Manufacturing method and system for manufacturing continuous fiber reinforced composite parts

Abstract

In order to achieve a composite material part with a fully load-adapted 3D fiber reinforcement while keeping tooling and process costs low, the present invention provides a manufacturing method for producing a part (10) made of a composite material (12) with continuous fiber reinforcement (14), comprising the steps of: a) Providing a body (16) with a tubular cavity (18) having at least one first portion made from a first polymeric material (22) and at least one second portion (24) made from a second polymeric material (26). b) Introducing resin and continuous fibers (28) into the tubular cavity (18). c) removing at least a portion of the second polymeric material (26);

Description

[Technical field]

[0001] The present invention relates to a manufacturing method for manufacturing parts made of a composite material with continuous fiber reinforcement. Furthermore, the present invention relates to a manufacturing system for manufacturing parts made of a composite material with continuous fiber reinforcement. [Background technology]

[0002] 3D reinforced composite structures are becoming increasingly relevant for all future structural applications in vehicles and aircraft, such as urban air vehicles, satellites, HAPS (High Altitude Pseudo Satellite), NGWS (Next Generation Weapon System) / FCAS (Future Combat Air System), drones or other carriers. In particular, load-adapted 3D reinforced composite structures are a common enabler for lightweight load-bearing structures.

[0003] One possible form of realization of 3D reinforced composite structures is composite 3D printing of the entire reinforced composite part, which can be used especially for small scale production. For larger series production, hot bending and overmolding manufacturing can be used with larger investment in manufacturing tooling.

[0004] EP 3 231 592 A1 relates to a method for manufacturing a part made of a composite material having a body and one or more continuous fibre bundles therein, characterized in that it comprises the following steps: a) Obtaining a body including one or more tubular cavities therein, the tubular cavities extending between a first end disposed on an exterior surface of the body and including an inlet orifice, and a second end opposite the first end. b) introducing a resin in a liquid state and a continuous fiber bundle into the interior of at least one tubular cavity through an inlet orifice thereof; c) Allow the resin to harden until it solidifies and bonds to the body, fixing the continuous fiber bundles in place. EP 3 231 592 A1 also relates to a system for producing parts made of composite material and to the resulting parts made of composite material. Summary of the Invention [Problem to be solved by the invention]

[0005] It is an object of the present invention to enable the production of lighter load-compatible 3D reinforced composite parts with lower manufacturing tooling and process costs. [Means for solving the problem]

[0006] To this end, the invention provides a manufacturing method, a manufacturing system and a composite material part obtained thereby according to the independent claims. Advantageous embodiments form the subject matter of the dependent claims.

[0007] According to one aspect, the invention provides a manufacturing method for producing a part made of a composite material with continuous fiber reinforcement, comprising the steps of: a) Providing a body having a tubular cavity, the body having at least one first portion made from a first polymeric material and at least one second portion made from a second polymeric material. b) Introducing resin and continuous fibers into the tubular cavity. c) at least partially removing the second polymeric material.

[0008] Step a) includes the following a1): a1) selecting a second polymeric material from materials that are soluble in the solvent, and selecting a first polymeric material from polymeric materials that are insoluble in said solvent.

[0009] Step c) includes: c1) Dissolving a second material in a solvent.

[0010] Preferably, step c) comprises: c2) removing at least the second portion;

[0011] Preferably, step c) comprises: c3) Removing all of the second material from the body.

[0012] Preferably, step a) comprises: a2) Manufacturing of additive layers of the body.

[0013] Preferably, step a) comprises: a3) Design a body having a first part that defines (surrounds and defines the extent / contour of) the opening of the cavity.

[0014] Preferably, step a) comprises: a4) Design a body having a first portion that defines a curved portion of the cavity.

[0015] Preferably, step a) comprises: a5) Design a body having a first portion defining a bonding area for continuous fibre reinforcement.

[0016] Preferably, step a) comprises: a6) Designing the body with at least one second portion defining a middle section of the tubular cavity.

[0017] Preferably, step a) comprises: a7) Designing the body with at least one second portion defining a straight section of the tubular cavity.

[0018] Preferably, step a) comprises: a8) Design a body with a greater amount of the second material and a lesser amount of the first material.

[0019] Preferably, at least 60% by weight, in particular 70% to 95% by weight, of the body is made from the second material.

[0020] Preferably, step a) comprises: a9) Design a body having several first parts spaced apart from one another and connected by at least one second part.

[0021] Preferably, step a) comprises: a10) Designing the body such that at least one tubular cavity passes through, in sequence, the at least one first portion and the at least one second portion.

[0022] Preferably, step a) comprises: a11) adding and / or connecting a metal member to the body such that the metal member has an opening that aligns with the open end of the tubular cavity.

[0023] Preferably, step b) comprises: b1) The resin in liquid state and the continuous fiber bundle are introduced simultaneously.

[0024] Preferably, step b) comprises: b2) introducing a continuous fiber bundle into said at least one tubular cavity, which exerts a pressure differential, a viscous drag on the continuous fibers by a pressurized fluid or resin;

[0025] Preferably, step b) comprises: b3) introducing a continuous fiber bundle into said at least one tubular cavity which exerts a mechanical pressing force on the continuous fiber bundle.

[0026] Preferably, step b) comprises: b4) The resin and the continuous fibres are introduced sequentially, in particular the continuous fibres are introduced first, followed by the resin in liquid form.

[0027] Preferably, step b) comprises: b5) introducing reinforcing fibres, in particular carbon fibres and / or carbon fibre bundles.

[0028] Preferably, step b) comprises: b6) Introducing functional fibres, in particular glass and / or ceramic fibres.

[0029] Preferably, step b) comprises: b7) introducing glass fibres for forming at least one heat gauge and / or strain gauge;

[0030] Preferably, step b) comprises: b8) Introducing ceramic fibers to form at least one actuator. In particular, one or more piezoelectric actuators can be formed in the textile structure by introducing ceramic bundles to form a textile structure having piezoelectric properties.

[0031] Preferably, step b) comprises: b9) Introducing the resin and continuous fibers into the tubular cavity and then curing the resin.

[0032] According to a further aspect, the present invention provides a composite material part obtainable by a manufacturing method according to any of the preceding embodiments.

[0033] Preferably, the composite section is formed as a reinforced fibre truss structure.

[0034] According to another aspect, the present invention provides a manufacturing system for manufacturing a part made of a composite material with continuous fiber reinforcement, comprising: an additive manufacturing device for additively manufacturing a body having at least a first portion from a first material that is insoluble in the solvent and a second portion from a second material that is soluble in the solvent, with at least one tubular cavity passing through the first and second portions; a resin and fiber introduction device for introducing resin and continuous fibers into the at least one tubular cavity; and a dissolving device for dissolving the second material in the solvent.

[0035] According to another aspect, the present invention provides transport carriers or vehicles, in particular manned or unmanned aerial vehicles or satellites, comprising parts obtained by a method according to any of the aforementioned embodiments and / or obtained using a manufacturing system of a further aspect of the invention and / or a composite material part as described above.

[0036] The present invention relates to the field of materials science, in particular to the manufacture of 3D reinforced composite structures. Preferred uses of such structures obtained by embodiments of the present invention are structural applications in transport carriers and vehicles and aircraft, such as urban air vehicles, manned satellites, HAPS (High Altitude Pseudo Satellite), NGWS (Next Generation Weapon System) / FCAS (Future Combat Air System), drones. More generally, the parts obtainable by the present invention are used as the basis for on-board lightweight structures.

[0037] Embodiments of the present invention in particular use a continuous fiber injection process as disclosed and described in EP 3 231 592 A1, which is incorporated herein by reference.Embodiments of the present invention provide full 3D (fully three dimensional) fiber reinforcement, the missing structural unit of lightweight parts, which was not previously manufacturable.

[0038] Embodiments of the present invention relate to a method for producing full 3D fiber reinforced polymer composites by 3D printed soluble manufacturing tools.

[0039] The continuous fiber infusion process has the advantage that reinforced composite parts adapted to 3D loads can be produced at low production costs with little investment in manufacturing tools. Since the fibers are injected at high pressure into the tubular cavities of the polymer body, the body needs a polymer structure capable of withstanding these pressures. Thanks to the invention it is possible to reduce the weight of parts obtained by such a continuous fiber infusion process.

[0040] Preferred embodiments of the present invention have at least one, some, or all of the following advantages: It is possible to provide carbon fiber UD (unidirectional) reinforcements with up to 50 times higher specific strength / modulus compared to high performance polymers, including the best resistance to creep, temperature / medium, fatigue, etc. The loads in the structure are oriented in full 3D (a technology with full 3D fiber orientation capability is required). Besides load-bearing reinforcements, functional fibers can be incorporated and integrated (e.g. glass fibers as heat / strain gauges, ceramic fibers as actuators). The preferred embodiment of the present invention provides a composite structure with ideal full 3D oriented reinforcing fibers with low polymer ratio (percentage of polymer by mass) but with the lowest possible manufacturing tooling and processing costs. This manufacturing method is ideal for low to medium polymer ratio series.

[0041] A preferred embodiment of the manufacturing system includes in particular the technical means for manufacturing full 3D composite structures.

[0042] In accordance with a preferred embodiment, a geometric design and configuration of fiber reinforcement, polymeric component material, and soluble auxiliary / support material is provided.

[0043] The geometric design configuration is transferred to a process path (G-code) via, for example, a slicer software.

[0044] The first material is in particular a polymeric part material (e.g., PEEK), and the second material is in particular a dissolvable support material (e.g., 3dGence ESM-10).

[0045] Preferably, a liquid resin and reinforcing / functional fibers are provided.

[0046] Preferably, ALM (Additive Layer Manufacturing) machines are used that can process at least one part of polymer material and one part of soluble material. Examples of such ALMs are FLM (Filament Layer Manufacturing (Fused filament fabrication; FFF)) printers (commercially available), modified HSS machines (HSS=High Speed ​​Sintering, e.g. binder jetting with IR activation with compatible inks) or compatible SLS (SLS=Selective Laser Sintering, especially realizable with two materials, e.g. Aerosint recoater available from Aerosint) machines with multi-material recoater.

[0047] An embodiment of the manufacturing system includes a fibre injection machine (CFIP) and eventually, in the case of thermosetting resins, further includes an oven. An example of a CFIP machine is shown and described in EP 3 231 592 A1, which is incorporated herein by reference.

[0048] An embodiment of the manufacturing system further provides a solvent for dissolving the support material.

[0049] A preferred embodiment of the manufacturing method comprises the following steps: 1) Geometrically design and configure the fiber reinforcement, polymer part material (an example of a first material), and the surrounding auxiliary / support material (an example of a second material). 2) Generate a process path using conventional slicer software (e.g., Simplify3d, Cura, Slic3r, …). 3) Printing the first and second materials in one step as an open cavity, in particular as a tubular cavity, with an integrated fiber path. 4) If necessary, clean the surface using subtractive processes (solvents, sandblasting, drilling, etc.). 5) Injecting the dry fibers and liquid resin according to the CFIP process and device, e.g. as described and shown in EP 3 231 592 A1. 6) If necessary, cure the thermosetting resin in the fiber reinforcement in an oven. 7) Dissolving the second material using subtractive techniques and / or solvents (acid, water, etc.). 8) If necessary, cut off the fiber ends and / or perform finishing processes such as sandblasting, milling, grinding, cleaning the surface with solvents, etc.

[0050] In accordance with the preferred embodiment, full 3D reinforced parts with local polymer and load-oriented "bare" (exposed) fiber reinforcement are realized.

[0051] Preferred embodiments of the invention will now be described in more detail with reference to the accompanying drawings. [Brief description of the drawings]

[0052] [Figure 1] 1 is a flow chart of a method for manufacturing a part made of a composite material using continuous fiber reinforcement. [Diagram 2] FIG. 2 is a perspective view of a body obtained in the first stage of the manufacturing method of FIG. 1; [Diagram 3] FIG. 3 is a perspective view of the body of FIG. 2 . [Figure 4]FIG. 3 is a side view of the body of FIG. 2. [Diagram 5] 2 is a plan view of a metal member optionally used in the method of FIG. 1; [Figure 6] FIG. 6 is a perspective view of the metal member of FIG. 5 . [Figure 7] 6 is a perspective view of the body of FIG. 2 to which the metal member of FIG. 5 is attached. [Figure 8] FIG. 8 is a further perspective view of the body and metal member arrangement of FIG. 7; [Figure 9] 8 is a view similar to FIG. 7 after a further step in the manufacturing method in which continuous fibers are injected into the body. [Figure 10] FIG. 10 is another perspective view of the arrangement of FIG. 9 with a body, a metal member, and continuous fibers infused into the body. [Figure 11] FIG. 2 is a perspective view of a part made using the method of FIG. 1 with an optional metal member. [Figure 12] FIG. 12 is a further perspective view of a portion of FIG. [Figure 13] FIG. 12 is a side view of a portion of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0053] Figure 1 is a flow chart of a manufacturing method for producing a part 10 made of a composite material 12 with continuous fibre reinforcement 14. Examples of such parts 10 obtained or that can be obtained by such a method are shown in Figures 11-13.

[0054] The method includes a first step S1. S1. Providing a body 16 (see FIGS. 2-4) having a tubular cavity 18, at least one first portion 20 made from a first polymeric material 22, and at least one second portion 24 made from a second polymeric material 26.

[0055] The manufacturing method of FIG. 1 further includes a second step S2. S2 Resin and continuous fibers 28 (see FIGS. 9-10) are introduced into the tubular cavity 18 of the body 16.

[0056] The manufacturing method of FIG. 1 further includes a third step S3. S3 At least one second portion 24 is removed.

[0057] In a preferred embodiment, the first step S1 involves manufacturing one or several tool parts that include an internal tubular cavity 18. Preferably, the second polymeric material 26 is a soluble polymer that is soluble in a particular solvent, while the first polymeric material 22 is an insoluble polymer that is not soluble in a particular solvent. Most preferably, the body 16 is made by additive layer manufacturing using the insoluble and soluble polymers 22, 26.

[0058] For the manufacture of the body 16, step S1 comprises a first sub-step S1a: S1a: Geometric design of the fiber reinforcement 14 is performed, i.e. of the first polymer material 22 that will be present in the part to be manufactured and of the second polymer material 26 that is used exclusively as a surrounding auxiliary or supporting material for the manufacture of the part 10 and that is removed in step S3.

[0059] For example, the design is performed with CAD software.

[0060] In a first sub-step S1a, the body 16 is preferably designed such that each tubular cavity 18 extends through the body 16 from a first open end 30 to a second open end 32.

[0061] In a preferred embodiment, the first portion 20 is designed such that the continuous fibers 28, injected in the second step S2 in the form of fiber bundles 36, are present in the region forming the curvature and / or in the joining region 40 of the part 10, where the different fiber bundles 36 are in close proximity to each other. In the embodiment shown, the part 10 is a composite truss structure 42 with truss struts formed by the continuous fiber bundles 36 and truss nodes formed by the joining regions.

[0062] The at least one second portion 24 is present in all other regions of the body 16. In particular, the at least one second portion 24 forms a wall of the tubular cavity 18 in its middle section and / or in its straight sections.

[0063] Most preferably, the tubular cavity 18 subsequently passes through the first portion 20 and the second portion 24. In a preferred embodiment, at least one of the first and second open ends 30, 32 of the tubular cavity 18 is formed by the first portion 20.

[0064] Returning to FIG. 1, the first step S1 of the manufacturing method further includes a second sub-step S1b. S1b An additive layer manufacturing machine (ALM machine - not shown) is used to manufacture the body 16.

[0065] In particular, the second sub-step S1b involves the generation of a process path using conventional slicer software such as Simplify3d Cura, Slic3r, ... In particular, the design obtained by the first sub-step S1a is converted into a machine-readable form that can be read and processed by an additive layer manufacturing machine (ALM machine).

[0066] As the ALM machine, any ALM machine (also called 3D printer) capable of processing the first and second polymeric materials 22, 26 can be used. The first and second polymeric materials 22, 26 can be selected according to need. In a preferred embodiment, these materials 22, 26 are selected such that the first polymeric material 22 is not soluble in a solvent and the second material 26 is soluble in a solvent. For example, the second polymeric material 26 is a material that is available on the market as a soluble auxiliary material to support the 3D structure during printing and can be removed afterwards. An example is 3dGenceESM-10. The first polymeric material 22 is a polymeric material that can be printed and is not soluble in the solvent used to remove the second polymeric material 26. An example is PEEK. Further examples are PE, PP, ABS, PETG, ...

[0067] Examples of ALM machines are FLM (Fused Layer Manufacturing) printers (available on the market), HS machines or SLS (Selective Laser Sintering) machines.

[0068] An example of the result of the second sub-step S1b is shown in figures 2 to 4. The body 16 shown in this example has a tubular cavity 18 with a first open end 30 and a second open end 32 and a complex path between these open ends 30, 32. Here, a first part 20 made of a first polymer material 22 is present to form the second open end 32, the junction or junction area 40 and / or the curved section of the tubular cavity 18. In an embodiment not shown, additional first parts 20 can also form the first open end 30. In the embodiment shown in figures 2 to 4, the first open end 30 is provided in a second part 24, i.e. in a second part 24 surrounding and connecting several first parts 20 arranged at a distance from each other.

[0069] One objective of the body design is to achieve a part with a very low ratio of polymer to reinforcing fibers. Thus, the second material 26, which is removed in the third step and is used only as a supplementary material, is preferably the main (predominant) material in the body 16. For example, 60% to 70% to 95% by weight of the body is made from the second material 26 and only the remainder is made from the first material. Thus, the part 10 will contain only 5 to 40% of the polymer material of the body 16.

[0070] The body 16 is used as a tool to manufacture the part 10 shown in Figures 11 to 13. The second portion 24 serves as a form for forming a tubular cavity 18 for injection of continuous fibers 28.

[0071] In the embodiment shown, it is possible to further add a third material, for example a metallic material. An example of a metallic member 44 is shown in Figures 5 and 6. The metallic member 44 has a configuration on one side that is complementary to one end of the body 16, and in particular to one end of the second portion 24. The metallic member 44 has an opening that can be aligned with the first open end 30. The metallic member 44 can be attached to the end of the body 16 that has the first open end 30 of the tubular cavity 18.

[0072] According to one example, the metal member 44 has a protruding portion 48 that defines an opening 46 that may be mated with a recess 50 in the second portion 24 that defines the first open end 30 of the tubular cavity 18.

[0073] Thus, referring back to FIG. 1, the first step S1 may optionally have additional sub-steps. S1c manufacturing the metal member 44; and S1d The body 16 and the metal member 44 are previously assembled together.

[0074] In a third sub-step S1c, the metal member 16 may be manufactured, for example, by machining or other manufacturing techniques.

[0075] In one preferred embodiment of the fourth sub-step S1d, pre-assembly is performed with the matching tubular cavity 18, i.e. the opening 46 is aligned with the first open end 30 of the tubular cavity 18. The assembly can be performed by different techniques. For example, the metal member 44 and the body 16 can be attached to each other by a positive interlocking between the protruding portion 48 and the recess 50. Different parts of the manufacturing tool 52, for example the body 16 and the metal member 44, can also be connected to each other, for example by gluing or bonding.

[0076] Preferably, manufacturing tool 52 is formed by assembling body 16 with an additional member, such as metal member 44, as shown in Figures 7-8.

[0077] After the fourth sub-step S1d in the first step S1, a second step S2 is performed. In the second step S2, this is performed by a continuous fiber infusion process (CFIP), for example as described for this in EP 3 231 592 A1. Preferably, the fiber bundle 36 is injected into the tubular cavity 18 together with a liquid resin. This process is generally known from EP 3231 592 A1 and will not be described further here. In particular, the carbon fibers are injected together with a thermosetting resin. The fiber bundle 36 is then formed by the path of the tubular cavity 18. That is to say, the fiber bundle 36 takes the form of a complex path of the tubular cavity 18. The resin injected together with the fiber bundle 36 is then cured so that the form of the fiber bundle 36 is fixed by the resin.

[0078] Thus, the manufacturing tool 52 is used as a form for forming the fiber reinforced structure.

[0079] Formwork and geometry can be selected so that loads within the composite truss structure 42 are oriented as desired.

[0080] According to a preferred embodiment, the load bearing reinforcement is not only load bearing reinforcement by using carbon fibers, which may incorporate carbon fiber bundles, but also functional fibers, so that functional fibers are introduced into at least one of the tubular cavities 18, such as glass fibers that can be used to form heat and / or strain gauges, or ceramic fibers that can be used to form actuators.

[0081] The second step S2 may also include curing the resin. To achieve this, the manufacturing tool 52 with the introduced fiber bundles 36 as well as the resin can be placed in an oven (not shown) for curing the thermosetting resin. After the second step S2, the structure shown in Figures 9 and 10 is obtained.

[0082] 9 and 10 show a manufacturing tool 52 with the introduced fiber bundles 36. The manufacturing tool 52 is then placed in a bath (not shown) with a solvent to remove, by dissolving, the second polymeric material 26. Such a bath is an example of a dissolving device for dissolving the second material 26.

[0083] Thus, dissolving the second polymer material 26 using a specific solvent is one preferred embodiment of the third step S3. The third step S3 may also include other techniques for removing the second material, such as subtractive techniques. In particular, the second polymer material 26 may be treated similarly to a sacrificial material as known in the manufacture of semiconductor components.

[0084] After removing the second material 26, the part 10 is realized as shown in Figures 11-13. In this particular embodiment, the part 10 is formed as a composite truss structure 42 where the first polymeric material 22 forms the bond areas 40 and / or curved (curvature) areas, where the fiber bundles 36 are fixed by the resin and act as truss struts.

[0085] As can be seen from FIGS. 11-13, the metal members 44 can be used as fastening means for fastening the composite truss structure 42 to other components.

[0086] In particular, the component 10 realized by the manufacturing method of FIG. 1 can be used for lightweight structural components in aircraft or spacecraft, such as lightweight structural components in manned or unmanned aircraft or satellites or other airframes or vessels.

[0087] In order to achieve a composite part (10) with a fully load-compatible 3D fiber reinforcement with low tooling and process costs, the present invention provides a manufacturing method for producing a part (10) made of a composite material (12) with continuous fiber reinforcement (14), comprising the steps of: a) Providing a body (16) having a tubular cavity (18), the body having at least one first portion (20) made from a first polymeric material (22) and at least one second portion (24) made from a second polymeric material (26). b) Introducing resin and continuous fibers (28) into the tubular cavity (18). c) removing at least a portion of the second polymeric material (26); [Explanation of symbols]

[0088] 10 parts 12 Composite materials 14 Continuous fiber reinforcement 16 Body 18 Tubular Cavity 20 First Part 22 First polymer material 24 Second Part 26 Second polymer material 28 Continuous Fiber 30 first open end 32 Second Open End 36 Fiber bundle 40 Joint area 42 Composite truss structure 44 Metallic parts 46 Aperture 48 Protruding part 50 Recess 52 Manufacturing tools (e.g. body 16 and metal parts 44) S1. Provide a body having first and second portions made from first and second materials, respectively. S1a: Perform geometric design of the fiber reinforcement and the first and second portions. S1b. Manufacture the body using additive layer manufacturing. S1c Manufacture metal components. S1d Different parts of the body, or the body and another part, can be pre-assembled together. S2 Resin and continuous fibers are introduced into the tubular cavity of the body. S3 Remove at least the second portion.

Claims

1. A method for producing a part (10) made of a composite material (12) with continuous fiber reinforcement (14), comprising the steps of: a) providing a body (16) having a tubular cavity (18) having at least one first portion made from a first polymeric material (22) and at least one second portion (24) made from a second polymeric material (26); b) Introducing resin and continuous fibers (28) into the tubular cavity (18). c) at least partially removing the second polymeric material (26). Here, step a) includes the following a1): a1) selecting a second polymeric material (26) from materials that are soluble in the solvent and selecting a first polymeric material (22) from polymeric materials that are insoluble in the solvent; Here, step c) includes the following c1). c1) Dissolving a second polymeric material in a solvent.

2. The method according to claim 1, characterized in that step a) comprises at least one or more of the following steps a2) to a11): a2) Additive layer manufacturing of the body (16). a3) Designing a body (16) with a first portion (20) defining an open end (32) of a tubular cavity (18). a4) Designing a body (16) with a first portion (20) defining a curved portion of a tubular cavity (18). a5) Designing a body (16) with a first portion (20) defining a bonding area (40) of a continuous fiber reinforcement (14). a6) Designing a body (16) with at least one second portion (24) defining a middle section of a tubular cavity (18). a7) Designing a body (16) with at least one second portion (24) defining a straight section of a tubular cavity (18). a8) Design the body (16) with a greater amount of the second material and a lesser amount of the first material. a9) Designing a body (16) having a plurality of first portions (20) spaced apart from one another and connected by at least one second portion (24). a10) Designing the body (16) such that at least one tubular cavity (18) passes through, in sequence, at least one first portion (20) and at least one second portion (24). a11) adding and / or connecting a metal member (44) to the body (16) such that the metal member (44) has an opening (46) that aligns with the open ends (30, 32) of the tubular cavity (18).

3. 3. The method according to claim 1, wherein step b) comprises at least one or more of the following steps b1) to b9): b1) The resin in liquid state and the continuous fiber bundles (36) are introduced simultaneously. b2) introducing a continuous fiber bundle (36) into said at least one tubular cavity (18) which exerts a viscous drag on the continuous fibers (28) by means of a pressurized fluid or resin exerting a pressure difference; b3) introducing a continuous fiber bundle (36) into said at least one tubular cavity (18), said tubular cavity (18) exerting a mechanical compressive force on the bundle of continuous fibers (28); b4) The resin and the continuous fibres (28) are introduced sequentially, in particular the continuous fibres (28) are introduced first, followed by the resin in liquid form. b5) introducing reinforcing fibers, in particular carbon fibers and / or carbon fiber bundles (36). b6) Introducing functional fibres, in particular glass fibres and / or ceramic fibres. b7) introducing glass fibres for forming at least one heat gauge and / or strain gauge; b8) introducing ceramic fibers for forming at least one actuator; b9) After the resin and the continuous fibers (28) are introduced into the tubular cavity (18), the resin is cured.

4. The method according to any one of claims 1 to 3, characterized in that step c) comprises at least one or more of the following steps c2) to c4): c2) removing at least a first portion (24); c3) Removing all of the second material (26) from the body (16). c4) removing one or more connection sections of the body connecting at least two of the first portions (20) such that the first portions (20) move away from each other.

5. A manufacturing method described in any one of claims 1 to 4, wherein the part (10) is formed as a reinforced fiber truss structure.

6. A manufacturing system for producing a part (10) made of a composite material (12) and continuous fiber reinforcement (14), comprising: an additive manufacturing device for additively manufacturing a body having at least a first portion (20) from a first material and a second portion (24) from a second material, where the second material is soluble in a solvent and the first material is insoluble in said solvent, the body having at least one tubular cavity (18) passing through the first and second portions (20, 24); a resin and fiber introduction device for introducing resin and continuous fibers (28) into the at least one tubular cavity (18); and a dissolving device for dissolving a second material in the solvent.

7. 6. A method for manufacturing a transport aircraft or vessel, comprising the steps of obtaining a part by the method according to any one of claims 1 to 5, and obtaining the transport aircraft or vessel from said part.

8. 6. A method for manufacturing a manned or unmanned aerial vehicle or spacecraft, comprising the steps of obtaining a part by a method according to any one of claims 1 to 5, and obtaining the manned or unmanned aerial vehicle or spacecraft from said part.

Images