Arevo has developed an innovative 3D Printing process for composites industrial-grade (real world use) parts and structures. Our company has driven innovation in the areas of software, material science, and automation/robotics. With the combination of these capabilities, our company can fabricate ultrastrong structures that take advantage of all of the attributes of 3D printing.
SDG’s of application
Offers from Arevo
Arevo is revolutionizing manufacturing by enabling digital manufacturing of ultra-strong lightweight composite parts.
Arevo has developed the ability to “3D Print” large (multiple-meter), complex composite structures with continuous carbon fiber (or other fibers)/PEEK (polyether-etherketone) thermoplastic resins by robot. Arevo’s fully integrated process comprises design and analysis leading to flexible additive manufacturing as a more cost-effective means to make composite parts. Arevo is addressing the technology barriers for additive manufacturing (AM) to transform AM from limited-use prototypes to full-scale production products. Arevo is currently working with leading OEMs in aerospace, automotive, consumer electronics, consumer goods, and construction industries. Arevo uniquely sits at the nexus of software, material science and automation/robotics. Arevo’s innovative additive manufacturing process starts with a digital model and employs Arevo’s patented Additive Finite Element Analysis (AFEA) process to simulate the entire lifecycle of the part and optimally place strength (e.g. carbon fibers) 3-dimensionally as it optimizes the design of a structure. This digital model is transferred to an off-the-shelf 6-axis robot that “prints” a carbon fiber composite part or structure by robotically laying down continuous carbon fiber/PEEK feedstock material (a filament) via laser-beam Direct Energy Deposition (DED) and consolidating the material as the structure is fabricated. High carbon-fiber volumes and industry benchmark low void contents have been achieved for commercial products such as a hollow tubular carbon fiber mountain bicycle frame. Since Arevo employs 6-axis, fully articulated robots, printing can be done in true-3D fashion (x, y, and z directions) – enabling strength in all directions. The vast majority of 3D printing today, in fact, is not true 3D printing, but 2D or 2.5D printing, which limits these structures to prototyping applications. Arevo holds the patent for true 3D printing. Arevo is also currently “printing” a load bearing bulkhead panel for an international commercial aircraft manufacturer. Arevo has developed the software to analyze the strength and stiffness of composite parts on an individual fiber basis as the parts are “printed” rather than the traditional laminate layer basis. Arevo’s continuous carbon-fiber thermoplastic filament has approximately 5 times the tensile strength of titanium at one-third the weight – making it a natural choice for applications where non-isotropic strength-to-weight ratios are key performance differentiators. Arevo’s process is a fully integrated manufacturing system: starting with computer aided design, material selection, FEA and leading to the robot operating program. The process is capable of robotically making complex composite parts, iso-grid rib stiffened structures and printed core sandwich panel structures with fiberglass or carbon fibers and a variety of engineering thermoplastic matrices. Robotic “printing” composite structures reduces and in some cases eliminates tooling which are typically long lead items and inflexible to design changes.