Adaptive, versatile and reliable – these are the composite products in the STAXX family. From the compact STAXX Box for layup tests and research facilities to the STAXX One single tow robotic system, the standalone fiber placement center STAXX Compact and the large 16 tow AFP system STAXX Flex for large structures, the STAXX family offers the right modular system for different fiber placement applications and the individual needs of customers. With this adaptive product line, Broetje-Automation provides the right equipment for modern and task-adapted production in the Factory of the Future.

A 4-Axis Fiber Placement Machine for cost-effective automated production of small composite parts. Its Digital Twin allows full simulation and offline programming, with a cost-efficient design eliminating the need for a foundation. 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.

An adaptable solution for automated fiber placement weighing just ~40 kg. It was developed for seamless integration with 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. Also equipped with the digital twin, programming becomes more efficient, offline programming and collision analysis are facilitated, as well as simulation based on real machine data. With layup flexibility that supports different materials and the Siemens NC controls, industrial adaptability and scalability is 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.

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. 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 a user-friendly HMI enhance ease of use. With its compact dimensions (6500mm x 3000mm x 3000mm), the standalone fiber placement system offers versatility for various industrial applications.

The STAXX 3D and STAXX Compact differ in their design and capabilities for high-volume production. While the STAXX Compact is a robust 16-lane fiber placement machine, the STAXX 3D 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 in the automotive and aerospace industry. 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 high-performance system in the STAXX Family. The STAXX Flex impresses with its high-performance, automated fiber placement end effector, which was developed for complex two- and three-dimensional parts. With a weight of 440 kg, it can be mounted on standard industrial robots and is therefore ideal for series production. It supports materials such as PrePreg and Dry Fiber with up to 50K per tow and is characterized by its versatility. 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 with 16 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, the largest 16 tow AFP system, 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.

Find us at booth 6P24 at the joint Composites United booth in hall 6. We are welcoming all interested participants and look forward to exciting conversations and an interesting exchange on innovations in the composite sector.