Composite Applications
3D printed CFRP forms speed construction of concrete nuclear reactor bioshield
In its first demonstration, Kairos Power and Oak Ridge National Laboratory tested the potential of AM and composites to enable fast, repeatable manufacturing for energy construction.
Hannah Mason
Technical Editor, CompositesWorld
80% Bio-Based Epoxy Moves Ski Manufacturing Toward Zero-Impact Goals
Sicomin’s GreenPoxy80 increases bio-based material by 60% over previous epoxies, developed for use in a ZAG touring ski that aims to push the use of sustainable materials to new levels.
Read MoreDemonstrating CFRP for high-precision, high-motion watch components
Japan-based watchmaker explains R&D results of using carbon fiber composites to replace metal in structural movement parts to increase stiffness while not sacrificing mobility or stability.
Read MorePolestar 5 takes aesthetics and circularity approach to biocomposite seatback design
The 2026 Polestar 5 expands the company’s use of sustainable materials design in the interior, including flax fiber/thermoplastic seatbacks that save 7 kilograms of weight and reduce overall plastics use.
Read MoreBiocomposites demonstrated as drop-in material option for truck interiors
Ongoing trials from Volvo Trucks with Forvia Group and subsidiary Materi’Act aim to prove out and commercialize biocomposites made from waste oyster shells for future long-haul truck platforms.
Read More3D Fiber Tethering for rapid fabrication of continuous fiber composites
CarbonForm’s 3DFit technology combines robotic, continuous fiber 3D printing and winding to produce small, high-strength, complex parts — like drone frames — in as little as 10 minutes.
Read MoreScaling up, optimizing the flax fiber composite camper
Greenlander’s Sherpa RV cab, which is largely constructed from flax fiber/bio-epoxy sandwich panels, nears commercial production readiness and next-generation scale-up.
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Scaling up thermoplastic composites recycling
Thermoplastic composites are always said to be “recyclable.” Netherlands-based recycler Spiral RTC discusses the process, challenges, applications and opportunities to building a real recycling ecosystem.
Hannah Mason
Technical Editor, CompositesWorld
Infused sandwich window frame components help double-decker buses meet weight targets
Prototype GFRP parts were evaluated by Spanish bus manufacturer Carrocerías Ayats as an initial move toward lighter, more efficient, more automated parts and processes.
Read MoreRecycled carbon fiber composite panels power 40% lighter, durable semi-rigid solar panels
Designed for auxiliary power use while traveling via boat or RV, Italian startup Levante’s custom flexible or standardized semi-rigid solar panels combine the benefits of ReCarbon’s rCF and thermoplastics.
Read MoreComposites housing improves organ transport to save lives
Vabo Composites collaborates on novel design, supplies lighter, higher volume production housing.
Read MoreModular, curved racing track design enabled by composites and adaptive molds
X-Track worked with bespline to develop an easy-to-install, reusable, customizable composite sandwich panel alternative to dirt BMX and motorcross tracks.
Read MoreLarge-format AM speeds plug production for manufacture of composite boat molds
Hungarian manufacturer Rapid Prototyping transitioned its conventional foam milling process to 3D printing to produce faster, higher quality, recyclable foam plugs and composite boat molds.
Read MoreOptimized CFRP gantry beam enhances Ultimate cutting machines
CompoTech, Kongsberg PCS collaboration integrates foam-cored design, automated placement of pitch and PAN fibers to achieve award-winning increase in speed and precision.
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Spanish startup to ramp up production of “recyclable” EV prototype
Liux’s BIG electric vehicle features multiple structural components manufactured via RTM from flax fabric and a thermoset resin said to enable the entire component to be recycled and reused again.
Hannah Mason
Technical Editor, CompositesWorld
Composite materials, design enable challenging Corvette exterior components
General Motors and partners Premix-Hadlock and Albar cite creative engineering and a move toward pigmented sheet molding compound (SMC) to produce cosmetic components that met strict thermal requirements.
Read MoreCFRP planing head: 50% less mass, 1.5 times faster rotation
Novel, modular design minimizes weight for high-precision cutting tools with faster production speeds.
Read MoreCarbon fiber satellite arm reduces weight, simplifies assembly onto naval vessels
Satcom developer EM Solutions partnered with ACS Australia to replace an aluminum arm design with a 65% lighter, one-piece, corrosion-resistant carbon fiber/epoxy alternative.
Read MoreOptimized rib-reinforced hollow composites via printed molds
Addyx topology optimization and water-soluble mandrel enables simultaneous rib and skin layup for one-shot, high-strength, lightweight structures.
Read MorePull-wound carbon fiber poles enable lightweight, compact, rigid emergency stretcher
Based on military feedback, Epsilon Composite developed an optimized, foldable stretcher that combines telescopic pull-wound carbon fiber tubes.
Read MoreComposite wrap system combats corrosion in industrial tank repair
A fiberglass and carbon fiber composite wrap system enabled an Australian nickel mine to quickly repair a stainless steel ammonium sulphate feed tank and protect against future corrosion.
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High-tension, vertical filament winding enables affordable flywheel energy storage system
French startup Energiestro’s prototype solar energy flywheel-based storage system aims to reduce costs with glass fiber composites and prestressed concrete.
Hannah Mason
Technical Editor, CompositesWorld
Designing an infused, two-piece composite baseball bat
With its Icon BBCOR bat, Rawlings leveraged its experience in braided fabrics and RTM to create an optimized, higher-performance two-piece design.
Read MoreDesigning and manufacturing turbine test nacelles
Michigan-based Ground Test Solutions (GTS) shares the design and manufacturing processes involved in building composite nacelle components used in testing jet and helicopter engines.
Read MoreRepurposing wind blades as functional community art pieces
Ohio-based Canvus Inc. upcycles fiberglass wind blades, car tires and post-consumer plastics to create outdoor furniture that amplifies sustainability messages in community spaces.
Read MoreMulti-material, self-sensing, 3D-printed scoliosis braces
Startup Fited and Brightlands Materials Center have developed a lighter weight, thinner CFRP corrective brace, including pressure sensors made from continuous carbon fibers.
Read MoreMold 3D printing helps automate composite bathtub, shower production
As part of its efforts to automate as much of its production process as it can, Lyons Industries acquired a Massivit 10000 additive manufacturing system to quickly produce high-performance molds and support fixtures.
Read MorePull-wound fiberglass composite 5G utility poles enable easier, faster installation
EasyStreet Systems is working with Exel Composites to develop and certify pull-wound fiberglass utility poles aimed at durable, lightweight poles for 5G small cell systems.
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