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Tuesday, June 1 • 10:25 - 10:50
Approaching Zero – Waste-Free Production of Composite Wheel Structures

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  • Spoke wheels
  • Zero waste design
  • Eco efficient production

Due to their complex geometry, wheels and wheel-like structures made of fibre-reinforced plastic (FRP) usually consist of a large number of blanks made of flat semi-finished products. These semi-finished products are cut from webs with cutters, whereby even with careful planning an unavoidable proportion of waste is produced. With "CompoSpoke" a process has been developed which enables the production of spoke wheel structures in wet winding with virtually no waste.
It consist of a multi-stage procedure, which allows full variability with regard to the geometry. In a first step, a ring is wound which already matches the later spokes in width and thickness. This ring is automatically formed into the spoke structure using moulded parts manufactured in 3D-printing. Compressions and strains are compensated precisely so that a constant band tension is maintained. In a further step, an outer ring can optionally be wound, for example as a rim bed. With rigorous use and suitable products, the entire component can be produced from a single continuous roving which makes multiple positioning unnecessary.
The optimized use of raw materials makes the CompoSpoke process competitive to metallic construction methods. This is particularly the case when, due to small batch sizes, casting of metallic components close to the final contour is not an option. For instance, the material input of milled components and the energy required to recycle the chips is significantly higher compared to the production of a FRP-spoke wheel using the CompoSpoke process. In addition, further energy saving potentials can be exploited through the advantages of lightweight construction throughout the life cycle of the component.

Speakers, Jury Members & Final...
avatar for Marcel BÜCKER


Project Leader, Institut für Verbundwerkstoffe GmbH
• Born 12.08.1981• 2009: Diplom-Wirtschaftsingenieur (TU Kaiserslautern, Germany)• 2016: Dr.-Ing. (Institute for Composite Materials, TU Kaiserslautern, Germany)• 2016 – 2019: Head of product development at Schäfer MWN GmbH, Renningen, Germany• Since 2019: Project leader... Read More →

Tuesday June 1, 2021 10:25 - 10:50 CEST
Conferences (Hall 6 - Room 611)