THE CAMX FORECAST

Published 07/17/2025

Contactless sensors enable smart composites production

CAMX 2025: Attendees can experience both of sensXPERT’s FlexCure and Insight sensor products, both achieving reduced waste, shorter cycle times and more actionable insights into resin curing.

Edited by: Grace Stubbins

Senior Managing Editor, CompositesWorld and Products Finishing

Source | sensXPERT

In composites manufacturing, where precision and quality assurance are everything — especially in challenging processes like resin infusion, filament winding, patch repairs and continuous production — SensXPERT, operating within Netzsch Process Intelligence GmbH (Selb, Germany), introduces FlexCure, a contactless, high-frequency dielectric analysis (HF-DEA) solution.

Where traditional sensors fail due to physical constraints, FlexCure thrives. Its contactless technology penetrates composite structures up to 40 mm thick, eliminating the need for embedded sensors or coupling media. This enables reliable, real-time detection of dry spots, air gaps and other critical curing anomalies, without interrupting the process.

FlexCure continuously monitors key dielectric properties such as permittivity and conductivity, offering a live window into the curing process. Its advanced analytics translate this data into actionable insights, enabling teams to fine-tune parameters like temperature and cure time on the fly. The result, SensXPERT reports, is reduced waste, shorter cycle times and enhanced production consistency.

What sets FlexCure apart is its ability to detect deviations and potential defects early. By analyzing resin behavior at the molecular level, the system proactively flags inconsistencies, minimizing costly rework and ensuring compliance with rigorous quality and safety standards.

Whether in aerospace, automotive or advanced industrial applications, sensXPERT FlexCure delivers a combination of quality assurance, process transparency and cost-efficiency. It empowers manufacturers to optimize curing processes, reduce energy consumption and eliminate downtime.

For applications requiring in-mold monitoring, sensXPERT Insight offers a complementary, integrated solution. This system uses embedded dielectric sensors and edge computing to monitor and control curing in real time. Machine learning algorithms analyze resin behavior, enabling automatic cycle adjustments based on actual material response. Insight provides full process transparency and traceability through its cloud-based platform, delivering up to 50% scrap reduction, 23% energy savings and 30% shorter cycle times.