#Blogs: Automation technology
Automated gluing for fiber-reinforced composite materials – the future of industrial lightweight construction
Learn how automated gluing systems are revolutionizing the manufacturing of fiber-reinforced composite components and why MICADO counts among the leading providers of customized gluing solutions.
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Robot-assisted gluing system in action
In the aerospace and automotive industries, manufacturing faces a central challenge: How can highly complex components made of fiber-reinforced composite materials be joined economically, reproducibly, and in the highest quality? Traditional joining methods such as riveting or welding reach their limits with modern lightweight materials such as CFRP and GFRP. The answer lies in automated gluing systems. In contrast to manual gluing processes, automated systems ensure consistent quality across the entire production batch. Robot-assisted dispensing and application technology enables reproducible adhesive beads with exact geometry, defined quantity, and precise positioning – particularly critical for safety-relevant components in aerospace.
What are automated gluing systems?
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6-axis robot applies adhesive precisely onto a CFRP component in an automated gluing cell.
Automated gluing refers to the robot-assisted, precise application of adhesives onto components. This technology is crucial for fiber-reinforced composite materials, as these materials react sensitively to mechanical joining techniques. MICADO offers customized systems for the most demanding applications with decisive advantages: reproducible adhesive application with consistent quality, automatic monitoring of adhesive quantity and bead geometry, integrated inline inspection systems, and complete traceability. In addition, there are reduced cycle times, minimized material waste through exact dosing, and higher system utilization. The systems adapt to different component geometries and can be integrated into existing production lines – scalable from semi-automation to full automation.
The advantages of automated gluing systems from MICADO
Adhesive systems and surface pretreatment
The selection of the suitable adhesive system is decisive. Epoxy resin adhesives are the first choice for structural gluing in aerospace with extremely high shear strengths and temperature resistance up to 180 °C. Methyl methacrylate adhesives (MMA) combine high strengths with extremely short curing times – ideal for short cycle times in series production. Polyurethane adhesives offer maximum flexibility for sandwich elements and act as stress-compensating as well as vibration-damping.
Fiber-reinforced composite materials must be absolutely free of dust and grease. Automated systems integrate mechanical pretreatment through grinding or blasting, chemical pretreatment by means of plasma activation or primer application, as well as quality control through surface energy measurement. This ensures reproducible conditions and optimal adhesion.
Robot-assisted application and quality assurance
MICADO relies on state-of-the-art 6-axis robots with highly precise dosing systems for the precise application of adhesives. All components used are designed to apply adhesives reliably and reproducibly in constant quality. Modern electro-volumetric dispensers enable a dosing accuracy of ± 1 % and ensure a constant material quantity in operation. Pressure compensation balances viscosity fluctuations, while temperature control systems keep the adhesive viscosity constant even in continuous operation. Multi-component mixing heads ensure homogeneous 2K adhesives during application. 3D path planning enables the precise application of complex bead geometries on curved surfaces, while speed-adaptive dosing ensures a consistent bead width during operation. The paths are programmed via teach-in or CAD import; automatic collision avoidance reliably protects the system during operation.
A decisive advantage is the integrated quality control. High-resolution camera systems inspect the adhesive bead immediately after application for completeness, position, width, and geometry. Laser triangulation sensors measure bead height and applied volume. Continuous monitoring of pressure, flow, and temperature detects process deviations in real time. All parameters are documented and provide complete traceability.
Holistic solutions from semi- to full automation
MICADO also offers semi-automatic solutions that combine human flexibility with machine precision. In human-robot collaboration, the employee takes over component handling, while the robot performs the precise adhesive application – particularly effective for medium quantities.
Quality control of the finished component
The curing time often determines the cycle time. Modern systems integrate intelligent curing concepts: temperature-controlled fixing devices accelerate curing through controlled heat supply, circulating buffer systems enable parallel curing, and IR or induction heating for selective rapid curing reduces the cycle time.
Automated gluing – practical examples
In the aerospace industry, automated gluing systems are used for the assembly of fuselage segments, wing structures, and interior panels. Especially with large-area CFRP sandwich structures, uniform adhesive distribution is critical. MICADO systems ensure reproducible quality with large component dimensions.
In the automotive sector, battery housings made of fiber-reinforced composite materials are a growing field of application. The gluing must be electrically insulating, thermally conductive, and crash-safe. Automated systems enable precise application of special thermal interface materials and structural adhesives. CFRP roofs for high-performance vehicles are also increasingly glued in an automated manner.
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Active clamping device with servo drive and BECKHOFF control/HMI
MICADO as a competent contact for successful project implementation
“Automated gluing is far more than just a robot with a glue gun,” emphasizes Eng. Markus Rath, Head of Tooling & Fixture Construction at MICADO. “Successful implementation requires deep understanding of materials, adhesives, and processes.” The suitable solution depends on component shape and material as well as on the adhesive used. Cycle time, production volume, quality requirements, and budget also play a decisive role.
From the first feasibility study to ongoing production, MICADO stands by as a full-service provider: First, we analyze the process and test the materials. On this basis, we select the appropriate adhesive. Then we develop the suitable automation solution. Afterwards, we design the required fixtures and robot cells in detail. This is followed by programming as well as the development of the operating interface (HMI). After precise manufacturing and assembly, we commission the system and support the process approval. Even after project completion, we continue to provide support.
Automated gluing systems make an important contribution to sustainability: reduced material consumption through exact dosing, minimization of scrap through process reliability, energy efficiency through optimized curing concepts, and enabling lightweight construction with CO₂ savings during operation.
Conclusion
Automated gluing of fiber-reinforced composite materials is a key technology for the future of industrial lightweight construction. With its expertise as a full-service provider for automation and fixture construction, MICADO supports companies in finding the optimal gluing solution and successfully implementing it. Whether fully automated production line or semi-automatic single cell – MICADO develops the solution that fits your requirements and creates sustainable added value in your manufacturing.
