Loop
Lace
MaterialsCarbon fibre bracket: from metal to composite
7075 aluminium machined from solid vs carbon/epoxy with LOOP
| Weight | −93% |
|---|---|
| Cost | −50% |
| Full cycle | 125 h → 51 h |
The full cycle covers design, programming, production and curing, from file to finished part.
Challenge
The starting point is a 7075 aluminium structural bracket machined from solid. It is heavy and expensive and most of the stock ends up as swarf. Machining from solid is the usual route for a part like this, but it leaves little room on weight and cost. The aim was to replace aluminium with a carbon fibre bracket that meets the same performance requirements. It is a typical job for high-performance composites.
Solution
LACE is the Spherecube software that turns a 3D model into fibre paths and a program for LOOP. Here we used it for the redesign, moving the part from metal to composite, with paths that follow the loads. LOOP, which works on up to 6 axes, then produced the bracket through automated manufacturing and the part was cured under pressure. The metal inserts in the three holes are co-cured with the laminate in the same cure cycle. The carbon/epoxy result is a 93% weight reduction and 50% lower cost than the version machined from solid. What would that look like on your part? The feasibility study takes 10 working days.