FPP Production System SAMBA

Scalable, automated 3D fiber lay-up production platforms.

SAMBA Series

The Fiber Patch Placement systems of the SAMBA Series are flexible, automated production platforms for challenging fiber lay-ups. Fully automated and programmed with ARTIST STUDIO software, SAMBA systems act as your economical production platform for a broad range of complex composite parts – customized to your part size and materials!

Sizes

Fiber Patch Placement means highly scalable additive manufacturing customized to your needs. We implement SAMBA production systems for different component sizes, working with patch sizes of 20 mm x 40 mm up to large patches of 200 mm x 300 mm.

Materials

SAMBA Series platforms work with a range of different dry-fiber and prepreg materials such as carbon fiber, glass fiber, adhesive prepregs, coppermesh prepregs and other technical fibers of all major suppliers, covering areal weights of 80 gsm to 300 gsm.

Customization

Speak to us for an individual implementation of Fiber Patch Placement. We will customize the SAMBA system for your applications and adjust it to your shopfloor requirements.

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SAMBA Series modules

SAMBA Pro systems feature an automated material feeding and cutting unit combined with at least one placement robot and a tool manipulator. They are designed for a fully automated, quality-controlled series production of complex fiber laminates. The modules can be combined flexibly to create a production set-up optimized to your requirements.

Download SAMBA datasheet

Feeding & cutting units ​

Modules for material feeding and cutting are compatible with a wide range of materials in tape form. They feature a single or double material feeder in a temperature-controlled housing. Tape width is customizable. Patches are cut from the fiber tape by ultrasonic knifes from GFM. A high-precision camera with dedicated image processing computer checks every patch for quality before further processing. ​

Placement units ​

Placement modules can be customized to meet individual requirements depending on the application​ along with tailored Cevotec patch grippers mounted to the placement robot. Our standard choice are Kuka robots, but we can consider different brands on request. An optional linear axis can extend the reach of the robots and thereby the range of suitable applications. A high-precision camera monitors the correct positioning of the patches on the gripper and, if necessary, adds offset parameter in real-time to ensure a precise lay-up on the determined position. Heating units, either in the gripper or externally, allow short-term heating of the patches for proper adhesion during placement.

Tool holders and manipulators ​

Tool holders and manipulators are specific to each application. Quick-mount tooling systems are available for flexible production set-ups in combination with e.g. 6-axis tool holder, which enables an efficient and economic batch production of smaller component batch sizes. Combining a 6-axis tool holder with a 6-axis placement robot gives 12 degrees of freedom to automate the lay-up of even very complex geometries.

Machine and quality control​

SAMBA systems are controlled by Siemens SIMATIC PLC  that can be accessed via an HMI Panel with Cevotec user interface (UI) optimized for Fiber Patch Placement. The quality control cameras of the feeding and cutting as well as the placement units are connected to a dedicated image processing computer. Each SAMBA system features a broad range of additional sensors to monitor and control e.g. temperatures, deposition pressures, etc. An industrial IoT gateway enables fast, efficient and secure remote support.

SAMBA Production System

Sample configurations

Fiber Patch Placement is a modular and flexible technology. Based on three key modules for feeding and cutting, placement, and mold manipulation, we customize SAMBA Series systems to your requirements and application.

Composite tanks

SAMBA Pro PV

Aerospace

SAMBA Pro Multi

R&D

SAMBA Step​ L

SAMBA Pro PV

  • 2x feeding and cutting units and 2x 6-axis placement robots for simultaneous patching of both tank domes
  • Variable length, adjustable to tank sizes up to 3 m length
  • In-process raw material inspection and documentation
  • Self-corrective positioning control, fully automated lay-up process
  • GFM ultrasonic cutting unit, cooled material storage
  • Comprehensive monitoring of process parameters
  • System optimized for fast cycle time and high vessel throughput
  • Compatible with a broad variety of carbon fiber and glass fiber materials
  • Fully automated robot offline programming with digital twin in ARTIST STUDIO

Optimized for pressure vessel reinforcements

More information

SAMBA Pro Multi

  • Large 6-axis placement robot with long reach
  • Additional linear rail for extended reach across large tools
  • Component sizes of 3 m x 2 m (indicative configuration) or more
  • Double feeding unit for processing different fiber tapes simultaneously
  • Scaled patch grippers for patches up to 300 mm x 200 mm
  • Force-torque sensor for controlled fiber placement e.g. on honeycomb cores
  • Automated, in-process patch gripper exchange
  • In-process raw material inspection and documentation
  • Self-corrective positioning control, fully automated lay-up process
  • GFM ultrasonic cutting unit, cooled material storage
  • Advanced sensor package for comprehensive monitoring of process parameters
  • System optimized for large, complex 2D / 3D component lay-up
  • Compatible with a broad variety of carbon fiber and glass fiber materials, as
    well as adhesive prepreg, insulation layers, lightning strike protection materials
  • Fully automated robot offline programming with digital twin in ARTIST STUDIO

Ideal for multi-material composite aerostructures

More information

SAMBA Step​ L

  • One 6-axis placement robot (size customizable)
  • Additional linear rail for extended reach across large tools ( 3m x 2m or more)
  • Maximum material flexibility by feeding pre-cut patches on a table
  • In-process quality control and monitoring of process parameters
  • Overall degree of automation customized to requirements
  • Advanced sensor package to analyze placement operations available
  • System optimized for application development, prototyping, material testing, R&D activities for the development process
  • Fully automated robot offline programming with digital twin in ARTIST STUDIO

Ideal for application development, prototyping, R&D

„The SAMBA Pro Prepreg system from Cevotec offers a unique and efficient automation option for complexly shaped components and tailored, load-optimized laminates. It complements our portfolio of automated placement technologies and expands our scope of research and development services at Fraunhofer IGCV.”

Dr.-Ing. Renato Bezerra

Research associate & project lead


You got questions?​

Contact us to explore the benefits of Fiber Patch Placement for your specific component and production process. We offer a cost-free evaluation and economic analysis for your application with FPP. Looking forward to hearing from you!

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