Abstract

The size of components manufactured by laser-based powder bed fusion (PBF-LB) is limited by the maximum available powder bed volume. To create larger structures, additively manufactured (AM) components can be combined with inexpensive intermediate products. A comprehensive consideration of the connection task is required. Joints of fibre-reinforced plastic profiles adhesively bonded with LPBF-manufactured aluminium couplers and stiffening elements were investigated as examples. The geometric freedom of design in AM-processes enables optimisation of the joint properties: • Optimisation of the bonding process (application and distribution) • Uniform stress distribution within the adhesive fill space • Strength optimisation of the joined parts To reveal the adhesive distribution during injection, tests with transparent acrylic models where carried out. The AM components’ topology was optimised using FEA with regard to a homogeneous stress distribution within the joint. The fatigue strength was validated using numerous samples. Specific results on adhesive distribution and fatigue behaviour will be presented.