capable of replicating toolpaths in an FEA model, ensuring precise filament orientations and infill cavities are considered during structural simulations. Rigorous testing, including the printing of a hyper-car footrest, has demonstrated promising results, with a five-fold difference in performance between prints in poor and optimal directions.
The OverHiPP project represents a significant advancement in additive manufacturing, promising to revolutionize the production of high-performance polymer components.
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