TY - CHAP A1 - Middendorf, Peter A1 - Böhler, Patrick A1 - Gnädinger, Florian A1 - Heieck, Frieder A1 - Birkefeld, Karin A2 - Beaumont, Peter W.R. A2 - Zweben, Carl H. T1 - 8.3 Design Study for a Carbon Composite Manipulator T2 - Comprehensive Composite Materials II N2 - Carbon fiber reinforced plastics (CFRP) allow to redesign well established metallic structures like manipulators in order to decrease their weight and to increase their level of performance. This task can only be successful, when the CFRP-design process does not copy the metallic structure, but solves the underlying functions in a new way. The present study shows, how an I-beam steel manipulator was transferred to a braided design with hollow cross sections and locally adapted material properties. Step by step we show, how to define the manipulator’s functions and mechanics and how they can be considered with a braided CFRP-structure. This includes analytical pre-design as well as detailed finite element method (FEM) design. A mechanical testing program was performed in order to measure input-values for the numerical calculations on coupon-level and validate the simulation on system level. Static and dynamic tests of the CFRP-manipulator showed that it fulfils all requirements to be certified for sale. Therefore, the braiding process for commercial production was investigated for two machine setups and the state of serial production was reached. The braided CFRP-manipulator is 70% lighter than the steel reference and has increased handling properties because of locally adapted material properties. Y1 - 2017 UR - https://opus4.kobv.de/opus4-hs-kempten/frontdoor/index/index/docId/1793 SN - 978-0-08-100534-7 SP - 47 EP - 60 PB - Elsevier CY - Amsterdam ER -