The composite eVTOL developer has now received two key operational certificates required from the FAA to begin operations when Midnight receives type certification.
Ragasco composite cylinders for LPG will become part of Worthington’s Building Products business, while Hexagon/Worthington Enterprises JV will target expanding storage and transport of CNG and hydrogen. Fiberglass Mesh For Plastering
The 19-seat hybrid-electric aircraft was conceived to use composite and metal construction. Aura Aero has signed a PAC with EASA to finalize the framework for its CS-23 category certification.
Brudeli’s patented plug-in Powerhybrid technology will use Hexagon Agility CNG/RNG fuel system with Type 4 tanks, enabling Class 7 and 8 trucks to meet ACT and ACF regulations.
Final airworthiness criteria provides a solidified path for Archer to achieve type certification for its eVTOL aircraft.
Positive progress during eVTOL prototype testing approaches full transition to forward flight, aids in final full-scale aircraft design for completion and testing in 2026.
An Aurora and Boeing team advances its high-speed, vertical lift concept to the preliminary design phase, which features three lift fans, a more refined composite exterior and an uncrewed cockpit.
Nesting, design, GUI and viewing features have been improved or added to the composites design software tool.
Ingersoll Masterprint LFAM printer will be used to produce and demonstrate 100% recyclable tooling that could cut large composite blade development cycles and tooling costs by as much as 50%.
Key structural elements for a 6-meter section of the Airbus biomimetic wing were undertaken by NCC engineering specialists to produce 28 one-off flying parts.
Pioneer in mandrel-based reinforced rubber and composite products, TANIQ offers TaniqWindPro software and robotic winding expertise for composite pressure vessels and more.
Designer and builder of compression molds for composite structures installs seven-axis CNC deep-hole drilling and milling machine to improve productivity.
European consortium develops novel processes, sustainable designs through three demonstrators to increase recycled carbon fiber use in transportation applications.
Swedish deep-tech startup Sinonus is launching an energy-storing composite material to produce efficient structural batteries, IoT devices, drones, computers, larger vehicles and airplanes.
Proof-of-concept part used bio-based acrylontrile precursor with same performance as conventional CFRP but with significantly less CO2.
Recent conference in Denver, Colorado, emphasized the tools and knowledge composites manufacturers will need to meet customer and government sustainability goals.
Production commencement on Iowa line is intended to recover and divert 30,000 tons of scrapped materials from wind blades each year.
CAMX 2024: Fairmat, through the presentation of its recycling technology capabilities and examples, highlights its commitment to develop high-performing and reliable composite materials.
High-angle AFP head featuring MTorres’ latest upgrades advances fabrication of wing skins and covers for the F-35.
Mel’s ongoing partnership culminates in the development of the Menorquín 42 and Menorquín 54 motor yachts, as well as extension of Sasga’s capacity for 68-foot-length boats.
VacPuc is expanding its range of global distributors to deliver its vacuum pressure measurement solution to the composites market.
GZero opens another location in West Chester, Ohio, to optimize the production of fiber-reinforced 3D printed parts for service bureau customers.
Ultra-lightweight and made of recycled composites, the Eco Bracket cuts weight and cost in half and reduces CO2 emissions, in addition to providing high performance.
CAMX 2024: ColorForm and long fiber injection (LFI) technologies by KraussMaffei support automotive, consumer and other end markets in their quest for high-performance, lightweight parts with aesthetic qualities.
CW explores key composite developments that have shaped how we see and think about the industry today.
Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.
Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.
With COVID in the past and passengers flying again, commercial aircraft production is ramping up. The aerocomposites supply chain is busy developing new M&P for an approaching next-generation aircraft program.
Electrification and a focus on sustainability lead to opportunities and innovations in composites, from battery enclosures to structural components and more.
Thermoplastic material systems have been used in aerospace for decades. Their use and adoption continues to grow and Trelleborg has been on the leading edge of development for many of these systems. In this webinar, Trelleborg will be presenting a range of topics from the use of in-situ, automated fiber placement of thermoplastics prepreg for structural and functional products to complex injection molding of thermoplastic interior pieces. It will explore some of the benefits these products provide and the potential for future growth and development. Agenda: Current state of thermoplastics in aerospace Thermoplastic composite use cases for high-performance electric motors and torque tubes Injection-molded thermoplastic interior pieces The future of potential for thermoplastic applications for aerospace
Find out how outsourced, costly tooling can be produced in-house to overcome bottlenecks, reduce costs and protect IP. Agenda: Explore durable casting materials that can be 3D-printed in complex designs Discover industry-proven Sika materials now available for high-speed, additive tooling Explore the benefits of thermoset molds that ensure uniform expansion, optimum bonding with the end part, as well as high durability
Explore next-gen composites engineering solutions in this webinar. Uncover the capabilities of Fives' Composite Optical Automated Surface Tracking (COAST) platform and Advanced Composites Environment Suite (ACES) software, optimizing design, production and quality control. Gain insights into how these end-to-end solutions enhance productivity and deliver measurable results. Join Fives to discover the transformative benefits of a fully-integrated digital solution for revolutionizing manufacturing processes. Agenda: Digital suite: CAD, CAM, robotic automated fiber placement (RAFP) and COAST Video demonstration Value propositions: maintenance and root cause analysis Product offerings (price, etc.) Customer use case
In addition to its proven fire resistance as a pure foam and within a sandwich composite system, the new material offers efficient manufacturing of 3-dimensional geometries and opens new possibilities for direct function integration. Agenda: Manufacturing process of thermoplastic particle foams Sandwich composite component requirements of commercial aircraft interior structures (e.g. FST, Heat Release) Function integration into net shape molded foam parts (e.g. inserts) Potential use-cases in fire critical applications
Discover the latest innovation in laser projection technology poised to increase accuracy, efficiency and reliability. LAP will unveil the features of its new CAD-PRO Xpert laser projection system and outline how various industries can benefit from the system's capabilities. Its cutting-edge technology platform empowers users with enhanced color range, speed and superior laser projection quality while increasing accuracy, efficiency and reliability. Explore how the advanced ergonomics of this system can reshape composite manufacturing processes across industries, ranging from aerospace and automotive to wind rotor blade production, yacht building and beyond. Agenda: Introduction of the features of the CAD-PRO Xpert Applications and advantages across industries Upgrading workplaces for enhanced digital worker guidance Modular system solutions based on the value-adding ecosystem
After having established a strong foundation in kinetic models in a previous webinar, part two delves into the exciting realm of machine learning and its transformative potential for composite manufacturing. While kinetic models have served the industry well, the growing complexity of composite manufacturing demands more sophisticated approaches. In this session, sensXPERT will explore innovative pathways to supercharge your production efficiency and enhance sustainability beyond the limits of traditional models. See how machine learning empowers composite manufacturers to achieve unprecedented accuracy in predicting key production parameters such as temperature, pressure and cure time. This translates to reduced cycle times and waste while increasing production throughput to maximize efficiency. SensXPERT will provide concrete examples and case studies demonstrating how to bridge the gap between meticulously-controlled laboratory experiments and the realities of the production floor, overcoming the limitations of kinetic models. Agenda: Define machine learning, its applications and their impact on composite manufacturing Explore real-world case studies in diverse composites manufacturing applications and how they exploit integration options Correlation analysis: uncovering hidden relationships between process parameters and product outcomes Time series analysis: forecasting production trends Anomaly detection: identifying irregularities
The 14th edition of the Graphene Conference will take place June 25-28, 2024, in Madrid, Spain. The international gathering includes thematic workshops, B2B networking and an Industrial Forum that dives into a variety of topics, including the latest developments in graphene production methods towards wide scale commercialization and examples of graphene in electronics, energy storage, aerospace and barrier applications.
The International Composites Summit (ICS) is renowned as the only solely focused UK event for professionals involved in the composites industry. ICS promises to be a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business.
Join us at the ACCE 2023 event and learn about how the automotive and transportation industries are advancing with composites playing a key role in the development of electric vehicles and sustainability initiatives worldwide. Lightweight composites are ideal materials for improving vehicle performance, reducing mass, extending range and compensating for battery weight. Polymer composites are enabling lower emission vehicles, reducing the carbon footprint and saving energy to benefit the environment now and in the future. Thermoset and thermoplastic composites are the key to EV, Mobility and Sustainability.
The International Composites Summit (ICS), THE single place to do the most cost effective and sustainable composites business in the UK, is back for its highly anticipated 2023 edition, bringing together industry leaders, researchers, and innovators from across the composites sector. ICS promises to be a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business. The International Composites Summit is renowned as the only solely focused UK event for professionals involved in the composites industry.
CAMX is your best source for new solutions, technologies, and ideas you need for your current and future projects. CAMX makes it easy to watch live process demos, see materials and interactive displays on what may be possible in the future, and meet with hundreds of manufacturers, distributors, and suppliers.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.
Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.
Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.
Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.
The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.
Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.
Upon his one-year anniversary as editor-in-chief of CW, Scott Francis looks back at some of the brand’s changes and hints at where it might be heading next.
In 2018, Teijin broke ground on a facility that is reportedly the largest capacity carbon fiber line currently in existence. The line has been fully functional for nearly two years and has plenty of room for expansion.
Spanish startup Reinforce3D’s continuous fiber injection process (CFIP) involves injection of fibers and liquid resin into hollow parts made from any material. Potential applications include sporting goods, aerospace and automotive components, and more.
Longtime parts manufacturer offers more than composites welding. CW’s conversation with CEO Kjelt van Rijswijk explains KVE’s vision with Daher and where it’s headed.
Steptics industrializes production of CFRP prostheses, enabling hundreds of parts/day and 50% lower cost.
Novel reinforcing patch uses braided sleeve to boost the load-carrying capacity of composite bolted joints.
Recent conference in Denver, Colorado, emphasized the tools and knowledge composites manufacturers will need to meet customer and government sustainability goals.
Ultra-lightweight and made of recycled composites, the Eco Bracket cuts weight and cost in half and reduces CO2 emissions, in addition to providing high performance.
Brudeli’s patented plug-in Powerhybrid technology will use Hexagon Agility CNG/RNG fuel system with Type 4 tanks, enabling Class 7 and 8 trucks to meet ACT and ACF regulations.
Envalior 30% glass fiber-reinforced Akulon RePurposed material helps Ahrend achieve lighter task chair with closed-loop value chain and reduced emissions.
Hydrogen storage and high-voltage battery system to support Class 8 heavy-duty fuel cell powertrains developed by Toyota.
Future cabin concepts, rCF floor coverings and panels, noise regulation and other efficiencies will be tested this year using a 777-200ER aircraft.
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.
Closed mold processes have many advantages over open molding. In this knowledge center, learn the basics and vital tools needed to produce parts accurately.
The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.
In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.
CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.
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.
Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
Explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.
This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.
This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.
This collection features recent CW stories that detail a range of tooling technologies, processes and materials.
Fibers used to reinforce composites are supplied directly by fiber manufacturers and indirectly by converters in a number of different forms, which vary depending on the application. Here's a guide to what's available.
Fibers used to reinforce composites are supplied directly by fiber manufacturers and indirectly by converters in a number of different forms, which vary depending on the application.
Roving and tow. Roving is the simplest and most common form of glass fiber. It can be chopped, woven or otherwise processed to create secondary fiber forms for composite manufacturing, such as mats, woven fabrics, braids, knitted fabrics and hybrid fabrics. Rovings are supplied by weight, with a specified filament diameter. The term yield is commonly used to indicate the number of yards in each pound of glass fiber rovings. Similarly, tow is the basic form of carbon fiber. Typical aerospace-grade tow size ranges from 1K to 24K (K = 1,000, so 12K indicates that the tow contains 12,000 carbon filaments). PAN- and pitch-based 12K carbon fibers are available with a moderate (33-35 Msi), intermediate (40-50 Msi), high (50-70 Msi) and ultrahigh (70-140 Msi) modulus. (Modulus is the mathematical value that describes the stiffness of a material by measuring its deflection or change in length under loading.) Newer heavy-tow carbon fibers, sometimes referred to as commercial-grade fibers, with 48K-320K filament counts, are available at a lower cost than aerospace-grade fibers. They typically have a 33-35 Msi modulus and 550-ksi tensile strength and are used when fast part build-up is required, most commonly in recreational, industrial, construction and automotive markets. Heavy-tow fibers exhibit properties that can approach those of aerospace-grade fibers but can be manufactured at a lower cost because of precursor and processing differences. (Carbon fiber's high cost and historically significant fluctuations in its supply and demand, generate perennially high interest in the composites industry about the state of the global carbon fiber market, a subject treated in "Supply and demand: Advanced fibers," under "Editor's Picks," at right.)
A potentially significant recent variation is carbon fiber tow that features aligned discontinuous fibers. These tows are created in special processes that either apply tension to carbon tow at differential speeds, which causes random breakage of individual filaments, or otherwise cut or separate individual carbon filaments such that the filament beginnings and ends are staggered and their relative lengths are roughly uniform so that they remain aligned and the tow maintains its integrity. The breaks permit the filaments to shift position in relation to adjacent filaments with greater independence, making the tow more formable and giving it the ability to stretch under load, with greater strength properties than chopped, random fibers. Fiber forms made from aligned discontinuous tows (see “Mats,” below) are more drapable; that is, they are more pliable and, therefore, conform more easily to curved tool surfaces than fiber forms made from standard tow.
Mats are nonwoven fabrics made from fibers that are held together by a chemical binder. They come in two distinct forms: chopped and continuous strand. Chopped mats contain randomly distributed fibers cut to lengths that typically range from 38 mm to 63.5 mm. Continuous-strand mat is formed from swirls of continuous fiber strands. Because their fibers are randomly oriented, mats are isotropic — they possess equal strength in all directions. Chopped-strand mats provide low-cost reinforcement primarily in hand layup, continuous laminating and some closed molding applications. Inherently stronger continuous-strand mat is used primarily in compression molding, resin transfer molding and pultrusion applications and in the fabrication of preforms and stampable thermoplastics. Certain continuous-strand mats used for pultrusion and needled mats used for sheet molding eliminate the need for creel storage and chopping.
Woven fabrics are made on looms in a variety of weights, weaves and widths. Pictured are Jacquard looms at Albany Engineered Composites’ (AEC, Rochester, NH, US) that facilitate manufacture of three-dimensional preforms (that is, fiber reinforcements that are interlocked not only in the x/y directions, but the z-direction (through-thickness). These mass-produced materials shorten the time necessary to develop prepregs and dry fabrics that can be layed up quickly by fabricators. Source: Albany International Corp.
Woven fabrics are made on looms in a variety of weights, weaves and widths. Wovens are bidirectional, providing good strength in the directions of yarn or roving axial orientation (0º/90º), and they facilitate fast composite fabrication. However, the tensile strength of woven fabrics is compromised to some degree because fibers are crimped as they pass over and under one another during the weaving process. Under tensile loading, these fibers tend to straighten, causing stress within the matrix system.
Multilayer fabrics have been woven on traditional 2-D weaving looms for some time. These fabrics are produced by splitting the warp fibers (oriented in the direction of fabric production) to create multiple sheds (spaces through which the weft or filling fibers are inserted at right angles to the warp). If the warp ends are moved up or down during weaving (in Jacquard looms this is done using heddles (pictured above), then the fabric can be made to consist of several layers stacked vertically. Warp ends can be interlaced with fill fibers in the adjacent layer to produce layer-to-layer locked fabrics, or they can be interlaced with fill fibers in the top and bottom layers to create angle-interlocked fabrics. Source: Albany International Corp.
Several different types of weaving are used for bidirectional fabrics. In a plain weave, each fill yarn (i.e., yarn oriented at right angles to the fabric length) alternately crosses over and under each warp yarn (the lengthwise yarn). Other weaves, such as harness, satin and basket weave, allow the yarn or roving to cross over and under multiple warp fibers (e.g., over two, under two). These weaves tend to be more drapable than plain weaves.
Woven roving is relatively thick and used for heavy reinforcement, especially in hand layup operations and tooling applications. Due to its relatively coarse weave, woven roving wets out quickly and is relatively inexpensive. Exceptionally fine woven fiberglass fabrics, however, can be produced for applications such as reinforced printed circuit boards.
Hybrid fabrics can be constructed with varying fiber types, strand compositions and fabric types. For example, high-strength strands of S-glass or small-diameter filaments may be used in the warp direction, while less-costly strands compose the fill. A hybrid also can be created by stitching woven fabric and nonwoven mat together.
Multiaxials are nonwoven fabrics made with unidirectional fiber layers stacked in different orientations and held together by through-the-thickness stitching, knitting or a chemical binder. The proportion of yarn in any direction can be selected at will. In multiaxial fabrics, the fiber crimp associated with woven fabrics is avoided because the fibers lie on top of each other, rather than crossing over and under. This makes better use of the fibers’ inherent strength and creates a fabric that is more pliable than a woven fabric of similar weight. Super-heavyweight nonwovens are available (up to 200 oz/yd²) and can significantly reduce the number of plies required for a layup, making fabrication more cost-effective, especially for large industrial structures. High interest in noncrimp multiaxials has spurred considerable growth in this reinforcement category.
Braided fabrics are continuously woven on the bias and have at least one axial yarn that is not crimped in the weaving process. The braid’s strength comes from intertwining three or more yarns without twisting any two yarns around each other. This unique architecture offers, typically, greater strength-to-weight than wovens. It also has natural conformability, which makes braid especially suited for production of sleeves and preforms (see “Preforms,” below) because it readily accepts the shape of the part that it is reinforcing, thereby obviating the need for cutting, stitching or manipulation of fiber placement. Braids also are available in flat fabric form. These can be produced with a triaxial architecture, with fibers oriented at 0°, +60°, -60° within one layer. This quasi-isotropic architecture within a single layer of braided fabric can eliminate problems associated with the layering of multiple 0˚, +45˚, -45˚ and 90˚ fabrics. Furthermore, the propensity for delamination (separation of fiber layers) is reduced dramatically with quasi-isotropic braided fabric. Its 0°, +60°, -60° architecture gives the fabric the same mechanical properties in every direction, so the possibility for a mismatch in stiffness between layers is eliminated.
In both sleeve and flat fabric form, the fibers are continuous and mechanically interlocked. Because all the fibers in the structure are involved in a loading event, the load is evenly distributed throughout the structure. Therefore, braid can absorb a great deal of energy as it fails. Braid’s impact resistance, damage tolerance and fatigue performance have attracted composite manufacturers in a variety of applications, ranging from hockey sticks to jet engine fan cases.
The growing sophistication of, and resulting use of, closed molding processes — high-pressure resin transfer molding, in particular — has increased demand for the fiber perform. Preforms are near-net shape reinforcement forms created by stacking and then shaping layers of chopped, unidirectional, woven, stitched and/or braided fiber into a predetermined three-dimensional form. This preform was created and shaped under heat by Albany Engineered Composites (Rochester, NH, US). The preform keeps its shape during transport to the fabricator/customer and during the fabricator's molding process because the fibers and fabrics are fixed in place by a binder resin — typically, a resin compatible with the resin that will form the composite part's matrix. Source: Albany International Corp.
Because of the preform's potential for great processing efficiency and speed, fiber converters have developed software that can predict the behavior of fiber forms and ensure expected performance in the finished part. This diagram illustrates how one converter, Albany Engineered Composites (Rochester, NH, US) uses internally developed design tools that can perform molding process simulations as well as predict the performance of a finished 3-D composite structure. Capabilities include forming simulation and prediction of strength, stiffness and performance vs. failure criteria. Source: Albany International Corp.
Preforms are near-net shape reinforcement forms designed for use in the manufacture of particular parts by stacking and shaping layers of chopped, unidirectional, woven, stitched and/or braided fiber into a predetermined three-dimensional form. Complex part shapes can be approximated closely by careful selection and integration of any number of reinforcement layers in varying shapes and orientations. Because of their potential for great processing efficiency and speed, a number of preforming technologies have been developed, with the aid of special binders, heating and consolidation methods and the use of automated methods for spray up, orientation and compaction of chopped fibers.
Prepregs are resin-impregnated fiber forms, manufactured by impregnating fibers with a controlled amount of resin (thermoset or thermoplastic), using solvent, hot-melt or powder-impregnation technologies. Prepregs can be stored in “B-stage,” that is, a partially cured state, until they are needed for fabrication. Prepreg tape or fabric is used in hand layup, automated tape laying, fiber placement and in some filament winding operations. Unidirectional tape (all fibers parallel) is the most common prepreg form. Prepregs made with woven fibers and other flat goods offer reinforcement in two or more dimensions and are typically sold in full rolls, although small quantities are available from some suppliers. Those made by impregnating fiber preforms and braids provide three-dimensional reinforcement.
Prepregs deliver a consistent fiber/resin combination and ensure complete wetout. They also eliminate the need to weigh and mix resin and catalyst for wet layup. For most thermoset prepregs, drape and tack are “processed in” for easy handling, but they must be stored below room temperature and have out-time limitations; that is, they must be used within a certain time period after removal from storage to avoid premature cure reaction. Thermoplastic prepregs need no refrigeration and are not subject to outlife limitations, but without special formulation, they lack the tack or drape of thermoset prepregs and, therefore, are more difficult to form.
Spread tow is an individual tow (or untwisted yarn) of fiber that has been spread out until the individual filaments lie side-by-side, forming an ultra-thin ribbon. For example, a 12K tow of carbon fiber may be spread from 5 mm to 25 mm in width, reducing its thickness by 80%. These spread tows can be woven into fabric, placed to form a multiaxial noncrimp fabric (NCF) or receive liquid or powder resin to form a spread-tow tape or towpreg. Use of woven spread-tow fabric in place of more convetional reinforcments can result in a 20-30% weight savings in the composite laminate. This is achieved by closing the warp and weft interstitial gaps between warp and weft so that less resin is trapped there, but also by reducing the fiber crimp, resulting in straighter fibers, which boosts strength. Thus, the final composite laminate may use fewer, thinner plies to achieve the same or better performance.
Fiber supplier Hexcel (Stamford, CT, US), claims 5-8% reductions in fabric gaps and the ability to achieve, with carbon fiber, 6K tow properties with 3K tow areal weight, 12K tow properties with 6K tow areal weight, etc. North Thin Ply Technology (NTPT, Penthalaz-Cossonay, Switzerland) claims that any fiber can be spread and claims that very low areal weights are achievable: 30 g/m2 for PAN-based carbon fiber and 14-micron diameter quartz fiber, 35 g/m2 for 9-micron diameter glass fiber, 20 g/m2 for aramid fiber and 30 g/m2 for polybenzoxazole (PBO) and other synthetic fibers. Suppliers of spread tow reinforcements include Hexcel, NTPT, Oxeon (Boras, Sweden), Sigmatex (UK) Ltd. (Runcorn, UK), Chomarat and FORMAX (Leicester, UK). Applications include bicycles, skis, hockey sticks, rackets, sailboats, racecars and the Solar Impulse aircraft.
Recycled carbon fiber (RCF) reinforcements are available in a variety of forms, including chopped fibers cut to specific lengths, chopped fibers compounded as long fiber thermoplastic (LFT) pellets, three-dimensional net-shaped preforms, and randomly oriented chopped fiber mats — either dry or combined with thermoplastics — including polypropylene (PP), polyethylene terephthalate (PET), polyamide (PA or nylon), polyphenylene sulfide (PPS), polyetherimide (PEI), polyetheretherketone (PEEK). The chopped fiber mats also can be processed — for example, via carding — to achieve greater fiber alignment, resulting in better mechanical properties. This variety of products is available from a range of RCF suppliers worldwide, and are recycled using pyrolysis, which burns resin from waste prepreg and cured structures. Technical Fibre Products Inc. (TFP, Schenectady, NY, US and Burneside, UK) makes veils from RCF as light as 2 g/m2.
RCF products are also made in-house from dry fiber manufacturing waste. SigmaRF products reuse Sigmatex’ in-house dry manufacturing waste by combining 45-mm to 60-mm carbon fibers with a thermoplastic carrier to form slivers which are used to make noncrimp fabrics, for example, a 220 g/m2 ±45° carbon fiber/PET biaxial NCF. Other variations include RCF/Kevlar/PEI, RCF/PA and RCF/PES.
Institute of Plastics Processing (IKV) at RWTH Aachen University (ITA, RWTH Aachen University, Aachen, Germany) has taken nascent fibers not collected by rollers during carbon fiber PAN precursor spinning — a carbon fiber production waste or byproduct — and then chopped, carbonized and formed these into homogeneous mats using a continuous airlay process.
New methods are also being developed to produce continuous recycled fibers including solvolysis using alcohols or other solvents to remove resins without burning or high temperatures, pyrolysis and unwinding of filament wound pressure vessels, and use of epoxy resins that enable the matrix to be recycled as a thermoplastic, such as Recyclamine hardeners by Connora Technologies (Hayward, CA, US).
Molding compounds are yet another way to incorporate fibers into a composite. Traditionally, these have been developed by the plastics industry and feature short fibers (2-25 mm) at low weight percentages (5-50%). Putty-like Bulk Molding Compounds Inc.(BMC) is used in injection molding while sheet molding compound (SMC) is used for larger parts and higher strength requirements, typically in a compression molding process. Glass mat thermoplastic (GMT), also a compression moldable material, has continuous random-fiber reinforcement. GMT was developed in the 1960s as a step up from short fiber-reinforced nylon. It has faced increasing competition from long fiber-reinforced thermoplastic (LFRT or LFT) which is produced by cutting small-diameter pultruded continuous glass fiber rods into pellets. LFT features continuous unidirectional fiber running the full length of the pellet and offers properties between GMT and short-glass thermoplastics. In the 1990s, machinery OEMs developed inline compounding (ILC) systems that integrate the previously separate compounding and molding processes. These direct long-fiber thermoplastic (D-LFT) systems combine resin, reinforcement and additives at the press, delivering a measured shot or charge directly to injection or compression molding equipment. This eliminates inventories of pre-compounded product and enables tailored fiber length.
SMC, BMC, GMT and LFT are used in a wide range of applications where complex shapes and molded details are required, including automotive parts, appliances (washing machine tub), medical devices, consumer goods, electronics, sporting goods, brackets, enclosures, parts for transportation vehicles and electrical applications.
Glass fiber is the most common and least expensive reinforcement used in molding compounds, aramid fiber provides wear resistance, stainless steel fiber achieves both electrostatic dissipation (ESD) and electromagnetic interference (EMI) shielding, while carbon fiber provides higher modulus and lower weight as well as ESD properties. Molding compounds reinforced with natural fibers (hemp, flax, sisal and wood-derived fibers) also have been developed, including. These are gaining popularity in automotive, sporting goods and consumer products.
Advanced molding compounds are aimed at higher performance applications including aerospace and military parts. These materials use higher performance resins, such as epoxy, phenolic, vinyl ester, bismaleimide (BMI) and polyimide, and fiber loadings from 45% to 63% by weight. Fibers include carbon and E-glass, but also higher performing S2-glass. TenCate Advanced Composites makes BMCs with epoxy, cyanate ester, Nylon, PPS or PEEK resins and carbon or S2-glass fiber in lengths from 12 mm to 50 mm. HexMC is produced by Hexcel, using 50 mm long carbon fibers and epoxy resin. A variety of other carbon fiber SMC products are available from suppliers that include Continental Structural Plastics(Auburn Hills, MI, US), Quantum Composites (Bay City, MI, US) and a joint venture between Zoltek Corporation (St. Louis, MO, US) and Magna (Paris, France).
CAMX 2023: Startup Weav3D will be demonstrating its two collaborative automotive demonstrator parts and present two conference papers.
Bally Ribbon Mills’ highlights its capabilities in design and manufacture of woven structural shapes for hybrid composite structures used in aerospace applications.
CW’s running summary of resin price change announcements from major material suppliers that serve the composites manufacturing industry.
Efficient, high-quality, well-controlled composites manufacturing at volume is the mantra for this 3D weaving specialist.
Discontinuous but aligned carbon fibers are proving formable and formidable in high-performance, compound-curvature applications.
In 2006, guest columnist Bob Hartunian related the story of his efforts two decades prior, while at McDonnell Douglas, to develop a thermoplastic composite crytank for hydrogen storage. He learned a lot of lessons.
Composites are used widely in oil/gas, wind and other renewable energy applications. Despite market challenges, growth potential and innovation for composites continue.
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