#WORKINPROGRESS

Aerospace

Tow steering, Part 3: The birth of tow shearing

In-plane shearing of tows, versus in-plane bending of tows, hopes to take automated fiber placement directionality to new levels. 

Design/Simulation

Thermoplastic tapes reinforced with textile-based PAN carbon fiber

IACMI project trials inline production of thermoplastic tapes reinforced with textile-based PAN carbon fiber. 

Molds/Tools

Invar, wire additive manufacturing expand aerocomposite tooling options

Invar facesheets and backing structures are candidates for large-format 3D printing to more quickly and efficiently produce aerostructures tooling.

Carbon Fibers

Composites design helps nano-sized lunar rover hit big milestones

Developed by Carnegie Mellon University, the ultralight, composites-intensive Iris nano-rover will make its lunar debut later this year.

Carbon Fibers

Flexible carbon fiber plates enable high-performance footwear

Carbitex’s flexible carbon fiber/thermoplastic composite plates use creative engineering to eliminate design compromises in athletic footwear.

Automotive

Bespoke process produces composite brake pedal every minute

Three composite materials are used to create structural composite member that meets demanding mechanical requirements.

Carbon Fibers

Hybrid, large-format additive tooling: Lighter, faster, less costly molds for big parts

Additively manufactured cores, CFRP face skins produce large tools for prototype, low-volume aerostructure parts.

Prepregs

Leveraging towpreg to reduce the cost of CMC

High-denier, spread-tow Nextel 610 fiber and novel alumina matrix enable AFP production of Ox-Ox ceramic matrix composites.

Nanomaterials

Graphene 101: Forms, properties and applications

Graphene-enhanced composites find new applications across end markets as the supply chain continues to mature. 

Epoxies

Vitrimers: The reprocessable thermoset

Vitrimers are not classic thermosets and they are not classic thermoplastics, but they behave like both and as such offer the best of both worlds. CW catches up with Mallinda for an explanation.

Defense

Data security in composites manufacturing

The U.S. Department of Defense is imposing new, strict rules on companies that supply composite parts and structures in a defense contract supply chain. Understanding and following those rules will not be trivial.

Composites fill the gaps in museum dinosaur skeletons

Ontario-based Research Casting International uses composites to build lightweight, durable dinosaur castings for museums around the world.

Carbon Fibers

The industrialization of thermoplastic epoxy

Fast-processing composites that are strong yet tough, thermoformable, reformable, recyclable and even FST-compliant save cost in aircraft and rail equipment.

Carbon Fibers

Narrow UD tapes to bridge the ATL-AFP gap

Automated tape laying and automated fiber placement are similar, but not the same. Can narrow tapes provide a middle ground with advantages of both processes for next-gen aircraft?

Thermoplastics

Composites speed concrete facade fabrication

The 45-story One South First building, on the 11-acre Domino Park campus in Brooklyn, N.Y., features a geometrically complex concrete facade made, in part, with composite molds fabricated using large-format additive manufacturing.

Epoxies

Revolutionizing the composites cost paradigm, Part 2: Forming

Boeing-led parts trials explore infusion, compression molding and thermoplastics, offering lessons and supply chain options to better compete with aluminum.

Aerospace

Curved pultrusions enter production

Corvette CFRP rear bumper beam is the auto industry’s first use of new technology.

Carbon Fibers

The evolution of composites in NASCAR

The growing role of carbon fiber in stock car racing.

Aerospace

Revolutionizing the composites cost paradigm, Part 1: Feedstock

Highly-aligned, short-fiber Tailorable Universal Feedstock for Forming achieves aerospace properties, metal-like formability in zero-waste, fiber-to-parts pilot plant.

Consumer

Greener camping: Sonic X breaks barriers

Prototype travel trailer generates excitement, leads to new commercial models.

Aerospace

Automation options arise for labor-intensive composites

Typically labor-intensive fabrication processes have more automation options as new technology works in concert with operators to improve efficiency.

Consumer

CFRP preform technology is fast, flexible, efficient

Porsche racecar is first to sport part-via-preform technology.

Carbon Fibers

One-piece, one-cure, infused carbon fiber wheel is ready to roll

ESE Carbon Co.’s new carbon fiber wheel uses tailored fiber placement and custom presses to minimize waste and improve scalability.

Injection/Overmolding

Overmolding on the cheap

Innovative injection/compression composites overmolding approach combines smaller injection molded inserts with compression molded parts.

View All #workinprogress Articles