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• Delcam gains users with CADCAM for composites design and manufacture

While Delcam’s software is best known for its applications with injection moulded plastics products, it is also used extensively for the design, manufacture and inspection of composites. It offers particular benefits in the development of products where aerodynamics or ergonomics are key considerations and in the manufacture of all types of tooling, including moulds and patterns.

Recent developments for the industry include new methods for the generation of 2D patterns for prepregs from 3D models of components, improved nesting to ensure the most economic use of materials cut from sheet and an increased range of five-axis machining methods, both for the manufacture of patterns and tooling and also for the trimming and drilling of moulded parts.

In all these areas, the software enables companies to maximise their profitability by increasing productivity, improving quality and reducing lead times. Successful applications include the manufacture of composite components for the autosport and luxury car industries, the production of aerospace lay-up tools, and the machining of patterns and tooling for compression moulding and reaction injection moulding.

The new methods for the generation of 2D patterns from 3D CAD models within PowerSHAPE are based on un-wrapping techniques first developed for the footwear industry to allow the cutting of leather shapes from shoe designs. They provide quick and easy methods for the creation of the prepreg designs needed for the manufacture of complex, curved shapes. The 2D patterns can then be arranged to give the most cost-effective use of material with new nesting functionality.

The range of five-axis machining methods in PowerMILL is essential for efficient composites manufacture and finishing. Large patterns can be made more quickly with five-axis machining because of the shorter tools and faster cutting speeds that can be used. PowerMILL also supports five-axis engraving of scribe lines to define the component boundaries on lay-up tools and five-axis profiling for trimming of the moulded part. Finally, the creation of fixing holes has been improved with new five-axis drilling methods that give faster drilling and more comprehensive hole recognition from a wider range of CAD systems.

New opportunities CD

A recent seminar at Delcam’s Birmingham headquarters highlighted the new opportunities available in the composites industry as the materials are used increasingly to replace metals and wood. A CD with all the presentations, including details of aerospace opportunities by the Airbus Composites Research Centre and marine applications by the British Marine Federation, can be obtained by e-mailing marketing@delcam.com.