In mid-2025, the Hamburg consortium consisting of CompriseTec GmbH and the Institute of Aircraft Production Technology at Hamburg University of Technology presented the successful completion of their BMWE-funded development project ‘iFish’. Conventional forming processes for thermoplastic composite semi-finished products, such as hot pressing, require full-surface, geometry-specific moulding tools and are therefore associated with high investment costs and long lead times until component production can start, which is a strong drawback for small series, prototypes or in case of geometry changes in particular.
The aim of ‘iFish’ was to develop a forming process that enables individual component geometries without costly moulding tools, thus making even small quantities economical and quick to produce. Over a period of four years, a process was developed in which two interacting robots with simple rounded tool tips exert local force on the heated organic sheet from both sides, draping and forming it. This double-sided incremental robo-forming allows complex geometries to be manufactured precisely even without moulding tools.
A Fully Digital Process Chain
A key aspect of this was the development of a continuous, digital process chain. This enables a direct transition from the CAD model to the software-supported derivation of robot movements using path planning algorithms developed specifically for composite materials, right through to the formed component. It takes less than 30 minutes between receiving the CAD data and starting the forming process, and depending on the complexity and size of the component, the entire component manufacturing process takes between 3 and 12 hours.
In addition to significant time savings, the process offers clear cost advantages over conventional processes, which rely on expensive moulding tools and large-scale equipment. ‘iFish’ thus opens up new perspectives for the flexible, economical and sustainable production of lightweight and high-performance composite materials – from prototypes and individual parts to small series. This can benefit, for example, the implementation of individual components such as prostheses and orthoses, customised seat shells or even specific design or structural components.
CompriseTec and the IFPT are looking forward to testing corresponding applications with interested parties and putting the advantages of the ‘iFish’ technology into practice.