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

SAMBA Series: SAMBA Multi, SAMA Scale, SAMBA Pro, SAMBA Step

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

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
SAMBA Scale

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 Scale Line

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 Pro

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 Step

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

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
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    Complex geometries

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    Flexible fiber orientation

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    Continuous quality documentation

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    Highest mechanical properties

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    Less material,
    lower weight

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    Unique design possibilities

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!

Your contacts

You got questions? Contact one of our specialists for an individual consultation.

Your personal consultant:

Thorsten Gröne

Thorsten Groene

Managing Director

+49 89 2314 165 51

thorsten.groene [@] cevotec.com

Your technical expert:

CTO Felix Michl

Felix Michl

Chief Technology Officer

+49 89 2314 165 11

felix.michl [@] cevotec.com