SOFTWARE FOR LARGE-FORMAT
ADDITIVE MANUFACTURING

Automated Fiber Placement (AFP) is a fully automated manufacturing process for composite parts. Fiber-reinforced plastics are placed along a path on a tool surface under pressure and temperature.
AFP is mainly used for double curved components. The CAESA® software provides the complete AFP process from path planning to robot program in a digital twin.

Automated Tape Laying (ATL) is a fully automated manufacturing process for composite parts. Fiber-reinforced plastics are placed along a path on a tool surface under pressure and temperature.
ATL is mainly used for 2D components or low-curvature geometry. The CAESA® software provides the complete ATL process from path planning to robot program in a digital twin.

The Laser Assisted Tape Winding (LATW) is an automated process for manufacturing fibre-reinforced thermoplastic tubular products, such as pipes and pressure vessels.
The CAESA® software provides the complete winding process (helical, polar or hoop) from path planning to robot program in a digital twin.

The laser assisted tape placement (LATP) is an automated process for manufacturing fibre-reinforced thermoplastic tubular products, such as pipes and pressure vessels.
The CAESA® software provides the complete winding process (helical, polar or hoop) from path planning to robot program in a digital twin.

In Fused Deposition Modeling (FDM), material is melted in wire form in a heating chamber and extruded through a nozzle by continuously feeding the material. The process offers high material flexibility (PLA, ABS, TPU, PETG). CAESA® expands FDM with completely new fields of application with REAL 3D slicing for robot-based 3D printing.

Fused Granulate Modeling (FGM) uses plastic pallets, which are melted within a screw extruder. Because the material flow is mostly constant, CAESA® dynamically adjusts the robot feed in the NC-Code.

To reinforce plastics, short or continuous (glass) fibers are added. The individual filaments with continuous fibers or also the addition of fibers during a running process can be realized with the software CAESA®

Direkt Energy Deposition uses metal powder, which is melted and applied with a highpower laser at the desired locations. Since the tilt of end effector has an influence on the part quality, the orientation can be optimized with CAESA®.

Wire Arc Additive Manufacturing involves melting a metal wire using an electric arc.

Pin Winding is a specialized process in which a carbon fiber is wound around pre-positioned pins in space. This method allows for precise control of the fiber's placement and tension, making it ideal for complex geometric structures and reinforcing specific areas with high strength requirements.

Spraying involves the application of materials such as resins, adhesives, or coatings onto surfaces through a controlled spray system. This process ensures even distribution and can be tailored for different thicknesses or surface textures, depending on the project’s specifications.

Gluing refers to the precise bonding of components using high-performance adhesives. This process creates strong and durable joints, ensuring structural integrity while allowing for material flexibility and minimizing the need for additional fasteners.

Sealing involves applying a protective layer or material to close joints or gaps, ensuring airtight or watertight finishes. This process is critical in enhancing the durability and longevity of composite structures, particularly in aerospace and automotive applications.

Singularity tests can be performed with the CAESA®. In the process, critical positions of a 6-axis robot are recorded during occupancy. Singularities are identified in the existing simulation module for robot systems and possible solutions are found.

The material application simulation carried out by CAESA® shows the finished component. The individual layers can also be examined.
The material application simulation is also required for collision checking.

The collision test CAESA® prevents contact between the robot, end effector, component and cell.

In the Speed-Parameter-Simulation, CAESA® can show the different web speeds.

The simulation for axis angles with the CAESA® software can detect and inform about critical axis positions.

The manufacturing time of a component influences the cost calculation. The process time is calculated by CAESA® on the basis of the distance covered and the production speed.

Inline thermography is part of the quality management and enables the detection of defects in the process. The obtained data are managed with a digital twin.

The data collected during the process is processed and categorized by an AI. In the AFP area, the AI detects fuzzballs, foils, etc.

The categorized errors are compared with the digital twin. The position of the occurring errors can thus be clearly determined and communicated to the machine operator. In this way, the errors can be identified during the process and precautions can be taken if necessary.

A direct connection to CATIA allows to directly extract information on open parts and to map them in CAESA®. Geometric objects can be imported directly to CATIA.

CAESA® can communicate with NX. The slicing results can be exported from CAESA® to NX, where they can be integrated into the previous process planning.

The further development and optimization of the STL format.

The STEP is a part of the CAESA® software. It is responsible for storing and displaying complex data formats in mathematical output (coordinate systems, lines, areas, points).

The STEP is a part of the CAESA® software. It is responsible for storing and displaying complex data formats in mathematical output (coordinate systems, lines, areas, points).

Simple format for pure graphical representation of parts. This format contains only the triangular information of the tesselated bodies.

BA Soul is the standard software used for controlling Broetje Automation systems. CAESA® seamlessly integrates with BA Soul, ensuring smooth data exchange and optimized automation processes for fiber placement and tape laying operations.

Fibersim is a leading software for composite part design and manufacturing. CAESA® supports integration with Fibersim, enabling streamlined workflows from design to production, ensuring accurate fiber placement and advanced composite engineering.

Ansys is a powerful simulation tool used for engineering analysis. CAESA® interfaces with Ansys, allowing for direct integration of simulation results into the manufacturing process, ensuring precision and compliance with design specifications.

CAESA® analyzes and optimizes the generation of courses and layouts. The laminates are optimally adapted to the machine. CAESA® calculates the component costs via the material usage and the production time.

Under extrusion occurs when less material is conveyed than is actually needed. This happens, among other things, because the layer height changes within a layer during real 3D printing. These deviations are detected by CAESA®.

Over extrusion occurs when more material is conveyed than is actually needed. This happens, among other things, because the layer height changes within a layer during real 3D printing. These deviations are detected by CAESA®.

Since material often has to be melted in additive manufacturing processes in order to apply it, the manufactured component becomes hot. In order to prevent unwanted deformation (e.g. sagging of material), certain cooling times must be observed. By storing these parameters, CAESA® dynamically adjusts the manufacturing speeds.

CAESA® calculates the material consumption by the robot path traveled, offset by other parameters such as the layer height. This allows the user to decide in advance whether the component meets his requirements (weight, material consumption, ...) or whether it should still be adapted.

The CO2 equivalents can be calculated and displayed in CAESA®. The prerequisite is that the customer provides the respective data required for the calculation (average equivalent electricity consumption, material production, etc.).

Based on the material consumption, CAESA® calculates the actual weight.

The singularity check allows critical position of a 6-axis robot to be pointed out during occupancy. Adds a singularity check to the existing simulation module for robot systems. The machine kinematics are used for the simulation and any singularities and possible solutions are identified.

Different types of gaps are created during the laying of the tracks. Parallel gaps and triangular gaps can be created. CAESA® analyses the minimum and maximum distances. CAESA® for example, avoids overlaps.

The maximum angle deviation of the Tows is generally +/-5°. The angle of the Tows is to be measured with the so-called measuring rosette to the neutral fiber. The measuring rosette consists of a plane which passes through the intersection of the line to be measured and the neutral fiber. The plane is perpendicular to the neutral fiber. Furthermore, the measuring rosette consists of a line which points in the normal direction of the plane and also has its origin in the intersection of the line to be measured and the neutral fiber. The angle of the line to be measured is measured to the line of the measuring rosette.

Steering is the deviation of a CFRP sheet from a straight line. Stresses arise due to different lengths of the edge contours. Steering always occurs at non-geodesic fiber runs or when depositing on non-planar surfaces. CAESA® analyzes the path for the optimum radius.

AFP has great potential on multi-curved surfaces. The resulting effects such as gaps, bridging and steering can be analyzed and controlled with CAESA®. The deformation behavior of a compaction roller is also analyzed. CAESA® shows the limits of the deformability of the compaction roller.

Machining End Of Ply (MEOP) specifies the area to be covered. CAESA® analyzes the MEOP area for maximum allowed gap areas.

Composite materials for advanced applications for aircraft components, space structures, racing cars and sporting goods are used in the form of continuous fiber reinforced material in the form of plies. In CAESA®, the ply is the basic unit for the design, analysis or manufacturing process phases.

A zone in composites is a group with the same physical properties. Zones can be used as a calculation basis in CAESA® for tool path calculation for 2D and 3D laminates.

The CAESA® 2D module enables web planning for flat laminar structures. Process reliability and cutting waste are optimized.

The CAESA® 3D module works with occupancy algorithms. These do not have problems in the area of material overflow or missing material in curves.

A course is the direction in which the part is manufactured. This includes reference lines such as the left limit (maximum point in the left direction).

Staggering describes the dislocation between several layers of material. The CAESA® takes into account not only the stacking but also the bonding of the material to obtain a greater load-bearing capacity by means of uniformly oriented tows under the consideration of staggering.

Boundaries are an essential information necessary for manufacturing CFRP laminates. CAESA® provides different ways of dealing with multiple and single boundaries. 

Minimumm Tow LEngth represents the length of material that must be laid in each case to obtain a safe process. Within CAESA®, larger values can also be selected per layer.

Minimum Tow Length represents the length of material that must be laid in each case to obtain a safe process. Within CAESA®, larger values can also be selected per layer.

A patch or ply is a reinforcement that does not extend over the entire component. They are applied to areas of the component that are subject to high stress. Patches open up new areas of application for gaps. With the CAESA® software, the function of patches can be used without any problems.

Real 3D allows slicing with complete freedom in three - dimensional space. REAL 3D combines all slicing methods. Complex components with multiple curved surfaces can be sliced.

Another function of the software is the Guide Curve or also called Slicing. A constant position orientation is used and rotated and shifted based on the guide curve. With this, CAESA® enables complex components such as hooks.

Tilted is an extension of flat slicen. Not only is the guide curve shifted and rotated, but the head tilt is also adjusted. This enables the CAESA® software to reproduce the enlargement of the guide curve, for example for a wine glass, much more easily and in greater detail.

Another function to produce complex parts is the NON - PLANAR manufacturing. With this function the software CAESA® can work with multiple curved surfaces.

Planar Slicing describes horizontal printing. A layer structure is produced by the CAESA® software without further modifications.

Featured based slicing enables the outsourcing of slicing algorithms to individual features. The special component geometries are available to the user as individual slicing functions in CAESA®.

With 6-axis systems, not only the X,Y,Z coordinates can be approached translationally, but also the respective tilts or rotations are achieved. This means that curved layers/surfaces can also be used to build the part. Most robots have 6 rotational axes. Most gantry systems have 3 linear axes and 3 rotational axes.

5-axis systems usually consist of three linear axes and 2 rotary axes. The 2 rotary axes open up new possibilities for non-planar manufacturing. The use of support structures can be mostly eliminated.

In CAESA®, each machine and robot can be extended by one or more additional linear axes. This increases the reachability and also the print volume by allowing the machine or robot to produce the part.

In CAESA®, additional rotation axes can be included, for example to achieve maximum accessibility of certain tilts or rotations. This is often done when the existing axes are restricted by certain axis limits.

 The combination of one or more linear and rotary axes can be implemented in CAESA®. This allows maximum accessibility of positions and also the build volume is scalable as desired.

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