Thermoplastic composite structure replaces metals on safety-critical brake pedals

First all-composite brake pedals developed by Boge Rubber & Plastics Group are lighter, stiffer, stronger and offer improved driving haptics.


Modernizing the mechanical rotor sail

Composites are key for Norsepower’s award-winning redesign of a century-old rotor sail for reducing carbon emissions on passenger and cargo ships.


The Alpha launch vehicle: Designing performance in, cost out

Firefly Aerospace’s Alpha 2.0 launch vehicle, designed to deliver satellites into low Earth orbit, gets a composites makeover in pursuit of larger payload capacity and more cost-effective performance.


EV battery enclosure inspires material, process innovations

High unit volume and low weight requirements for electric bus battery enclosures fueled development of TRB Lightweight Structures’ specialized epoxy system and automated composites production line.


Reimagining wind blade design

Wind turbine blade architecture is so well established that it’s difficult to imagine there might be a better alternative. ACT Blade’s skeleton-based design is a step in that direction.

Glass Fibers

Composites-intensive masterwork: 2020 Corvette, Part 2

Innovative composite materials trim mass, costs and noise on the high-volume mid-engine sports car.


Composites-intensive masterwork: 2020 Corvette, Part 1

Eighth-generation vehicle sports more composites, and features parts produced using unique materials and processes.

Filament Winding

Composite output shaft ready for automotive proving ground

Unlike automotive driveshafts, automotive output shafts cannot leverage shaft length as a factor when making the case for composites. Instead, other beneficial features have made a composite output shaft able to compete with metal shafts, especially in electric vehicles.


Tooling, precision enable composites in satellite subsystems

Tight tolerances drive design and engineering of large-format composite component and dishes to create unique satellite structures.

Filament Winding

Composite T-boom accelerates industrial automation

A manufacturing method that integrates filament winding with axil winding of 0-degree fibers opens new design options in industrial automated equipment.


Corrosion-resistant composite piping over the long haul

Three decades of lessons learned using corrosion-resistant glass fiber-reinforced composites in piping at SABIC’s Netherlands chlorine production plant.


Composites enable novel flying speedboat

Candela Boats’ Seven speedboat combines all-electric propulsion with precision foiling in a design made possible by creative composites engineering.

Glass Fibers

Demand for longer sprayer boom arms enables composites in agricultural equipment

Shift from steel to carbon fiber/glass fiber composites extends sprayer boom arm width, lowers weight, reduces cost and enhances productivity.


Recycled carbon fiber on the rails

Aiming to increase the cost-weight viability of carbon fiber-reinforced composite structural components in railway vehicles, a prototype rail bogie prominently features recycled carbon fiber.

Carbon Fibers

3D filament winding enables vehicle seating concept

Multi-company collaboration uses xFK in 3D and additive manufacturing to develop an ultra-lightweight seat for hypercars and future mobility platforms.

Carbon Fibers

Tuning the running shoe

Continuous fiber-reinforced thermoplastic composites enable high-performance athletic shoe components.


Composite catamaran hits high watermarks

Inspired by design elements found in racing catamarans and employing composite structures in innovative ways, Compmillennia has rolled out a fishing/excursion cat that uniquely combines high speed, great fuel economy and a smooth ride.

Carbon Fibers

Consumer electronics: hybrid composite covers

Study demonstrates feasibility of thermoplastic composites, high-speed production process.


Thermoplastic primary aerostructures take another step forward

Employing new manufacturing techniques and the design freedom they create, GKN Fokker has joined forces with Gulfstream to assess thermoplastic composites for primary aircraft structures.


Chopped carbon fiber, polyamide and innovation redefine the modern pickup truck bed

CarbonPro, the first thermoplastic composite box, boosts damage resistance, reduces mass 28 kg, scales to high production volumes.


Autocomposites: Impact shield protects 12-volt battery in severe crash

GMT protection buys time for offboarding emergency services call before battery shorts out.


Skeleton design enables more competitive composite autostructures

New approach combines thermoplastic pultrusions with injection overmolding in a two-step, 75-second process.

Additive Manufacturing

Micro transportation: BMW personal mover concept

Recycled composites, additive manufacturing and 3D printing enhance form, function of fun-to-drive personal transport.

Carbon Fibers

Proving performance in EV powertrains

Simulation-driven development replaces aluminum with thermoplastic composites in gearbox housing.

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