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M.Sc. Sven Coutandin

Gruppenleiter Leichtbaufertigung
Bereich: Maschinen, Anlagen und Prozessautomatisierung
Sprechstunden: nach Vereinbarung
Raum: 013, Geb. 50.36
Tel.: +49 721 608-42449
Fax: +49 721 608-45005
Sven CoutandinMwa1∂kit edu

76131 Karlsruhe
Kaiserstraße 12

M. Sc. Sven Coutandin

Forschungs- und Arbeitsgebiete:

  • Automatisierungslösungen und sensorbasierte Greiftechnik im Umfeld der Leichtbaufertigung
  • Prozess- und Maschinenentwicklung für additive Fertigung von faserverstärkten Kunststoffen
  • Untersuchung von Verfahren und Fügetechnik zur Fertigung von FVK-Metall Hybriden
  • Charakterisierung des Umformverhaltens von gebinderten, textilen Materialien
  • Analyse der Umformung von textilen Materialien mit Hilfe segmentierter Werkzeuge


Allgemeine Aufgaben:

  • Leitung der Gruppe Leichtbaufertigung mit den Themenschwerpunkten FVK-Metall Hybride, Fügetechnik, Greiftechnik und Robotik, additive Fertigung
  • Mitglied im Kernteam des Leichtbauzentrums Baden-Württemberg e.V.






Dissertation: Methodik zur endkonturnahen, faltenfreien Herstellung von textilen Preforms mit Hilfe einer segmentbasierten Stempeldrapierung


[ 1 ] Fleischer, J.; Koch, S. & Coutandin, S. (2015), „Manufacturing of polygon fiber reinforced plastic profiles by rotational molding and intrinsic hybridization “, Prod. Eng. Res. Devel. , Band 9, Nr. 3, S. 317-328.
The manufacturing of lightweight shafts, pipes and profiles often uses hollow structures made from fiber reinforced plastics (FRP) due to their better density related properties. For applications with locally high tribological stresses, the use of FRP is not yielding proper results. In terms of lightweight construction, a hybrid design with a hollow FRP basic structure and local metallic elements in areas of high tribological stress is ideal for these applications. A promising approach for the production of these parts is rotational molding. Rotational molding for FRP– metal profiles is understood as a manufacturing process where machined, metallic elements and dry continuous fiber structures will be assembled and laid in a closed mold. Afterwards, the liquid matrix will be casted and the mold is then rotated at high speed until the fiber structure is fully impregnated and the matrix is cured. As there are short flow paths, this process is offering the potential to realize short cycle times of only a few minutes. Within this paper, the manufacturing of polygon profiles via rotational molding is described. These profiles can be produced by using centrifugal cores which were developed at the wbk Institute of Production Science. These cores are made of an elastomer composite material and they expand during the rotational molding process. The modeling of these cores and their impact on the impregnation pressure is shown here as well as their contribution in achieving higher fiber volume fractions.

[ 2 ] Fleischer, J.; Albers, A.; Coutandin, S. & Spadinger, M. (2016), „Materialeffizienz im Resin-Transfer-Moulding-Prozess“, VDI-Z Integrierte Produktion, Nr. 1, S. 82-84.
Innovative Leichtbaulösungen unter Einsatz von endlosfaserverstärkten Kunststoffen bieten große Potentiale im automobilen Leichtbau. Allerdings verhindern technische und wirtschaftliche Herausforderungen in der Resin-Transfer-Moulding-Prozesskette, dass sich diese Werkstoffe in der Großserie durchsetzen. Um die hohen Materialkosten während des Preformings zu senken, wird eine neue Werkzeugtechnologie entwickelt, mit der sich der Faserverschnitt reduzieren lässt. Zudem bietet eine ganzheitliche Subpreform-Strategie unter Berücksichtigung von fertigungstechnischen, mechanischen und wirtschaftlichen Gesichtspunkten der Industrie Chancen zur weiteren Kostenreduktion bei gleichzeitiger Ressourcenschonung.

[ 3 ] Förster, F.; Ballier, F.; Coutandin, S.; Defranceski, A. & Fleischer, J. (2017), „Manufacturing of Textile Preforms with an Intelligent Draping and Gripping System“, Procedia CIRP, S. 39-44.
In this paper, a novel pixel-based draping and gripping unit will be presented. To monitor and control the draping during the forming of a stack of semi-finished textiles, the pixels are equipped with integrated sensors. With these sensors, it is possible to adjust the tangential sliding and the normal holding force at each pixel. The sensor principle is based on the electrical conductivity of carbon fibers. Electrodes inside the gripping system allow a conclusion to the gripping force between the gripper and the carbon textile. Therefore, the gripping force can be adjusted to the special boundary conditions during the draping process.

[ 4 ] Kupzik, D.; Ballier, F.; Roller, T.; Coutandin, S. & Fleischer, J. (2018), „Development and evaluation of separation concepts for the controllable release of tacky prepreg from handling devices“. Procedia CIRP, Hrsg. Lihui Wang, S. 574-579.
The handling and layup of unidirectionally reinforced thermoset prepreg patches is currently a largely manual process. To reduce labor costs and increase part quality, automated handling of the material is desired. However, laying down the prepreg is challenging due to the tack of some materials. This paper investigates various modifications to an existing vacuum gripping system to enable a reliable separation process between the prepreg and the gripping system. The investigation focuses on the improvement of the integrated pneumatic blow-off mechanism, the development of a mechanical separation system and the application of different suction pads.

[ 5 ] Kupzik, D.; Ballier, F.; Lang, J.; Coutandin, S. & Fleischer, J. (2018), „Development and evaluation of concepts for the removal of backing foils from prepreg for the automated production of UD reinforced SMC parts“. Proceedings of the 18th European Conference on Composite Materials (ECCM18), Hrsg. European Society for Composite Materials (ESCM), S. 1-8.
Backing foil or paper needs to be removed from the raw material prior to the processing of Sheet-Moulding-Compound (SMC) or unidirectionally reinforced prepreg (UD-Tapes). In present automated production processes, this step is conducted after unrolling the raw material and prior to the cutting. In a process chain, which is conducted in the authors project, the backing foil needs to remain at the material after the cutting step. For these process chains, a method needs to be found to remove the backing foil from the material. In the state of the art, methods are shown to remove backing paper from prepreg. In this paper new methods are developed and tested for the removal of backing foil together with existing concepts. The main difficulty is the transition from backing paper to backing foil which has a higher tack to the material, is thinner and mechanically less strong. Concepts which are investigated use compressed air, mechanical forces or the stiffness of the foil. The application of compressed air is tested between foil and prepreg. Mechanical forces can either be introduced using grippers, brushes, friction to rubber or adhesive tape. The stiffness of the foil is used when removing it through bending the prepreg.

[ 6 ] Dackweiler, M.; Coutandin, S. & Fleischer, J. (2018), „Filament winding for automated joining of lightweight profiles“, JEC Magazine, S. 25-26.
Hollow profiles made of fibre-reinforced composites are ideally suited for the production of highly rigid lightweight lattice structures. Due to their excellent mechanical properties, these structures follow the current trend of resource-efficient and thus environmentally friendly construction. Compared to the flat structures, however, there are still major challenges in the joining process of such profiles. Today, these are often circumvented by the use of additional metallic elements such as screws or node elements. However, the consequence of these joining techniques is usually damage to the fiber composite struc-ture and thus a weakening of the overall structure. For this reason, the wbk Institute of Production Engi-neering at the Karlsruhe Institute of Technology (KIT) has developed an innovative method of joining in order to be able to produce such lattice structures flexibly and with a high load-bearing capacity. With the aid of a kinematic system attached to a vertical articulated arm robot, consisting of a stator and a rotor rotating inside, individual rovings and towpregs can be applied to the joining zone of the profiles to be joined in a load-fair and non-destructive manner and thus generate both a load-bearing form and ad-hesive bond.

[ 7 ] Coutandin, S.; Brandt, D.; Heinemann, P.; Ruhland, P. & Fleischer, J. (2018), „Influence of punch sequence and prediction of wrinkling in textile forming with a multi-punch tool“, Production Engineering, S. 1-10. https://doi.org/10.1007/s11740-018-0845-9 [13.08.18].
Liquid composite moulding (LCM) processes show a high potential in automated, large scale production of continuous fibre-reinforced plastics (FRP). One of the most challenging steps is the forming of the two-dimensional textile material into a complex, three-dimensional fibre structure. In this paper, a multi-punch forming process is presented. The upper mould of a generic part geometry is divided into 15 independently controllable punches. Depending on the different punch sequences, draping effects as well as defects related to wrinkling and shearing of the textile material are investigated. It has been shown that the sequence of the punches has a significant influence on the final preform quality. To predict the resulting regions of wrinkling and shearing, a finite-element based simulation model is set up. Forming tests and simulations with different punch-sequences are then performed and evaluated for validation purposes. To make a statement about the global preform quality, different objective functions regarding wrinkling are presented and analysed.