SAMBA production system

SAMBA Series – automated 3D fiber lay-up production platforms

SAMBA Multi

The Fiber Patch Placement systems of the SAMBA Series are your ﬂexible, automated production platforms for challenging fiber lay-ups. Fully automated and programmed with ARTIST STUDIO software and equipped with a fast-mounting tool interface, SAMBA systems act as your economical production platform for a variety of parts.

Customized to your part size and materials

Sizes: Highly scalable. It is additive manufacturing in “sensible increments”, depending on your component. We implement FPP technology with small patches of 20 mm x 40 mm up to large patches of 200 mm x 300 mm and beyond.

Materials: SAMBA Series platforms work with a range of different dry-fiber and thermoset prepreg materials of all major material suppliers, covering areal weights of 80 gsm to 300 gsm and beyond.

Customization: Speak to us for an individual implementation of Fiber Patch Placement. Together with our Partner Baumann Automation, we provide turnkey production lines in any dimension you require.

Explore SAMBA Series

SAMBA Scale

Key features

Scaled configuration for high fiber throughput
Patch grippers in DIN-A5 and DIN-A4 sizes
Fiber throughput ~ 15 kg/h per feeding unit
Integrated gripper station for changing gripper sizes in process
Multitude of sensors for comprehensive process monitoring

Application focus

Complex 3D shapes of large to medium-size
High material throughput requirements

Application areas

Automotive: Battery boxes, roof rails, window frames, hoods, spoilers
Aerospace: 90°/±45° layers in spars, battery boxes, panel reinforcements

SAMBA Scale Line

Line configuration with high throughput of > 100 kg/h

SAMBA Pro

Key features

Fast SCARA robot for fiber placement
Precise 6-axis robot for tool manipulation
Smaller patch sizes adapted to geometrical complexity
Fiber throughput ~ 2-3 kg/h with thin ply tape
Fast and easy tool change system
Multitude of sensors for comprehensive process monitoring
Optional: Integrated gripper station for changing gripper sizes in process

Application focus

Flexible batch production of multiple products
Medium-sized to smaller parts of high geometrical complexity
Reinforcements of larger parts

Application areas

Aerospace: Window frames, reinforcement patches
Automotive: Spoilers, decoration parts, A/B/C-pillar structures
Medical: Prosthetics, orthotics
Sports: Snowboard and ski reinforcements

SAMBA Step

Key features

R&D-focused, low-investment patch placement system
Flexible degree of automation
Individual robot configuration, up to 12 axes
Fiber throughput ~ 500 g/h
Fast and easy tool change system
Optional: Sensors to monitor production process

Application focus

Prototyping and product development in R&D departments, institutes and universities

SAMBA Multi – automated multi-material 3D fiber lay-up

Configuration example:

Key features

Multiple feeding units for parallel processing of up to 4 different materials
Automated change of tapes
Direct fiber lay-up of complex 3D & 2D laminates
6-axis robot with large reach for fiber placement
Individual tool manipulators
Linear rail for production of large components (optional)
Patch grippers scaled to DIN-A5 and DIN-A4 sizes
Integrated gripper station for changing gripper sizes in process
Cooled material storage for prepreg material
Seamless integration of machine in ARTIST STUDIO software
Multitude of sensors for comprehensive process monitoring
Seamless quality protocol of process parameters
100% in-process, self-corrective tape quality inspection & position accuracy control
High accuracy of fiber deposition

Get detailed specification by clicking on the following modules:

Process specifications

Tape configuration: 50 mm – 200 mm
Min/Max patch length: 100 mm – 300 mm
Maximum placement cycle time: 4 s
Fiber throughput: ~ 15 kg/h per unit
Spool change: < 5 min
Tape accuracy inspection: < 0,25 mm
Patch cutting repeatability: < 0,5 mm
Placement accuracy: < 0,5 mm
Vision inspection: 12 MP camera resolution
Cutting: Ultrasonic knife
Compaction force & momentum control: Up to 2.800 N und 120 Nm
Patch heating: Infrared heating up to 200°C
Patch surface temperature control: < 5°C
Material storage cooling: Minimum 8°C
Backing film: Rewinding unit
Spool diameter: 450 mm
Tape volume per spool: 400 m – 600 m
Tape tension: Magnetic break
Touch HMI: Advanced production management

Options

Photonic heating for carbon material: LED light
Automated patch gripper exchange rig: Up to 3 gripper sizes
Laser cutting device: 100 W, diode laser
Dust and gas suction: Appropriate filters according to material spec
Spool diameter: 500 mm; 590 mm; 630 mm
Tension controlled tape feeding: Electronic controlled breaking
Material traceability: Bar code scanner

Cell configuration

Placement robot: 6-DOF stand-alone robot
Linear axis: Length to specification
Additional axis mold manipulator: To specification; 1–3 DOF positioners
Mold weight acceptable: Up to 3 t

Main components

Robots: Stäubli, Kuka, other brands on request
Controller: Siemens, Beckhoff
SAMBA cell: Baumann, Cevotec
Patch gripper: Cevotec

Software support

Patch & tape laminate design software: PATCH ARTIST & TAPE ARTIST
Offline programming software: MOTION ARTIST
FEA simulation software: ARTIST STUDIO Plug-in for HyperMeshTM

Materials

Dry carbon fiber: 40 gsm – 300 gsm
Dry glass fiber: 40 gsm – 300 gsm
Dry aramid fiber: On request
Other technical fibers: On request
Thermoset carbon prepreg: 40 gsm – 300 gsm
Thermoset glass prepreg: 40 gsm – 300 gs
Thermoset adhesive film: 100 gsm – 200 gsm
Thermoset metal fabric: On request

Application focus

Large, complex 3D / 2D components
Multi-material placement
Sandwich core placement

Industry-specific examples

Aerospace: Control surfaces, nacelle structures, radomes, battery boxes, bulkheads
Automotive: Fiber-metal reinforcement

Key advantages

24/7 fully automated series production of complex 3D geometries
Combination of different materials or tape geometries within one part
High productivity, especially on strongly curved surfaces
Very low material scrap, weight and cost through additive manufacturing
High stiffness and strength of parts through load-adjusted fiber orientation
In-process, self-regulatory quality inspection with full documentation

End-to-end automation for dry fiber preforming

After fiber lay-up, an additional robot detaches the inherently stable laminates automatically from the tool and moves them to the next processing step.

We manufacture the SAMBA production system in cooperation with Baumann Automation. With more than 20 years of experience in complex robotic applications, Baumann is the ideal partner for our high-performance, efficient and reliable production machine SAMBA.

Convince yourself and let’s arrange a live demonstration at our facilities!