#INSIDEMANUFACTURING

Aerospace

Overmolded hybrid parts open new composites markets

A process that combines continuous carbon fiber-reinforced PAEK with chopped fiber/PEEK overmolding is making inroads in the aerospace market. Parts that previously could not be produced cost-effectively from composites can now be made at less cost than their metal counterparts.

Fabrics/Preforms

Automated joining of hybrid metal-thermoplastic composite structures

The FlexHyJoin production cell combines surface structuring, induction and laser joining and NDT for automotive mass production.

Filament Winding

Filament wound utility poles offer design flexibility

In Turkey, a utility pole manufacturer combines filament winding, automation, glass and carbon fiber composites to expand its product line.

Automotive

Composites design and process engineering form next-generation truck body panels

Glass fiber/foam preform technology is key to the all-composite refrigerated truck body panels.

Fabrics/Preforms

Spar forming simplified

Adapting its Automated Stiffener Forming (ASF) technology to build spars directly in female molds, Northrop Grumman Innovation Systems anticipates dramatic drops in cycle time and manufacturing cost.

Prepregs

Thermoplastic overmolded thermosets, 2-minute cycle, one cell

Adhesive-free, functionalized hybrid composites enabled by industry-first, integrated molding cell.

Fabrics/Preforms

Composite radar masts assembled for megayachts

Vabo Composites designs, builds and assembles 10m-tall composite radar masts, improving weight, stability and performance for modern megayachts.

Aerospace

Leveraging composites for space tourism

Virgin Galactic’s WhiteKnightTwo will carry its SpaceShipTwo to launch position, then rocket passengers to suborbital space for a heavenly view of Earth.

Thermoplastics

Thermoplastic composites: Scenic view

First use of thermoplastic composite guide rails to replace aluminum brings many benefits to fixed-glass, roller-blind sunroof modules.

Marine

The International 14: High-tech but still accessible

Naval architect Paul Bieker and Henderson Boat Co. team take this venerable marine racing class to a more affordable performance/cost combination.

Aerospace

Infused wing sheds light on aerocomposites future

In the Irkut MS-21 infused and co-cured wings, the aerocomposites industry gets a glimpse of how out-of-autoclave technologies might be applied to primary aircraft structures.

Infusion

A complete paradigm shift in aircraft construction

With its new Torreswing automated system for mold-free, fastener-free composite fuselage and wing construction, MTorres aims to revolutionize aerostructure.

RTM

Rear wall reboot: One-stop, tow to tape to CFRP part

Audi and Voith Composites iterate the CFRP rear wall from R8 sports car to A8 luxury sedan via an automated production line able to output hundreds of parts per day.

Carbon Fibers

The future of CFRP aerostructures assembly

Metrology, robotics and inline inspection cut cost, reduce shimming and enable future automated production of three vertical tail planes per day.

Additive Manufacturing

Additive manufacturing: Big and going commercial

A demonstration of large-format 3D printing delivers parts for an excavator cab, from CAD data to ready for assembly, in only five hours.

Carbon Fibers

Higher performance in precast concrete with CFRP

C-GRID trusses in CarbonCast wall system cut construction time, cost, complexity and carbon footprint in energy-efficient urban student housing.

Epoxies

Fiber-metal laminates in the spotlight

Interest in FMLs is growing again as aeroengineers search for lightweight solutions adaptable to new narrowbody commercial aircraft.

Thermoplastics

Thermoplastic composite panels deliver affordable housing solutions

Modular construction concept takes composite housing another step forward, offering a wide range of comparably priced housing solutions to builders of all types.