Evaluation of Large Format 3D Printing in the Manufacturing of Tooling for Resin Transfer Molding - Carfair Composites Inc. (RESUBMISSION)

Carfair Composites，Inc.是一家总部位于温尼伯的公司，是为原始设备制造商（OEM）制造和供应高质量复合材料结构的全球领导者。该公司的创新使用轻树脂传递模塑（LRTM）过程中，生产轻型关键部件开辟了一个机会，开发更省油和低排放的巴士。Carfair目前正在寻找显著降低生产成本和提高生产率的方法，作为他们努力支持重型车辆制造中越来越多地采用轻质复合材料结构的一部分。因此，该公司正在努力评估复合材料模具的大幅面3D打印，与传统工具制造技术相比，这是一种更快，更经济的工具开发方法。在聚合物3D打印在大尺寸工具制造中的应用方面仍然存在很大的知识差距。大多数现有的3D打印机都是针对两英尺或更小尺寸的零件开发和优化的。大幅面3D打印需要深入了解增材制造的设计、工艺参数优化、尺寸分析和制造后处理，以应用于打印更大的部件，Carfair和航空航天与制造技术访问中心（TACAM）红河学院理工学院正在将他们的技术专长结合起来，以解决目前在复合材料模具的大幅面3D打印方面的局限性。该团队将专注于工艺开发，为LRTM创建原型复合材料模具。TACAM和Carfair都已经在聚合物3D打印方面进行了一些投资，并收购了一些大型打印机。学院团队在聚合物增材制造工艺方面积累了丰富的专业知识，可以很容易地转移到大幅面组件的打印中。该团队将利用他们在3D建模、工艺参数选择、3D激光测量和CNC加工方面的技能，为LRTM工艺生产原型大尺寸复合材料模具，并将进行测试和行业采用。Carfair能够立即利用这项研究工作的结果，具有显著节省成本和时间以及提高流程效率的潜力。

Carfair Composites, Inc. is a Winnipeg-based company and a global leader in the manufacturing andsupply of high-quality composite structures for Original Equipment Manufacturers (OEMs). Thecompany's innovative use of the Light Resin Transfer Molding (LRTM) process to produce lightweightcritical components has opened up an opportunity for the development of more fuel-efficient andlower emission buses. Carfair is currently looking for ways to significantly lower production costs andimprove productivity as part of their effort to support the growing adoption of lightweight compositestructures in heavy vehicle manufacturing. Accordingly, the company is making a significant effort inevaluating large format 3D printing of composite molds as a faster and cost-effective method oftooling development compared to the traditional tool manufacturing techniques.There is still a large knowledge gap in the application of 3D printing of polymers in the manufacturingof large-size tooling. Majority of the existing 3D printers were developed and optimized for parts inthe scale of two feet or less. Large format 3D printing requires an in-depth knowledge of design foradditive manufacturing, process parameters optimization, dimensional analysis and manufacturingpost-processing as applied to printing larger components, usually at the scale of four feet and above.Carfair and the Technology Access Centre for Aerospace and Manufacturing (TACAM) at Red RiverCollege Polytechnic are pulling their technical expertise together to address the current limitations inlarge format 3D printing for composite molds. The team will focus on process development leadingto the creation of prototype composite molds for LRTM.Both TACAM and Carfair have already made some investments in 3D printing of polymers, with theacquisition of some large printers. The College team has developed significant expertise in polymeradditive manufacturing processes that can be easily transferred to the printing of large-formatcomponents. The team will use their skills in 3D modeling, process parameters selection, 3D lasermetrology and CNC machining to produce prototype large-format composite molds for the LRTMprocess, which will be tested and adopted by industry. Carfair is in a position to utilize the results ofthis research work immediately, with potentials for significant cost and time savings and improvedprocess efficiency.