Agenda
Wednesday, June 24, 2026
11:00 AM – 2:00 PM
All times U.S. ET
Welcome
Scott Francis, CompositesWorld, Editor-in-Chief
Quiet, Lightweight, Scalable – High-Rate Manufacturing of Next-Generation Thermoplastic Composite Drone Rotor Blades
11:00 AM – 11:30 AM
Presenter: Lexington Peterson and Eva Kobler, ENGEL North America
Abstract: Thermoplastic composites are enabling scalable production of lightweight rotor blades for drone and Urban Air Mobility applications. ENGEL demonstrates how one-shot tape-sandwich injection moulding combines continuous fibre-reinforced thermoplastic tapes with an injection-moulded thermoplastic core in a single, fully automated step.
This integrated process achieves cycle times below 45 seconds and moulds functional aeroacoustic features—such as serrated trailing edges and modified leading edges—directly into the component. The result: high-performance, low-noise rotor blades produced with automotive-level productivity, high reproducibility, and an improved sustainability profile versus conventional composites.
The timing is critical. The global UAV/drone market is projected to grow from $26.1B in 2025 to $40.6B by 2030 (9.2% CAGR) [1], with the U.S. market rising from $10.8B to $15.8B over the same period (8.0% CAGR) [2,3]. With manufacturing still concentrated in Asia and demand accelerating across defense, inspection, energy, logistics, and advanced mobility, North American producers need scalable, repeatable methods for lightweight UAS components.
ENGEL will connect material selection, process engineering, automation, and industrial scalability to show how advanced thermoplastic composite processing reduces cost, cycle time, and CO₂ footprint while improving reproducibility compared to benchmark thermoset processes.
From Joining the World’s Largest Thermoplastic Fuselage to Rotor Blades and Beyond: Continuous Laser In-Situ Layup With CONTIjoin
11:30 AM – 12:00 PM
Presenter: Eric Pohl, Fraunhofer IPT
Abstract: High performance thermoplastic composites have evolved from an emerging material class into a mature enabling technology for highly demanding industries such as aerospace, energy, and automotive. Despite their growing adoption, manufacturing remains challenging, particularly with respect to high production rates, reproducible quality assurance and reliable high strength bonding. CONTIjoin addresses these challenges by combining a CO₂ laser based continuous layup technology for homogeneous matrix and fiber heating with closed loop, online process control. This approach enables the one shot layup of multi layer laminates with widths of 500 mm and beyond. This presentation introduces the underlying process principles and highlights successful applications, ongoing research activities and future potential.
An Injection Overmolding Simulation Framework to Enable High-Rate, High-Quality Thermoplastic Composite Parts Production
12:00 PM -12:30 PM
Presenter: Dr. Francesco Rondina, Thermoplastic Composites Research Center (TPRC)
Abstract: High-rate manufacturing of lightweight aerospace structures is driving demand for thermoplastic composites (TPCs). At TPRC, we develop best practices and physics-based simulation tools for TPC processing, assembly, and performance.
One key technology is TPC overmolding, which combines laminate stamp-forming with injection molding of reinforced polymers to produce complex, structurally efficient components. However, achieving consistent quality is challenging due to defects such as wrinkles, warpage, and poor interface adhesion.
This talk addresses the underlying mechanisms governing part quality and presents a numerical framework for analyzing overmolded parts, validated on a demonstrator. Using advanced material modelling and data transfer between commercial FE software, we evaluate process-induced defects and structural performance. The results demonstrate that such a simulation framework is a key enabler for industrializing overmolded TPC parts.
Break — 12:30 PM – 1:00 PM
Automated Equipment Solutions for Welded Assemblies in Thermoplastic Composites
1:00 PM – 1:30 PM
Presenters: Pierre Rouch, KVE and Eric Jeannin, Pinette PEI
Abstract: Thermoplastic composites hold the promise for lighter weight, lower cost and faster, higher-rate aerostructures production. Welding is a key enabling technology to make use of the unique properties of thermoplastic composites (TPC) most effectively. Currently the only qualified process for flightworthy welded carbon fiber-reinforced thermoplastics, KVE's patented induction welding process has been implemented for assembly of TPC structures on the Gulfstream G650/700/800 and Airbus A220. In 2025, KVE and Pinette PEI signed a partnership agreement to supply automated welding equipment, sharing a vision to advance high-rate, sustainable manufacturing of structural TPC aerospace components. This collaboration will offer integrated solutions for TPC stamp forming and part assembly via induction welding, opening new opportunities to increase part sizes, reduce weight, improve cycle times, optimize recyclability and cut productions costs. This presentation will discuss these integrated KVE and Pinette PEI equipment solutions and how they can benefit companies in the production of welded assemblies.
Thermoplastic Composite Solutions for Aerospace Structures
1:30 PM – 2:00 PM
Presenters: David Leach and Wade Bowles, Thermoplastic Composite Solutions
Abstract: Thermoplastic composites (TPCs) are now well established in small-scale, secondary structure applications in aerospace. Many new programs are opening in the near future including air mobility (AAM), unmanned vehicles and the next generation single aisle (NGSA). These all require high-rate manufacturing and low recurring cost of parts and assemblies and TPCs are the ideal candidates. While TPCs have been very successful in the current applications there are some challenges to overcome for adoption in larger and primary structures. There is still confusion in optimizing material form, fabrication methods, tooling and design for manufacturing, and how this relates to total cost of ownership. Inspection and finishing are areas where the current approaches with thermoset composites are not relevant or effective and alternate approaches are needed. Welded assembly of TPCs is a significant opportunity for cost reduction and a generalized, process-oriented approach is needed for widespread implementation. Publicly available design databases are becoming available but these must be related to the fabrication methods being used. This presentation will review how materials, processes, design, assembly and inspection can be holistically addressed to optimize total cost of ownership and ensure the benefits of TPCs are realized in large-scale and high-rate aerospace structures.
