MTorres, Airbus enable next-gen composites via thin-ply AFP

Thin-ply or spread tow tapes are very low-weight, low-thickness composite prepregs that are gaining traction in aerospace for their potential to cut weight and increase toughness, crack resistance and impact resistance in high-performance structures. However, weighing as little as 15 grams/square meter with a thickness of only 0.02 millimeter, these materials present serious technical challenges when used in automated fiber placement (AFP) processes. For example, their low stiffness makes them prone to twisting, wrinkling and misalignment during layup, especially when processed at high speeds or over curved surfaces.

MTorres (Torres de Elorz, Navarra, Spain) has addressed these issues by redesigning its AFP heads to ensure stable and precise handling of thin plies. From the spool to the compaction roller, every stage of the material path is now optimized to maintain tow integrity and placement accuracy. Process temperature control is also a critical factor and helps stabilize the material behavior. These adaptations are essential to achieve defect-free lamination with materials that are highly sensitive to tension variations, trajectory curvature and thermal fluctuations.

CAM software for complex geometries

In parallel, MTorres has enhanced its proprietary TorFiber CAM software (supported and integrated in Dassault Systemes’ CATIA) to support closed geometries and self-intersecting paths. These capabilities are critical for components like pressure vessels, where fiber trajectories often loop and cross over themselves. The software now allows engineers to generate complex layup strategies with precise control over tow paths, enabling better material use and structural optimization.

Another key advancement is the ability to generate these trajectories directly, automatically and also with greater agility. This streamlines the programming process and reduces the time required to prepare layups for complex parts, making AFP more scalable for industrial applications.

New level of flexibility versus winding

While traditional methods like filament winding have proven effective for rotationally symmetric parts, AFP introduces a new level of flexibility and control that expands the design and performance possibilities. Its capabilities are well suited for manufacturing components with closed or complex geometries, such as pressure vessels and hydrogen storage tanks:

• Freedom in fiber orientation, including 0º and 90º angles, which are difficult to achieve with winding techniques.
• Tow-by-tow control, enabling selective addition or cutting of individual tows to create localized reinforcements or structural patches.
• Multi-tow capability with independent management, enabling precise control over each tow’s feed and cut, optimizing both productivity and material use.
• Layer-by-layer customization, supporting variable thickness and tailored mechanical properties across the part.
• Steering without slippage, ensuring accurate fiber alignment even on curved or non-developable surfaces, which helps maintain structural integrity and surface quality.

These features make AFP a powerful tool for applications that demand high precision, structural efficiency and adaptability in design — especially as the industry moves toward more advanced composite solutions.

Platform for future innovation

MTorres worked with Airbus (Toulouse, France) to validate these developments in a real-world setting, successfully laminating two tank halves using thin-ply tapes and advanced AFP strategies. Demonstrating its ability to adapt technology to emerging industry needs, MTorres’ developments are paving the way for broader adoption of AFP in hydrogen storage and other high-performance composite applications.