Adaptive, versatile and reliable – these are the main highlights of the STAXX family product line. From the compact STAXX Box for layup tests to the STAXX One single tow robotic system to the standalone fiber placement center STAXX Compact and the scalable multitow AFP system STAXX Flex for large structures, the STAXX family offers a modular system to cover different AFP applications and the individual needs of each customer. With this adaptive product line, Broetje-Automation provides the right equipment for modern and task-adapted production in the Factory of the Future. This is extremely important, especially for the rapid ramp-up of new composite designs and products in various industries. 

The STAXX Box is a 4-Axis Fiber Placement Machine for cost-effective automated production of small composite parts as well as test coupons or trial parts. The system is flexible and robust, accommodating various material types (PrePreg, TowPreg, DryFiber, Thermoplast, etc.) and featuring Siemens NC Controls. Special features include controlled compaction and heating units like the optional infrared emitter, diode laser, or flash-lamp. The compact design and standardized components make it easy to relocate, providing an ergonomic and user-friendly solution for automated production. The system can support the transition from manual to automated production or can free up machine time from larger systems. It shares the modular AFP endeffector with its robotic sister-machine, the STAXX One. 

The STAXX one is an adaptable solution for automated fiber placement. The STAXX One single tow end-effector is weighing just ~40 kg. It was developed for seamless integration with small standard industrial robots and is the extension of the STAXX Box. The end-effector can be paired with the robot in simple steps and is then ready to manufacture complex parts. Thanks to the standardized design, an upgrade from the STAXX Box to a STAXX One is easily possible.  

Equipped with a digital twin, programming becomes more efficient, offline programming and collision analysis are facilitated, as well as highly precise simulation. With layup flexibility that supports different material types and widths combined with the Siemens NC controls, industrial adaptability and scalability are guaranteed. The cost-effective design allows for flexible work cell configuration and controlled pneumatic compaction. STAXX ONE is ideal for various applications and automates fiber placement of complex parts with ease. In a mobile robotic workcell configuration, the system is also available to be rented for a limited time, e.g. for prototyping campaigns, a feature that can help companies within the transition phase between demonstrator manufacturing and serial production. 

This robust 16-lane fiber placement machine is developed for the industrial mass production of small composite parts. The focus is on high workpiece quality and minimal material waste combined with a scalable machine concept. The machine is equipped with Broetje-Automation HMI SCORE, automatic loading and unloading and intelligent quality control to reduce labor costs and cycle times. The machine supports direct laying of unidirectional 2D carbon fiber mesh with flexible fiber orientation. The climate-controlled housing ensures safety and scalability, while features such as easy material reloading and is capable to operate in environmentally uncontrolled workshops. Relocation of the production unit is possible within a few days due to its compact design. With its compact dimensions (6500mm x 3000mm x 3000mm), the standalone fiber placement system offers versatility for various industrial applications. 

The STAXX 3D is based on the STAXX COMPACT design but provides more layup space combined with 3 dimensional capabilities. It is highly flexible, emphasizing versatility with a swiveling rotary table for the efficient production of small individual composite parts. The STAXX 3D achieves high part quality and is tailored for cost-effective and sustainable production for the automotive and aerospace industry, especially interesting for the growing UAS market. It features a 16-tow AFP head, a 6-axis system with a tilting rotary table, and a feed rate of 60m/min. Both systems cater to different production needs, with the STAXX 3D providing additional options and capabilities for specific composite part requirements. 

The STAXX Flex is the high-performance system in the STAXX Family. The STAXX FLEX impresses with its scalable multitow automated fiber placement end effector, which was developed for complex two- and three-dimensional parts. With a weight of 440 kg at 100mm layup width, it can be mounted on standard industrial robots and is therefore ideal for series production in a cost-effective manner. It supports multiple materials such as PrePreg and Dry Fiber with up to 50K per tow and is characterized by its versatility and accuracy. The system features built-in quality control, including constant compaction force and camera-based inline layer inspection, ensuring precise operation. With a flexible work cell configuration, an open and modular design and quick maintenance without tools, the STAXX FLEX offers a user-friendly experience. The high stacking mass, achieved by a high laying and cutting speed on 16 individually controlled tracks, increases productivity and is suitable for various positioning systems. In addition, the system offers further configurations with different heating units to accelerate the stiffening of the material. 

The STAXX Family stands as a beacon of innovation and adaptability in the realm of automated fiber placement. From the compact STAXX Box for layup tests to the STAXX Flex,  each member of the family embodies adaptability, versatility, and reliability and covers the entire bandwidth of industrial production needs. These composite automation products cater to a wide range of fiber placement applications and address the diverse needs of customers in the Factory of the Future.  

The STAXX Family incorporates many technologies in a joint standardized approach, such as Digital Twin applications, Siemens NC Controls, Multi-Material coverage, and integrated quality control, ensuring precise and efficient operations. Whether it’s the cost-effective STAXX Box, the adaptable STAXX One, the industrially focused STAXX Compact, or the high-performance STAXX Flex, each system contributes to the evolution of modern, task-adapted production, making the STAXX Family a cornerstone for the future of automated fiber placement. 

At CAMX 2024 Broetje-Automation is looking forward to introducing this versatile product family to the participants showcasing a 16 tow endeffector of the STAXX Flex AFP system. Visit booth W33 from September 10-12 at the San Diego Convention Center and meet the professionals of Broetje-Automation to engage over the flexible composites solutions for the Factory of the Future.