As part of the BERTL research project, and in collaboration with VÆRIDION and Bauhaus Luftfahrt, we explored innovative tooling approaches for composite manufacturing.

Using Dahltram C-250CF from Airtech Advanced Materials Group for out-of-autoclave prepreg from Hexcel Corporation, we developed a streamlined process for mold production. With AiBuild’s Mould Designer, the print strategy and path planning were set up within minutes. We integrated fast slicing, segment printing, and automated CNC milling with the CEAD Flexbot, resulting in dimensionally accurate molds ready for targeted finishing, lamination, and curing within a shortened schedule.

This systematic approach allows us to accelerate development cycles and support more sustainable manufacturing in advanced air mobility.

As an interdisciplinary group, led by Margarita Etchegaray Bello and Maximilian Konstantin Strobel, the Chair of Carbon Composites brings together expertise in additive manufacturing, process automation, and fiber-reinforced polymers, from material development through to industrial-scale prototyping.