Bionically vault structured materials
Vault structuring is a process within forming technology based on controlled self-organization.
We offer you design, simulation, calculation and concept design of bionically vault-structured materials for various industries.
Improved stability and strength
The bionic structure distributes loads more effectively and thus reduces the risk of material failure, resulting in greater stability and strength.
Lightweight construction
These materials are lighter because the structure reduces the weight, which lowers energy consumption and costs, especially in aviation and automotive engineering.
Increased flexibility and adaptability
The structure can adapt to different loads and environmental conditions, which increases its functionality and durability.
What exactly is bionic vault structuring?
Curvature structuring is a process within forming technology based on controlled self-organization. It enables the creation of three-dimensional structures in thin-walled materials such as sheet metal, plastic film, cardboard and paper. Either square or hexagonal structures can be produced. Compared to conventional sheet metal forming processes such as embossing, beading or hydroforming, camber structuring is characterized by an energy-efficient self-organization process. This process is particularly gentle on the material and saves energy and resources. One of the most important properties of arch structures is their increased rigidity, both in terms of bending and buckling stiffness.
Arched structures in nature have numerous useful properties. Research experiments have shown that this controlled self-organization process can also be replicated in technology. By applying gentle pressure to a curved, thin material that is simultaneously supported, a smart and energy-efficient 3D structure can be created. This structure is stiffer in all directions than the original material while maintaining the surface finish. This ingenious process makes it possible to apply curved structures to sheets, foils and other materials.
Applications of bionic vault structuring
Automotive engineering
Curvilinear materials are used in automotive engineering, for example, to produce lighter components with high rigidity, crash energy absorption capacity with low energy consumption and are particularly sustainable. One example of the application of arch-structured materials in automotive engineering is their use in structural body components. By integrating arch structures into certain areas of the body, such as doors, hoods, crash-relevant support structures or roof panels, structural rigidity, crash absorption capacity and sound absorption can be improved without adding additional weight. The arch structure is used in a series-produced bionically arch-structured rear panel of the Mercedes SLK, which gives the vehicle a high level of vibration damping coupled with a high degree of sound absorption with minimal space requirements.
Building services
Vault-structured materials are also used, for example, in the domestic appliances sector for MIELE washing machine drums. Arched structures have been used for washing machine drums since the "Softronic" generation of washing machines.
According to MIELE, the main advantage of this globally unique bionic washing machine drum, patented by Miele, is not only its high mechanical strength and rigidity, but also an improved washing process. Thanks to the honeycomb drum made of sheet steel, on which the laundry moves on a film of water, the laundry is treated gently. This results in gentle, sustainable, economical and faster washing machines. This honeycomb drum differs significantly from a perforated drum.
Lighting technology
A vault structure has also been used in the lighting technology sector (SITECO). Siteco Beleuchtungstechnik GmbH uses arch-structured aluminum sheets for the production of LED designer lamps. The optimum light reflection of the structure achieves a high quality of light. The material fulfills the function of both the housing and the reflector of the lamp, resulting in a total material saving of 80 percent. In addition, less distortion occurs in the structured sheets at higher temperatures.
Construction and architecture
The vault structure is also used in the construction and architecture sector for building roofs and façades as well as for construction vehicles and agricultural machinery. The Yuzhny Odessa sports complex in the Ukraine, also known as the blue turtle, was completed in 2003 and has a roof area of around 6000 square meters with a special aluminium sheet covering that is only 0.7 mm thick thanks to the vault structure.
Particle accelerator
The electron synchrotron DESY (Deutsches Elektronen-Synchrotron) in Hamburg uses a domed conical aluminum tube system that has been in operation for over 10 years without any problems for elementary particle research.
The synergetic properties are dimensionally stable, extremely thin tubes under high vacuum stress and flexibility when thermal expansion is restricted.
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