Hahlbrock manufactured the largest substructure of the new driving simulation system, the testing room made of carbon fiber reinforced plastic.

The simulator dome can accommodate a complete Mercedes vehicle (not just mock-ups); The 360° projection screen provides a realistic representation of road traffic. This testing room is housed as a hexapod with six movable supports.

To simulate highly dynamic driving processes, the goal was to develop a very light and at the same time stiff simulator dome.

CONSTRUCTION

• Round support platform with an attached spherical section as a projection surface
• Top end with a roof in the shape of a flat cone
• The roof supports the eight high-performance image projectors
• Door opening for bringing cars into the cathedral

GEOMETRY AND WEIGHT

• Spherical diameter, outside: 7.67m
• Spherical diameter, inside: 7.52m
• Spherical height: 3.00m
• Dome height with roof: 4.52m
• Dome width with gate: 7.81m
• Gate width: 2.68m
• Gate height: 2.49m
• Weight (without car): approx. 5.5t

MATERIALS

• Platform: Central cast aluminum element with radially attached molded parts made of carbon fiber reinforced plastic (CFRP)
• Dome jacket (spherical section): Fiber composite sandwich material, consisting of a core made of lightweight PVC foam and thin cover layers made of CFRP on both sides
• Dome roof: Roof cap also made of fiber composite sandwich material, radially stiffened with ribs and struts made of CFRP

MANUFACTURING PROCESS

The CFRP parts were manufactured using a vacuum-assisted resin injection process. Flat fabrics made of carbon fibers were placed in several dry layers in a mold and then impregnated with epoxy resin under vacuum. The composite of carbon fibers and the synthetic resin then hardened at temperatures of up to approx. 80°. After removing the hardened CFRP raw parts from the molding tools, the edges of the moldings were milled into their final contour using NC-controlled machines and, if necessary, drilled.

ASSEMBLY

The individual CFRP molded parts were glued together using an epoxy resin adhesive and riveted with around 24,000 special titanium rivets. The arrangement and alignment of the over 200 individual CFRP parts was carried out in NC-milled assembly devices, with individual parts being precisely adjusted using distance lasers. The accuracy of the spherical shells of the dome mantle was determined by laser scanning.

PROJECT IMAGES

Based on the designers’ 3D models, the pool landscapes were designed and manufactured from glass fiber reinforced plastic. Measurements taken on board. Visible components embedded flush into the surfaces. Integrated buffet and slide-in furniture. Handrails, glass panes, hatches were purchased and adjusted in advance. The pool landscapes were delivered to the shipyard in several pieces, connected to each other and attached to the ship structure by gluing. The interface to the shipyard was the empty deck.

The company: Northern German shipyards

The shipyards in northern Germany have been producing the largest yachts in the world for many years, making them the global market leader in the mega and superyacht segment. In the 2021 order backlog for civil shipbuilding, megayachts ranked right after cruise ships and are therefore a permanent fixture in the maritime economy.

The challenge: equipment

The designers of the yachts place high demands on the quality and appearance of all components. Everything has to be perfect and reflect the design concepts. The equipment must be integrated in the best possible way. These interfaces must be maintained. Here we are relieving capacity in the construction departments of the shipyards.

The solution: interface support

Depending on the scope of services ordered, we have taken over interface support from the shipyards and take care of the design, procurement and assembly of the high-quality equipment, thereby keeping the “big picture” in mind. There is no need for technical coordinations between various parties. If the shipyard and the owner representatives approve our designs, we will get started.

PROJECT IMAGES

The two mirror-symmetrical wings are made of glass fiber reinforced plastic (GRP) and have a span of 19.30 m. Parallel slats were inserted between the wing surfaces. The openings between the leading and trailing edges of the wing were completely covered with translucent GRP material.
By using modern fiber composite materials, around 50% of the weight could be saved compared to an aluminum construction. And all of this with the same strength – after all, the shade roof has to withstand wind speeds of up to 250 km/h.

The 68,500 GT cruise ship AIDAdiva was christened in April 2007, the identical AIDAbella in April 2008. The AIDAluna followed in 2009 and the AIDAbella in 2010.

PROJECT IMAGES

The inner steel skeleton was renovated and permanently protected against corrosion. The concrete that was originally poured in for the foundation, which played a key role in the damage process, had previously been removed. A stainless steel construction individually adapted to each sculpture now ensures stability on the platform.

After an extensive mapping of all damage by the MPA Hannover and analysis of the original colors, the GRP outer shell was sanded down, covered with a new GRP skin and finally recolored to match the original color areas as closely as possible.

Caroline, the first of the three Nana sisters, was put back in her original place in autumn 2004, Sophie and the massive Charlotte followed in May 2005. Hanover’s famous three ladies now shine in new splendor on the banks of the Leine.

PROJECT IMAGES

Hahlbrock created the impressive wall object made of glass fiber reinforced plastic in just two months. The biggest challenge: the high-gloss chrome plating of the two BMW-typical “kidneys” of the radiator grille.

Never before had such large one-piece surfaces been chrome-plated to a high quality. The prerequisites for creating the kidney wall were also precise shaping of the dynamic contours, high accuracy of fit of the individual parts like the original and a Class A paint finish. An installation that had been set up for a long time, with slats covered on both sides with photo film, was also supposed to be covered with the wall object and form the radiator grille of the oversized BMW front.

Despite their lightweight construction, all GRP molded parts produced using the CAD-CAM system had to remain extremely true to shape throughout the entire manufacturing process. The prerequisite for the effect of chrome plating was the creation of harmonious, highly smooth surfaces and edges without the appearance of stiffeners. All relevant molded part edges were milled with CNC support. During the assembly, which was carried out in a very short time, the 35 m² wall object was inserted precisely into the existing components.

Just in time for the start of the 2005 Geneva Motor Show, BMW was able to present the visually spectacular revision of the Welcome Wall in Hall E03 at Munich Airport. The high-quality execution of the advertising object optimally highlighted the quality of the brand presented.

In the “Munich Airport Award 2005” creative competition, the thinknewgroup agency won gold in the “Switched Motifs” category with the “Welcome Wall” motif. Reger Studios was a finalist in the Best of GWA – Production Awards 2005 in the “Outdoor Advertising Materials” category. Congratulations to everyone!

PROJECT IMAGES

The similar but not identical bulwarks were carried out as a Turn Key including engineering, FE-calculation of the structures and their connection, class drawings, manufacturing, equipping with niche and liferaft integrations, as well as their assembly at the shipyard by our employees. The interface was the decks on which the GRP superstructures were placed and glued. The weight was reduced immensely compared to steel and the bulwarks could be assembled after the “hot works” in the equipment phases. By producing large-format sections, assembly time could be reduced.

The company: Nobiskrug GmbH

Nobiskrug GmbH is a shipyard based in Rendsburg on the Kiel Canal. The shipyard, which currently has around 400 employees, is particularly known for building superyachts.

The challenge: complex designs

Complex designs are difficult to produce from steel, especially when high contour precision is required. This repeatedly leads to excessive filler application on the steel structures, which in extreme cases leads to cracks.

The solution: large-format lightweight fortification made of GFRP

The constructions made of glass fiber reinforced plastics, made from milled negative molds in maximum transport dimensions with a “ready to use” surface for a minimum filler application of 3 mm. Significant weight savings compared to the steel filler solution. Low maintenance thanks to the non-corrosive material.

PROJECT IMAGES