The U.S. Air Force conducted on-base and cross-country mission and performance evaluations of Beta’s composites-intensive CTOL aircraft, hitting key milestones.
Horizontal and vertical tail, aileron, and rudder and elevator will be developed and manufactured for the lift + cruise aircraft, scheduled to enter service in 2026. Fiber Glass Mesh
In addition to its composite aircraft, Overair will support infrastructure, aircraft operations and training to ensure a comprehensive and sustainable AAM ecosystem.
This initial project under the Space Act Agreement is focused on studying and developing high-performance battery cells, as well as performing safety testing, to achieve purpose-built solutions for electric aircraft.
AeroZero TPS, applicable for metals and composites, will protect critical battery housing and parts in the Lilium Jet eVTOL aircraft from burn through and risk of thermal runaway.
V-tail, five-passenger aircraft builds on the vison of the S-A1, designed with a priority on safety and a focus on sustainability.
The new alliance will broaden National Composites’ capabilities in SMC and BMC and tooling, while providing customers with comprehensive solutions, from initial design to final delivery.
A new ASTM-standardized test method established in 2022 assesses the compression-loaded damage tolerance of sandwich composites.
Composites automation specialist increases access to next-gen technologies, including novel AFP systems and unique 3D parts using adaptive molds.
Combined LSAM and five-axis CNC milling capabilities will optimize D-Composites’ production services, flexibility and cut time and cost for composite tooling manufacture.
Evaluation of CFRTP m-pipe through Element’s U.K. facility aims to qualify the system for new operating environments.
Innovative prepreg tooling is highly drapable, capable of forming complex carbon fiber tooling shapes, in addition to reducing through thickness porosity and only requiring one debulk during layup.
Inshore vessel is the largest yet to incorporate the recyclable thermoplastic resin, promotes future sustainability in boat manufacturing.
Projects use Duplicor prepreg panels with highest Euroclass B fire performance without fire retardants for reduced weight, CO2 footprint in sustainable yet affordable roofs, high-rise façades and modular housing.
Available as filament and granules for extrusion, new wood composite matches properties yet is compostable, eliminates microplastics and reduces carbon footprint.
A recent study conducted on vacuum-infused thermoplastic fiber-metal laminates has highlighted the performance benefits behind using TFP’s nonwovens for consistent, uniform bondlines and interfacial bonding.
To incorporate more environmentally conscious practices into its manufacturing processes, VSC is working with Carbon Conversions to reclaim, recycle and reuse its carbon fiber materials.
Switching from prepreg to RTM led to significant time and cost savings for the manufacture of fiberglass struts and complex carbon fiber composite foils that power ORPC’s RivGen systems.
Automated fiber placement develops into more compact, flexible, modular and digitized systems with multi-material and process capabilities.
Available as filament and granules for extrusion, new wood composite matches properties yet is compostable, eliminates microplastics and reduces carbon footprint.
A recent study conducted on vacuum-infused thermoplastic fiber-metal laminates has highlighted the performance benefits behind using TFP’s nonwovens for consistent, uniform bondlines and interfacial bonding.
Switching from prepreg to RTM led to significant time and cost savings for the manufacture of fiberglass struts and complex carbon fiber composite foils that power ORPC’s RivGen systems.
Sara Black’s 2015 report on the development of snap-cure epoxies for automotive manufacturing still resonates today.
JEC World 2024: Zünd is highlighting digital excellence via its ZCC Cut Center, heat sealing module (HSM), G3 Cutter and ZPC software.
CW explores key composite developments that have shaped how we see and think about the industry today.
Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.
As battery electric and fuel cell electric vehicles continue to supplant internal combustion engine vehicles, composite materials are quickly finding adoption to offset a variety of challenges, particularly for battery enclosure and fuel cell development.
Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.
Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.
The composite pressure vessel market is fast-growing and now dominated by demand for hydrogen storage.
The burgeoning advanced air mobility (AAM) market promises to introduce a new mode of transport for urban and intercity travelers — particularly those who wish to bypass the traffic congestion endemic to the world’s largest cities. The electric vertical take-off and landing (eVTOL) aircraft serving this market, because they depend on battery-powered propulsion, also depend on high-strength, high-performance composite structures produced at volumes heretofore unseen in the aerospace composites industry. This CW Tech Days will feature subject matter experts exploring the materials, tooling and manufacturing challenges of ramping up composites fabrication operations to efficiently meet the demands of a challenging and promising new marketplace.
Manufacturers often struggle with production anomalies that can be traced back to material deviations. These can cause fluctuations in material flow, cooling, and cure according to environmental influences and/or batch-to-batch variations. Today’s competitive environment demands cost-efficient, error-free production using automated production and stable processes. As industries advance new bio-based, faster reacting and increased recycled content materials and faster processes, how can manufacturers quickly establish and maintain quality control? In-mold dielectric sensors paired with data analytics technology enable manufacturers to: Determine glass transition temperature in real time Monitor material deviations such as resin mix ratio, aging, and batch-to-batch variations throughout the process Predict the influence of deviations or material defects during the process See the progression of curing and demold the part when the desired degree of cure, Tg or crystallinity is achieved Document resin mix ratios using snap-cure resins for qualification and certification of RTM parts Successful case histories with real parts illustrate how sensXPERT sensors, machine learning, and material models monitor, predict, and optimize production to compensate for deviations. This Digital Mold technology has enabled manufacturers to reduce scrap by up to 50% and generated energy savings of up to 23%. Agenda: Dealing with the challenge of material deviations and production anomalies How dielectric sensors work with different composite resins, fibers and processes What is required for installation Case histories of in-mold dielectric sensors and data analytics used to monitor resin mixing ratios and predict potential material deviations How this Digital Mold technology has enabled manufacturers to optimize production, and improve quality and reliability
SolvaLite is a family of new fast cure epoxy systems that — combined with Solvay's proprietary Double Diaphragm Forming technology — allows short cycle times and reproducibility. Agenda: Application Development Center and capabilities Solutions for high-rate manufacturing for automotive Application examples: battery enclosures and body panels
OEMs around the world are looking for smarter materials to forward-think their products by combining high mechanical performance with lightweight design and long-lasting durability. In this webinar, composite experts from Exel Composites explain the benefits of a unique continuous manufacturing process for composites profiles and tubes called pull-winding. Pull-winding makes it possible to manufacture strong, lightweight and extremely thin-walled composite tubes and profiles that meet both demanding mechanical specifications and aesthetic needs. The possibilities for customizing the profile’s features are almost limitless — and because pull-winding is a continuous process, it is well suited for high volume production with consistent quality. Join the webinar to learn why you should consider pull-wound composites for your product. Agenda: Introducing pull-winding, and how it compares to other composite manufacturing technologies like filament winding or pultrusion What are the benefits of pull-winding and how can it achieve thin-walled profiles? Practical examples of product challenges solved by pull-winding
Composite systems consist of two sub-constituents: woven fibers as the reinforcement element and resin as the matrix. The most commonly used fibers are glass and carbon, which can be processed in plane or satin structures to form woven fabrics. Carbon fibers, in particular, are known for their high strength/weight properties. Thermoset resins, such as epoxies and polyurethanes, are used in more demanding applications due to their high physical-mechanical properties. However, composites manufacturers still face the challenge of designing the right cure cycles and repairing out-of-shelf-life parts. To address these issues, Alpha Technologies proposes using the encapsulated sample rheometer (premier ESR) to determine the viscoelastic properties of thermosets. Premier ESR generates repeatable and reproducible analytical data and can measure a broad range of viscosity values, making it ideal for resins such as low viscous uncured prepreg or neat resins as well as highly viscous cured prepregs. During testing, before cure, cure and after cure properties can be detected without removing the material from the test chamber. Moreover, ESR can run a broad range of tests, from isothermal and non-isothermal cures to advanced techniques such as large amplitude oscillatory shear tests. During this webinar, Alpha Technologies will be presenting some of the selected studies that were completed on epoxy prepreg systems utilizing ESR and how it solves many issues in a fast and effective way. It will highlight the advantages of this technique that were proven with the work of several researchers. Moreover, Alpha Technologies will display part of these interesting findings using the correlations between the viscoelastic properties such as G’ and mechanical properties such as short beam shear strength (SBS).
Surface preparation is a critical step in composite structure bonding and plays a major role in determining the final bonding performance. Solvay has developed FusePly, a breakthrough technology that offers the potential to build reliable and robust bonded composite parts through the creation of covalently-bonded structures at bondline interface. FusePly technology meets the manufacturing challenges faced by aircraft builders and industrial bonding users looking for improved performance, buildrates and lightweighting. In this webinar, you will discover FusePly's key benefits as well as processing and data. Agenda: Surface preparation challenges for composite bonding FusePly technology overview Properties and performance data
Venue ONLY ON-SITE @AZL Hub in Aachen Building Part 3B, 4th Floor Campus Boulevard 30 52074 Aachen Time: January 31st, 2024 | 11:00-16:00h (CET) This first constitutive session will shape the future of the workgroup. ✓ Insights into solutions for e.g. circularity, recycling, sustainability, end of life etc. ✓ Interactive exchange along the value chain to tackle these challenges: Share your input in the “World Café” workshop session! ✓ Are you a solution provider? Take your chance and present your solution approach in a short 5-minute pitch. Get in touch with Alexander.
The Transformative Vertical Flight (TVF) 2024 meeting will take place Feb. 6–8, 2024 in Santa Clara, California, in the heart of Silicon Valley and will feature more than 100 speakers on important progress on vertical takeoff and landing (VTOL) aircraft and technology.
The EPTA – European Pultrusion Technology Association in cooperation with the American Composites Manufacturers Association (ACMA) invites you to the 17th World Pultrusion Conference which takes place on 29 February – 1 March 2024 in Hamburg, Germany. Visit the most important event in Europe in the market for pultruded fiber reinforced materials This conference takes place every two years and is the meeting point of the European and worldwide Pultrusion Industry. More than 25 international speakers from Finland, Belgium, Germany, France, Spain, The Netherlands, Turkey, UK, USA, Canada and others will present practical presentations about innovative applications, technologies and processes. Equally current market trends and developments are on the agenda. This World Pultrusion Conference takes place again in the week before the JEC World Composites Show (5-7 March 2024, Paris). The presentation language will be English. Please finde here the full program and booking opportunities. We appreciate very much welcoming you in Hamburg! Inquiries should be requested by email: info@pultruders.com
The Program of this Summit consists of a range of 12 high-level lectures by 14 invited speakers only. Topics are composite related innovations in Automotive & Transport, Space & Aerospace, Advanced Materials, and Process Engineering, as well as Challenging Applications in other markets like Architecture, Construction, Sports, Energy, Marine & more.
JEC World in Paris is the only trade show that unites the global composite industry: an indication of the industry’s commitment to an international platform where users can find a full spectrum of processes, new materials, and composite solutions.
Charting the Skies of Tomorrow: The Sustainable Aviation Revolution Welcome to a new era of air travel where innovation meets sustainability. Electric, hybrid-electric and hydrogen-powered aircraft represent a promising path to reach climate neutrality goals, with the aviation industry and governments jointly pushing boundaries to bring disruptive aircraft into service by 2035. From cutting-edge technologies to revamped regulations and greener airports, the pursuit of sustainable aviation requires unparalleled collaboration throughout the whole aviation value chain and ecosystem. Join us at the Clean Aviation Annual Forum from 5 until 6 March 2024, as we navigate towards cleaner skies together.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.
Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.
Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.
Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.
The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.
Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.
To incorporate more environmentally conscious practices into its manufacturing processes, VSC is working with Carbon Conversions to reclaim, recycle and reuse its carbon fiber materials.
As the marine market corrects after the COVID-19 upswing, the emphasis is on decarbonization and sustainability, automation and new forms of mobility offering opportunity for composites.
Novel material to combine Ohoskin’s leather alternative made from orange and cactus byproducts with ReCarbon’s recycled carbon fiber.
The three-year strategic collaboration will help boost the company’s growth, reinforce its commitments to become carbon neutral by 2040 and innovate more circular chemicals and materials.
Oak Ridge National Laboratory's Sustainable Manufacturing Technologies Group helps industrial partners tackle the sustainability challenges presented by fiber-reinforced composite materials.
Eco-friendly carbon fiber slashes carbon footprint by half through renewable energy, a commitment echoed in SGL’s Lavradio biomass plant set to reduce CO2 emissions by 90,000 tons.
In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.
This CW Tech Days event will explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.
During CW Tech Days: Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
Closed mold processes offer many advantages over open molding. This knowledge center details the basics of closed mold methods and the products and tools essential to producing a part correctly.
The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.
CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.
CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.
CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.
Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.
Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
Explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.
This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.
This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.
This collection features recent CW stories that detail a range of tooling technologies, processes and materials.
GKN Aerospace and its partners developed an aircraft demonstrator component made with TeXtreme’s latest Gapped UD material, proving out a dry, infusible tape meant to compare in performance to UD prepreg.
As sectors of the aerospace industry look to adopt composite materials for more programs — and programs with high volume requirements, especially — replacing traditional prepreg layup and autoclave cure with lower cost, faster processing methods like resin infusion is increasingly attractive — that is, if the same quality standards can be achieved.
Demonstrating high infusibility with high performance. This aircraft engine guide vane demonstrator, built by GKN Aerospace and partners, was developed to test TeXtreme Gapped UD, a unidirectional (UD) spread-tow carbon fiber product from Oxeon AB that shows potential for UD prepreg-like properties in an infusible fabric. Photo Credit, all images: TeXtreme
In recent years, a number of materials and equipment suppliers have introduced products and solutions that aim to balance high performance with high volume processability such as in automated resin transfer molding (RTM) systems. One relatively new product is a dry, unidirectional (UD), spread-tow tape called TeXtreme Gapped UD, developed by TeXtreme (Boras, Sweden), a registered trademark of spread-tow carbon fiber material developer Oxeon AB.
As debuted at JEC World 2023 in Paris, France, TeXtreme Gapped UD is being used as part of an ongoing demonstrator project with GKN Aerospace (Solihull, U.K.) targeting the aerospace composites market.
“Spread tow” refers to the practice of spreading a fiber into a thinner, flatter reinforcement. Read The spread of spread tow for more on this process.
Oxeon first introduced its TeXtreme spread-tow carbon fiber fabrics in 2005. For these materials, UD carbon fiber tows are “spread” into a thinner, flatter form, resulting in a lighter material with straighter fibers and greater impact resistance. These tapes can then be used in automated tape laying (ATL) or automated fiber placement (AFP) processes, or to produce woven fabrics or noncrimp fabrics (NCF).
Andreas Martsman, cofounder and VP of marketing and sales at TeXtreme, explains that TeXtreme Gapped UD was developed in response to requests from customers in the aerospace sector who wanted to replace UD prepreg with infusible materials. “We started by experimenting with infusion of our regular spread-tow tapes, but when you spread out the fibers like this, you also close everything up and there’s a very high fiber volume content,” Martsman says. “This is a bit of a drawback when you’re trying to infuse it with resin.”
Gapped UD tape. TeXtreme claims precise control of gap width and frequency within its UD tape product. The company also offers woven fabrics made with gaps for better resin permeability.
TeXtreme’s team went to the drawing board to develop a dry, spread-tow UD tape specifically suited for infusion, but with the high performance that comes from straight, UD fibers. “The answer was creating gaps in the material for resin to infuse into,” Martsman says, “but that was also a challenge. How big do the gaps need to be? How do you keep them uniform and maintained over different surfaces? So, we had to create an architecture that was robust and stable enough to ensure quality and control during infusion and in service.”
He explains that to do this, TeXtreme uses an in-line vision system during manufacture of the tapes for the highest possible control of gap width and frequency. Typical gaps are 0.3 to 0.4 millimeter in width, but TeXtreme can tailor the width and frequency to enable slower or faster permeability as needed.
After a 5-year development process, the resulting TeXtreme Gapped UD product was officially released at JEC World 2023. It is available in a variety of sizes and fiber weights — and as woven fabrics, if desired — and is said to enable easy handling and resin permeability with fiber volume fractions (FVF) of up to 60%.
Martsman adds that the tapes can be customized to fit a customer’s needs, as they are able to be produced from a wide variety of fibers (various grades of carbon fiber, glass fiber or aramids) and resins (epoxies, various thermosets, even thermoplastic resins). “You can also slice the tapes down to narrower widths, maybe with just one gap in the middle, for example, and then use it for AFP layup,” he says.
Since its launch in spring 2022, Martsman reports that TeXtreme has begun selling material to sporting goods and industrial customers, with a few sports applications made with the material already in production.
Working toward commercial applications in the aerospace market, earlier this year TeXtreme debuted the first results of its ongoing demonstrator program with GKN Aerospace incorporating the Gapped UD composite material.
“We have worked with GKN Aerospace for several years on different types of materials and development projects, and when they began looking into new materials for use in RTM [resin transfer molding], we introduced the Gapped UD tape we had been working on,” Martsman says.
Previously, the company had worked with typical infusible materials like dry NCF or dry woven fabrics. However, Fredrik Ohlsson, product development director at TeXtreme, explains that any kind of weft-direction stitching in a dry fabric, even the relatively minimal stitching threads in an NCF fabric, “creates a small kink in the warp direction tow, where it is interrupted by the stitch. In compression, that little deviation from the perfectly straight fiber initiates a point where the structure becomes weaker.” He explains that to account for this weakness, parts made from infused NCF have to be overdesigned, with additional plies and therefore increased thickness and weight to the part. “With our materials, on the other hand, you have absolutely no deviation both in and out of plane, and you can therefore optimize both the material use and weight,” Ohlsson says.
Why not use a UD prepreg? “With a UD prepreg you have the absolute straightness of the filaments and you have the resin there exactly as you want it, but you also have drawbacks with respect to autoclave curing, and logistics such as cold transport and shelf life, which are especially problematic when you’re trying to scale up production,” Ohlsson explains. “So, many companies want to move toward infusion, and we want to aid this process with our material. We’re aiming at prepreg properties with an infusible material. It’s all reflected by the FVF we can reach using our materials. Infusible materials normally have very open structures to allow for infusion of the resin and air evacuation, but this means a relatively low FVF. With our material, we have very precise, designated flow channels for introduction of the resin and to evacuate air for that low void content, but the material is tight enough to also reach an FVF up to 60% for the higher mechanical properties possible with more fiber.”
In collaboration with testing and demo specialist Produktionstekniskt Centrum (PTC, Trollhättan, Sweden) and with financial support from Tillväxtverket (The Swedish Agency for Economic and Regional Growth) and regional council Västra Götalandsregionen, GKN Aerospace and TeXtreme began a demonstrator project at GKN’s Trollhättan, Sweden facility.
An engine guide vane — a curved panel for directing gas, water or air within a turbine — was selected as the demonstrator component, based on a typical customer design from GKN. “It has a complex geometry with double curvatures, and is fairly thick compared to, say, your typical single-ply, flat test panel, which is good for demonstrating infusibility of the material over differing thicknesses and over curves,” Ohlsson explains. “The load case is also very complex, so performance, especially in compression, is critical for a part like this.”
The part was designed as a multi-ply, rectangular structure with varying thickness along the part, up to 10 millimeters thick in the center section. For this project, an intermediate modulus carbon fiber and Hexcel (Stamford, Conn., U.S.) RTM6 epoxy were used. “We wanted to start with materials most similar to what GKN had been using previously, to give an apples-to-apples comparison,” Ohlsson says.
Guided layup. For the GKN guide vane demonstrator, multiple plies of TeXtreme Gapped UD were laid up at varying orientations for the desired thickness and curvature.
To manufacture the demonstrator part, the plies were cut via a Zünd (Altstätten, Switzerland) automated cutting system. The goal was to simulate use of the material in a high-volume, automation-driven production process, explains Guillaume Moreau, project manager for product development at TeXtreme, and to show that the material handles well with GKN’s automated equipment. “Unlike a typical dry fabric, there is no fraying at the edges when it’s cut,” he adds.
Into the press. The GKN demonstrator guide vane is infused with resin under pressure and heat.
Guided by a laser projector, technicians then laid up the plies onto a mold and debulked under a vacuum bag to create the preform. The preform was then transferred to a closed mold, and loaded into a Langzauner (Lambrechton, Austria) compression press, where resin was injected under heat and pressure to complete the RTM process.
The first demonstrator parts were completed in late 2022 and displayed in April 2023 at JEC World. Ohlsson explains that after this initial success, the teams are continuing to work on adjusting process parameters and material characteristics for an optimized final product. Next, the teams also plan to evaluate additional materials, such as alternative fiber configurations and tougher epoxies, with the same part, aiming for mechanical testing to compare the properties of various Gapped UD guide vanes with each other and with traditional NCF composite versions.
Ultimately, the goal is to optimize the materials and process for adoption by GKN Aerospace for use on a production part, and for TeXtreme, the learnings gained from this first program will help guide its development of Gapped UD materials for other customers and end markets. “There’s a lot of work to do, but there’s a lot of potential for a UD infused fabric, both in aerospace and in markets like marine, wind and more,” Ohlsson says.
Continuing developments. The original guide vane demonstrators were showcased at JEC World 2023, followed by continued work throughout this year by the TeXtreme and GKN Aerospace teams to optimize the materials and process.
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