A customer from the field of large-area electronics was unable to carry out reliable vibration measurements over large temperature ranges due to the thermal expansion of its recordings in the measuring field.

CIKONI designed, manufactured and optimized thermally stable measuring fixtures using FEM simulation, which can be used over a wide temperature range. With the coordination of production, a complete solution was created from the concept to validation in the measuring field.

The increasing weight in the body of an automotive OEM pushed even the heaviest robot classes to their limits, so that the weight on the gripper had to be significantly reduced without violating rigidity and precision requirements.

CIKONI developed a multi-material gripper in which the right material is used in the right place, resulting in a cost- and weight-optimized result. In addition, production was managed, coordinated and monitored. The hybrid gripper with carbon fiber insert was ultimately 47% lighter than the reference gripper.

For the temporary storage of oil and gas during deep-sea production, pressure tanks 12 meters in length are required that can withstand the effects of salt water and external pressure. Steel tanks cannot be used for this purpose.

CIKONI contributed its expertise in the areas of material selection, material characterization and process definition to the project. Together with the customer, a fiber composite-compatible development was carried out and evaluated in detail with regard to the opportunities and risks.

A supplier in the field of centrifuge technology requested a new design in fiber composite construction that could be implemented cost-effectively to increase the possible centrifuge size and speed.

CIKONI began the conceptual work with in-depth structural FEM simulations and, once the concept had been defined, translated the result into a fiber composite-compatible design.

The centrifuge was realized in partnership with CIKONI’s supplier network.

For a surfboard powered by an electric turbine, a CFRP shell and a production concept for higher quantities had to be developed, which could no longer be realized using the autoclave prepreg process.

As part of a technology consultation, the component was analyzed, design optimizations in terms of manufacturability were proposed and production scenarios were compared in terms of costs, quality and scalability.

Spengle was faced with the challenge of manufacturing complex-shaped CFRP impellers in large series. The aim was to overcome the limitations of autoclave prepreg production and optimize the impeller.

CIKONI analyzed the geometry and derived manufacturing processes with high scaling potential. In addition, a catalog of measures was developed for implementation in production and the impeller was simulatively optimized.

In order to tailor bicycles to the needs of customers, the dimensions of the frame needed to be flexibly changeable without tool modifications in manufacturing. At the same time, additive processes do not provided the necessary stability.

Through a requirements analysis and technology consultation with TZMann, CIKONI was able to derive a new type of design for e-bikes that can be implemented cost-effectively but is also flexible in terms of frame dimensions.

A start-up in the field of vertical take-off of air cabs is developing a unique lift concept with high-performance rotors. Due to the high loads, a strength analysis had to be carried out for the drive units and optimization potential had to be identified.

CIKONI transferred the laminate structure of the prototype from the plybooks into an FEM model, carried out extensive simulations and analyzed the composite structures. Based on the results and the optimizations carried out, weight savings of 12% were achieved.

Our customer manufactures state-of-the-art lightweight seats for civil aviation. An innovative process is used to manufacture the fiber-reinforced seats, which requires material and process-specific FEM simulation methods.

CIKONI analysed the manufacturing process and derived the material characterization tests required for the simulation. Based on the test results, a powerful simulation model was derived, which was successfully validated and used for simulative optimization.

Our customer is testing the use of fiber-reinforced composites to reduce the weight of a door component on a civil aircraft. The complex load cases require both the development of geometric methods and the implementation of simulations.

CIKONI worked with the customer to develop meaningful load scenarios and carried out extensive simulations based on these load spectra, which were used to optimize the design and process of the component. Process-specific optimizations of the laminate were also carried out.

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Hydrogen pressure tanks in vehicles are exposed to loads that standardized test methods do not reflect. A simulation method was to be developed for a commercial vehicle OEM that allows a crash calculation of pressure tanks under different operating conditions.

CIKONI transferred the production documents of the pressure tank manufacturer into a winding simulation and thus generated an initial model for the explicit crash simulation in the FEM. The model made it possible to investigate various influencing factors (pressure level, impact angle, speed, etc.) on the crash behavior of the pressure tank. The simulations were used to optimize the design of the suspension and positioning.

Hydrogen pressure tanks usually have cylindrical shapes, which are ideal for hydrogen pressure storage, but cannot be used optimally to utilize available installation space. The aim was to find alternatives that would make the installation space of battery electric vehicles usable for hydrogen storage.

After extensive concept work, patent research and literature studies, a new approach to hydrogen storage was found and simulatively validated by modifying an existing composite manufacturing process. This makes it possible to use the installation space of BEVs to store hydrogen below 700 bar.

For honeycomb structures used in lightweight helmets, our customer was looking for an automated solution that would enable a double-curved honeycomb structure. In addition, internal knowledge of production parameters was to be developed so that the customer had the authority to interpret the process.

CIKONI carried out early experiments on a laboratory scale to investigate various approaches with regard to their suitability for automation. The preferred concept was implemented in a fully automated system. The storage, handling, forming and unloading was patented. CIKONI built three machines for the customer and enabled near-shoring of production in the Netherlands.