3D OptiLock

Development of lightweight and safe auto-lock components

The overall objective of the “3D Opti Lock” project is the development of an innovative hybrid manufacturing process chain for optimizing safety-critical metal components, using auto-lock components for vertical rope climbing systems as an example. Conventional subtractive manufacturing methods are combined with modern additive technologies to achieve lighter, stronger, and more resource-efficient components. The project investigates both design and manufacturing approaches.

A key element is the development of an improved design of the auto-lock component as a safety-critical part that prevents fall hazards. The goal is to significantly reduce weight without compromising safety and functionality. New materials, lightweight structures, and generative design approaches are used for this purpose.

Additive manufacturing is primarily used for rapid prototyping and design optimization. The results are then transferred to conventional manufacturing processes such as casting to enable cost-efficient series production. This hybrid approach combines the design freedom of additive manufacturing with the economic efficiency of conventional methods.

For the project duration, the following objectives are defined:

• Analysis and evaluation of existing auto-lock components regarding material, geometry, and manufacturing
• Development and simulation of optimized component designs using FEM and topology optimization
• Manufacturing and testing of prototypes using additive manufacturing
• Investigation of suitable materials for hybrid manufacturing processes
• Transfer of optimized designs to conventional manufacturing processes
• Construction and testing of a functional demonstrator (auto-lock system)
• Validation of the process chain and overall system under real operating conditions

Grant number: 16KN112402

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