Composites Processes

Processes in composites manufacturing encompass a diverse array of techniques employed to fabricate composite materials. These processes include methods like hand layup, where layers of resin and reinforcement materials are manually placed, and vacuum infusion, where a vacuum draws resin into a preform. Other techniques like compression molding, filament winding, and automated methods such as 3D printing are utilized to create intricate and specialized composite structures. Each process offers unique advantages in terms of precision, scalability, and efficiency, catering to diverse industry needs. As technology advances, newer methods are emerging, promising faster production cycles, reduced waste, and increased customization, driving the evolution of composite manufacturing towards more sophisticated and versatile methodologies.

Plastic injection to composite overmolding: Evolving mold design for lightweight manufacturing
Automotive

Plastic injection to composite overmolding: Evolving mold design for lightweight manufacturing

Hybrid molding is increasing for faster, high-volume production of more integrated parts, but success requires process knowledge which includes new mold developments as processes converge.      

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Greenerd Compression Molding
Hydraulic & Pneumatic Presses

Latest Processes Articles

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Filament Winding

Cygnet Multi-Axis Winder is adopted for TCI oil and gas pipeline work

Housed within TCI’s purpose-designed modified shoring box, the winder will support more efficient composite pipeline upgrades while also enabling the company to adjust to new safety and regulatory measures.

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Pultrusion

Guill expands expertise to pultrusion dies for industries using FRP

The Guill Extrusion Division enters the pultrusion market with a line of custom-engineered pultrusion tooling solutions.

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RTM

CAELESTIS project presents final results, composite OGV demonstrator

Aimen, with consortium partners, led the validation of a full-scale outlet engine vane (OGV) aircraft component with ~35% less weight and 80% manufacturing defect reduction.

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Royal3D adapts DAC system inlet production to 3D printing process

Recycled glass fiber-reinforced PET-G and 3D printing expertise minimizes waste, reduces weight and lead times for Carbyon Go’s direct air capture (DAC) systems.

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University of Illinois Urbana-Champaign innovates space tech with morphing composite structures

Energy-efficient frontal polymerization process method eliminates the need of oven or autoclave to transform 2D continuous fiber printed structures into 3D curved designs.

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Sustainability

AFP with very-thin plies of carbon fiber/LMPAEK prepreg for sustainable helicopter structures

DLR, Airbus Helicopters, Fraunhofer and TU Dresden work in the NATURE project for environmentally friendly aviation

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Knowledge Centers

CompositesWorld Collections
CompositesWorld Collections

CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.

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Composites in Advanced Air Mobility
Composites in Advanced Air Mobility

Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.

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Epoxy, Adhesive, Bonding
Industrial CNC Routers
ELFOAM rigid foam products
Toray Advanced Composites hi-temperature materials
Airtech 3D printing Solutions

Latest Processes News And Updates

Aether launches RapidPrint 3D printing polymer

RapidPrint, with its first commercial fiber-reinforced filament formulation, enables up to 5X faster print speeds with no compromise on strength.

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Infusion

EuReComp team highlights ROCCA Cabin demonstrator for EOL composites

The ROCCA Cabin serves as a proof of concept for how large composite parts, often destined for disposal, can re-enter the value chain as architectural elements with both functional and aesthetic value.

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Trends

Tidal turbine project builds double-sided, 3D printed composite tool for blade development

Collaborative project with Thermwood successfully prints 2-meter-long tidal turbine blade mold in days versus months, with the now-manufactured hybrid blade in testing and extended trials.

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KraussMaffei presents automotive-focused BrightStar electric press

Fully electric press offers precise temperature control and fast mold change for press lamination, edge folding applications and even ultrasonic welding of TPC.

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Space

Orbex makes part setup 900% faster for key composite parts ahead of inaugural rocket launch

The introduction of MSP metrology products have ensured right-first-time machining for Orbex as it ramps up production of its carbon fiber Payload Avionic Module.

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Adhesives

Metyx Metybond self-adhesive reinforcement achieves clean, efficient composite layup

Directly integrated adhesive on carbon, glass or hybrid multiaxial fabrics enables clean repositioning, uniform adhesive distribution and improved edge stability.

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Composites One - distributor
PTXPO 26
Encapsulated Sample Rheometer (ESR)
NewStar Adhseives - The Glue Pros
Composites One - distributor

Featured Posts

Wind/Energy

Modular composites enable larger tanks for wastewater and biogas reactors

Toro Equipment uses biaxial fabrics, carbon fiber and Flex Molding for corrosion-resistant tanks that compete with steel, concrete and speed global installations.

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Application

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.

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Automation

Modular, hybrid machining centers with intelligence for complex composites

Machine Tool Camp’s purpose-built systems combine CNC machine centers and robots with specialized machining tools, clamping and configuration, automating steps before and after, including data integration, to empower manufacturers for the future.

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Carbon Fibers

KraussMaffei makes LFAM both a product line and an internal benefit

Plastics processing equipment supplier now offers two LFAM machines to customers and to complement its own production uses, enabling a variety of polymer to fiber-filled application options.

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Improving hail impact resistance of discontinuous thermoplastic composite parts

Greene Tweed examines failure behavior, identifying key factors for improvement and demonstrating sufficient design for complex-shaped aeroengine components.

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3D 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.

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Airtech
PTXPO 26