Project Overview
MAI iSPAN is a multi-year, international research initiative focused on solving one of the most persistent challenges in CFRP (carbon-fiber reinforced polymer) mass production: precise, clean, and scalable trimming of near-net-shape composite components.
ARRTSM participated as an industrial engineering partner, contributing robotics integration, autonomous machining strategies, and dry trimming expertise.
The Challenge
Mass production of CFRP components is hindered by several structural limitations:
- Excess resin accumulation at edges
- Non-precision trimming leading to rework and scrap
- Heavy reliance on coolant-intensive processes
- Environmental impact from waste material and fluids
Traditional trimming approaches struggle to balance precision, speed, and sustainability, especially at industrial scale.
ARRTSM’s Role
ARRTSM contributed core expertise across multiple areas:
- Engineering of dry CNC trimming processes
- Integration of robotic machining systems
- Development and validation through pilot projects and trials
- Alignment of trimming workflows with autonomous manufacturing concepts
These contributions enabled the transition from laboratory research to industry-ready trimming solutions.
Motivation & Background
The MAI iSPAN consortium set out to enable near-net-shape CFRP manufacturing, reducing post-processing effort while improving quality and sustainability.
To achieve this, advanced trimming methods were explored and validated, including:
- Dry CNC machining
- Laser trimming
- Waterjet cutting
Each approach was evaluated for scalability, precision, and environmental footprint.
Key Technical Breakthroughs
-
Dry CNC Trimming:
Novel toolpaths minimized the need for coolants, reducing emissions and waste. -
Improved Surface Quality:
Optimized trimming strategies delivered cleaner edges and tighter tolerances. -
Lower Scrap Rates:
Reduced excess material removal improved yield and material efficiency.
Collectively, these advances significantly lowered the environmental and operational cost of CFRP trimming.
External Validation
“Partnering within the MAI iSPAN project has empowered ARRTSM to deliver precision-driven trim automation that aligns with future industrial requirements.”
— Project leadership, MAI iSPAN consortium
Strategic Impact for ARRTSM
-
Robotics Integration:
Trimming processes align seamlessly with ARRTSM’s autonomous fabrication systems. -
Cost & Sustainability:
Reduced scrap and coolant usage enhance both economic and environmental performance. -
Industry Reach:
Collaboration with partners such as BMW, Fraunhofer IPA, and international research institutions reinforces ARRTSM’s position within a premium engineering network.
Project Details
- Project Duration: January 1, 2019 – December 31, 2021
- Budget: €2.0 million
- Coordinator: Fraunhofer IPA (Andreas Gebhardt)
Consortium Partners (Selection)
ARRTSM, BMW, Dynamic Robotic Solutions (DE/USA), Fraunhofer IPA, Hochschule Augsburg, Hufschmied, IACMI (USA), Michigan State University, SGL Carbon, TRUMPF, University of Augsburg, Voith HySTech, technotrans AG, Reichenbacher, and others.
Conclusion
MAI iSPAN represents a decisive step toward scalable, sustainable CFRP manufacturing. Through its contributions, ARRTSM helped translate advanced trimming research into practical, autonomous solutions—reducing waste, increasing precision, and strengthening the industrial future of composite production.