Work In Progress Column
Single Endless Roving Placement Saves Up to 70% CFRP Weight, Enables Closed-Loop Fiber Recovery
Holy Technologies’ robotic Infinite Fiber Placement deposits carbon fiber as one continuous, uncut tow using six-axis robotics and RTM, enabling significant lightweighting and full-length fiber recovery via mild acetic acid solvolysis.
Stewart Mitchell
Technical Writer
GKN Aerospace's ASPIRE program targets next-gen composite wing manufacturing technologies
The three-year, £12 million ASPIRE consortium brings together rapid tow shearing, tailored fiber placement, aligned recycled discontinuous carbon fiber and self-heated tool curing to prove lighter, high-rate composite wings for the next-generation single-aisle aircraft.
Read MoreThe Future of CFRP Pressure Vessels: Larger Sizes, Lightweighting, Data Centers and Space
Hexagon Composites discusses the largest Titan 510 Mobile Pipeline, use of thermoplastic composites for lightweighting modules, towpreg, Chinese carbon fiber and growth from data centers and space.
Read MoreDialing in composites performance via dynamic digital twins
Sport Dynamics Lab uses Flexdynamics testing, digital models and AI tools to compare designs, materials and systems, enabling optimization with potential for propellers, drones and vibrational structures.
Read MoreIndustrial ultrasonic NDT adaptation permits accessible composite bicycle inspection
Cycle Inspect's ASNT-aligned certification program employs affordable twin-crystal ultrasonic testing equipment and standardized inspection methods to detect damage in composite bicycle components.
Read MoreKaneka BMI material attains >25% lead time, >20% tool cost reductions in Janicki evaluations
Process evaluations find that novel BMI polymer chemistry addresses longstanding manufacturing challenges of BMI tooling prepregs while maintaining high temperature performance and durability.
Read MoreSentherm conductive polymers match aluminum thermal performance, cut weight
Tailored filler networks, anisotropic material design and manufacturing process control achieve hybrid polymers for EVs, batteries and other automotive-related electronics with 95% of aluminum’s thermal performance and 25-45% reduced component weight.
Read More
LED technology improves the tensile strength of Z-axis interlayers in composite 3D printing by 30%
LEAM Technologies’ layer interface remelt technology enhances composite printed parts, sandwich structures and complex frameworks, offering improved design flexibility and structural integrity.
Stewart Mitchell
Technical Writer
Robotic computed laminography brings X-ray CT resolution to large composite structures
Omni NDE collaborative robots, X-ray end effectors and Voxray’s reconstruction approach enables 5-micron inspection of aerospace parts without size constraints.
Read MoreCutting engine weight via thermoplastic composite guide vanes
Greene Tweed replaces metal stator vanes with its DLF material co-molded with a metal leading edge that meets performance, cost and high-rate production targets while cutting 4 kg per engine.
Read MoreMultilayer TPC achieves electrically conductive, gas-impermeable fuel cells at 100 microns
Carbon ID hydrogen fuel cell bipolar plates for aerospace combine contradictory properties for a corrosion-free alternative designed for 1 million m²/year production.
Read MoreKAI demonstrates thermoplastic and infused structures for future airframes
Korea Aerospace Industries advances its expertise through a welded TPC fuselage section and resin-infused wing skin module and torsion box demonstrators.
Read MoreComposite helicopter "monolage" modernizes private rotorcraft production
The Hill Helicopters’ fully composite structure HX50 rotorcraft uses oven consolidation and splice joining for a cost-effective, lightweight fuselage.
Read MoreCustom FR epoxy, hybrid glass/carbon fiber composites enable massive mosque ceiling expansion
Premier Composite Technologies delivered more than 25,000 FRP sandwich panels to massive Great Mosque of Mecca expansion, meeting weight, fire and 10,000 units/month goals.
Read More
Advancing the Thermoplastic Composite Battery Enclosure into Production
Having achieved its first few commercial series successes, Kautex Textron explains the design process for its Pentatonic battery enclosure platform, which comprise glass fiber/PP or PA6 and injection overmolding a compression molded laminate.
Hannah Mason
Technical Editor, CompositesWorld
Electromagnetically transparent GFRP rotor for rare earth magnet-free electric motors
A research consortium within the Baden-Württemberg’s ICM research cluster has created a prototype GFRP wireless power transfer electric motor rotor.
Read MoreIndustrializing rapid tape shearing for high-rate, 3D composite structures
ICOMAT’s first RTS factory creates preforms in 5 minutes for parts with -65% weight, higher strength and damage tolerance for wingskins, spars, fuselage, space tanks, auto chassis and more.
Read MoreUltrasonic welding for in-space manufacturing of CFRTP
Agile Ultrasonics and NASA trial robotic-compatible carbon fiber-reinforced thermoplastic ultrasonic welding technology for space structures.
Read MoreRevolutionizing space composites: A new era of satellite materials
A new approach for high volumes of small satellite structures uses low-CTE, low-cost CFRP cellular core, robust single-ply skins and modular panel systems to cut lead time, labor and cost for reflectors, solar arrays and more.
Read MoreHybrid composite architecture enables rigid wind propulsion solution for maritime decarbonization
GT Wings’ AirWing leverages aerospace engineering principles combined with hybrid glass and carbon fiber composite construction to deliver up to 30% fuel savings through compact, deck-compatible wind propulsion.
Read MoreOligomer polymer engineering transforms 100% recyclable thermoplastic composite paradigms
MET-OL thermoplastic technology alters high molecular weight polybutylene terephthalate into low-viscosity oligomers, enhancing fiber impregnation and catalytic repolymerization for fully recyclable, high-performance composites.
Read More
Braided CF/LMPAEK tube system reduces liquid hydrogen fuel line weight by 50-60%
Herone GmbH’s automated technology, combining tape braiding and press molding, produces lightweight, unitized TPC cryogenic fuel lines for applications like liquid hydrogen aircraft propulsion systems and space launchers.
Stewart Mitchell
Technical Writer
Aerospace prepregs with braided reinforcement demonstrate improved production rates, cost
A recent time study compares the layup of a wing spar using prepreg with A&P’s TX-45 continuous braided reinforcement versus traditional twill woven prepreg.
Read MoreASCEND program completion: Transforming the U.K.'s high-rate composites manufacturing capability
GKN Aerospace, McLaren Automotive and U.K. partners chart the final chapter of the 4-year, £39.6 million ASCEND program, which accomplished significant progress in high-rate production, Industry 4.0 and sustainable composites manufacturing.
Read MorePUR composite sandwich panels for 3D automotive parts, high-volume panels and more
At its U.S. sites, Ascorium produces glass fiber/PUR 3D parts via semi-automated molding, high-volume flat panels via a continuous line while working toward bio-based PUR and recycling.
Read MoreEvolving natural fiber technology to meet industry sustainability needs
From flax fiber composite boats to RV exterior panels to a circularity model with partnerships in various end markets, Greenboats strives toward its biomaterials and sustainable composites vision in an ever-changing market.
Read MoreBladder-assisted compression molding derivative produces complex, autoclave-quality automotive parts
HP Composites’ AirPower technology enables high-rate CFRP roof production with 50% energy savings for the Maserati MC20.
Read MoreComposite SIPs for more affordable, efficient and sustainable buildings
LiteSIP panels and modules enable framing in days, cutting structural labor and total cost by up to 70% and 30%, respectively, while increasing energy efficiency and durability.
Read More
