SAMPE Journal - July/August 2021 - 23

De-Comp
Composites, Inc.
Composite Materials
& Supplies
Figure 7. Illustration of the FlexSkin connection.
sandwich panels that are assembled together to create a large curved composite
surface or shell. The panels have structural single-or multi-step overlaps that
are joined with their neighbouring panels for load transfer.
Details of two panels of a 3D Composite Kit are found in Figure 6. The
panels shown are both doubly curved with overlapping joints (Figure 6b)
and can be joined both along their long (Figure 6c) and short edges (Figure
6d). All neighbouring edges align perfectly demonstrating the accuracy of
this technology. Curve Works has applied 3D Composite Kits in architectural
projects and for the manufacturing of moulds that are larger than the adaptive
mould. The next step is proving the technology for highly structurally loaded
applications.
Panel Connections Using FlexSkin
The edge details shown in Figure 6b and schematically in Figure 7 is a special
form of connection developed by Curve Works and termed the " FlexSkin "
connection. The FlexSkin connection has the following features:
1) Matching negative tolerances.
It is important that each panel of the 3D Composite Kit, with its
individual tolerances, enables the assembly of a complete shell
structure that is compliant with the required dimensions and
overall tolerances. The in-plane dimensions are therefore always
manufactured slightly smaller than their theoretical CAD-model and
overlaps are slightly shorter than their corresponding recesses. The
assessment of the negative tolerances depends on the accuracy of
the adaptive mould set-up and the tolerances of the manufacturing
and assembly procedure. All tolerances can be accommodated by
selecting appropriate dimensions for the overlapping connections.
2) Compliant integration at the panel edges.
All panels deviate from their theoretical CAD-model within a certain
tolerance range. The deviations depend on the specifications of
the adaptive mould and the complexity of the shape. The tolerance
deviations need to be captured and compensated at the edges to
ensure a compliant integration. This can be achieved in 2 ways:
* by allowing deeper recesses and out-of-plane deviations are
compensated through varying adhesive thicknesses, or,
* by creating flexibility through an unreinforced core at the
edge of the panel as shown in Figure 8.
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JULY/AUGUST 2021
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SAMPE JOURNAL |
23
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SAMPE Journal - July/August 2021

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