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Lightweight
construction
in 3D
Festo Bionic Learning Network: 3D Cocooner
N
ature has a virtually limitless supply of intelligent solutions for challenging
tasks. Bionics transforms these solutions into technical applications that are
useful for people. One area that is set to define the future of production is
the manufacture of customised products with batch sizes as small as one.
3D printers are already making major advances in this field. However, their one major
disadvantage is the fact that they can only work one layer at a time. With the new
3D Cocooner, Festo goes a step further. Inspired by the impressive shapes created
by butterfly caterpillars, it constructs complex structures freely in space. Just like a
caterpillar, the 3D Cocooner spins delicate shapes and creates lightweight structures
out of a strong glass-fibre thread. A delicate handling system accurately manoeuvres
the spinneret and glues the glass fibres together while at the same time laminating
them with UV-curing resin.
Soft thread, solid lattice
A three-armed, vertically mounted parallel kinematic system EXPT-45 is used as a
specialised handling unit for the 3D Cocooner. It can be controlled precisely, quickly and
with exceptional manoeuvrability. To convert the soft thread into a solid lattice structure,
it is moved forward over a pair of rollers inside the spinneret and simultaneously
covered with a viscous resin. As soon as it comes out, a UV light cures resin-soaked
fibre with absolute accuracy and hardens it into a sturdy little rod. A small cutting
disc cuts off the thread so that the spinneret can start again in a different place.
By precisely regulating the amount of UV light, the resin can also be temporarily kept
The new 3D Cocooner brings ideas to life.
Free-moving,
fast and individual. Creating a tangible product directly from
a design. Although still at the research stage, this bionic
development is already showing enormous potential for the
production of tomorrow.