Stephen Heinz, vice president of R&I for Syensqo delivered an inspirational keynote at SAMPE 2024, highlighting the significant role of composite materials in emerging technologies and encouraging broader collaboration within the manufacturing community.

Germany has funded a long-term strategy to continue developing photonics technology because of the key role itplays in the current global digital transformation of manufacturing. The composites industry should take note, because photonics enable not only advanced processing such as automated fiber placement, laser welding of thermoplastics, precision machining and various 3D printing processes, but also sensor and visual communication for metrology, process monitoring and inline inspection. In OPTO-Light, a near infrared (NIR) laser was used to pretreat surfaces for overmolding; in addition, a variety of laser-based sensors provided data for process control and inline quality assurance (QA).

Main reason is, the labor and other expenses going to make an iphone case from scrap are greater than the value of the product.

Additionally, stitch-bonded non-crimp fabrics (NCFs) provide manufacturers and asset owners even more ways to gain a competitive advantage with products built specifically for the environments and loading conditions in which they will be utilized. Join Vectorply Corporation and Creative Composites Group (CCG) for this in-depth webinar detailing the process of engineering NCFs to build composite parts that will stand the test of time. Unlike steel, concrete and wood, composite NCFs can be optimized utilizing various fiber types, architectures and substrates to achieve the specific goals of their application efficiently. High corrosion resistance, strength and stiffness, and longevity can all be accomplished with custom-designed laminates for these heavily abused applications. Vectorply Vice President of Engineering Trevor Gundberg and Creative Composites Group Chief Sales Officer Dustin Troutman will share their industry-leading expertise on the process of laminate design and part production. Attendees can expect to learn when to use composite NCFs in their production process and the wide range of fiber-reinforced plastic (FRP) composites that Creative Composites Group produces for the industrial and infrastructure markets. Whether you want to learn more about utilizing NCFs in your production process or why CCG’s extensive product line may be the choice for your project, this webinar is the place learn the process and how to take the next steps. Agenda:  Distinct advantages of non-crimp fabrics versus alternative materials How to design laminates for specific processes such as pultrusion and infusion Real-world success spotlights of NCFs in industrial applications

CW Tech Days are virtual events dedicated to the topics impacting the composites industry today. Access past event recordings and register for upcoming Tech Days.

How the predictive tool “CZone” is applied to simulate the axial crushing response of composites, providing valuable insights into their use for motorsport applications.

A KraussMaffei CXW-200-380/180 injection molding machine is combined with a multifunctional laser scanner end effector on a Kuka robot to integrate three processes into one molding cell.

That’s why for a backyard aluminum foundry melting cans you need something to crush many cans together into blocks. That way the metal inside the block will heat and melt with minimal air to oxidize it. Adding to the problem is any leftovers of the contents, especially if still wet. Cleaning and drying lots of pop or beer cans takes lots of time and effort.

Flat tank enabling standard platform for BEV and FCEV uses thermoplastic and thermoset composites, overwrapped skeleton design in pursuit of 25% more H2 storage.

Four unidirectional prepregs were evaluated for the demonstrator’s shell. These were converted into net-shaped, 2D tailored blanks using Broetje-Automation’s (Rastede, Germany) STAXX tape placement cell.

Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.

Validation of 80-100% tensile strength and comparability to injection molding via Voxelfill extrusion process was achieved through plastic and fiber-filled test series.

Those bags don’t seem very UV stable (tend to go brittle and crumble when left out in the sun), but maybe useful indoors or if kept in a dark area.

OPTO-Light’s obvious achievement is combining the high stiffness, light weight and low creep of epoxy-based carbon fiber-reinforced plastic (CFRP) with the high freedom of design and low cycle times of thermoplastic overmolding. But this is just one of myriad potential composites industry disruptors the project has achieved, including:

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

CompositesWorld's Carbon Fiber conference offers you cutting-edge information and access to industry experts in streamlining manufacturing costs, market outlooks and forecasting, and more. You will make invaluable contacts as you meet and network with the industry's most innovative and influential leaders at Carbon Fiber. __PRESENT

This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.

During this webinar, the audience will be introduced to a variety of fiber composite technologies — as well as the machines and equipment — from short fibers to continuous fibers, from thermoset to thermoplastic, as well as the according process technology, including a special focus on long-fiber injection (LFI) and structural composite spray (SCS). Focus markets include automotive, aviation and AAM, transportation, and construction. This webinar will provide a detailed overview of according application examples. Agenda: Long fiber injection (LFI) Structural composite spray (SCS) Resin transfer molding (RTM), wet compression molding, etc. Pultrusion FiberForm

The composites-intensive VTOL platform is next expected to undergo a series of test flights in various conditions to validate its performance, safety and reliability, leading up to eventual certification.

This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.

https://hackaday.com/2016/06/11/new-cnc-machine-diy-machinable-wax/ , https://hackaday.com/2017/12/30/fresh-baked-plastic-tiles-for-all/ , https://hackaday.com/2015/02/21/turning-plastic-milk-jugs-into-a-useful-tool/ , https://hackaday.com/2010/08/05/recyclebot-digests-milk-jugs-to-feed-makerbot/

The epoxy CFRP shell resulting from the compression molding process must be treated prior to thermoplastic overmolding to achieve sufficient join strength between the disparate materials. Laser ablation offers an environmentally friendly, single-step process compared to mechanical or chemical pretreatment and enables a precise ablation depth and path, well-suited for joining ribs to parts along 3D surfaces. The ablation method entails exposing the carbon fibers by locally removing the topmost 10-micron-thick layer of epoxy resin. This cleans the surface and produces a microstructure that allows the overmolding compound to wet and infiltrate the exposed fibers.

Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.

First, let me say, this does not in any way mean I am against the idea. I love the concept of encouraging individuals to make more stuff themselves. I very much think that encouraging making over consumerism will give us a much more creative, knowledgeable and self sufficient population that ultimately will do greater things and make a better world.

The OPTO-Light demonstration part was a 470-millimeter-long by 317-millimeter-wide by 130-millimeter-deep portion of the BMW i3 Life Module floor, including the end wall at the wheel well. “The load cases of this component require good stiffness and strength characteristics in case of a crash,” Schares explains. “We also wanted complexity of shape and draping to prove out the horizontal prepreg compression molding, laser ablation and overmolding along a free-form surface.”

The composites industry plays a crucial role in developing lightweight and durable materials for a range of applications, including those critical to national defense. One key focus area is the development of advanced structural materials and manufacturing technologies that support next-generation space, missile and aircraft systems for the U.S. Department of Defense (DOD). ARC Technologies LLC (ARC), a division of Hexcel Corporation, based in Amesbury, Massachusetts, is a provider of advanced composites structures, specialty materials and other unique products that provide the U.S. Department of Defense with advanced capabilities to protect service members while in harm’s way. This team’s specialty is to understand a specific need from a program office, PEO, platform manufacturer or other offices within the DOD. With that understanding, the team can design a solution, develop a prototype for test and evaluation, perform extensive in-house testing — including electromagnetic, environmental and structural testing — and then partner with the customer through platform evaluation. The Hexcel Amesbury division has a team of engineers on staff, including mechanical, chemical, electrical and research and development specialists that can provide design, testing and manufacturing capabilities to service customer requirements from concept through production. This presentation will illustrate capabilities in advanced composites and other specialty materials structures, focusing on the Hexcel Amesbury team's niche in electromagnetic signature reduction and other unique capabilities.

OPTO-Light’s potential for disruption was recognized with the AVK Innovation Award for the research and science category in 2017. The project’s 2018 final report asserts that for composites to achieve cost parity with metal in series automotive production, it is necessary not only to maximize the integration of functions in parts but also the integration of the processes used to manufacture those parts. OPTO-Light has developed an array of technologies, including photonics-based metrology, surface treatment and thermoplastic/thermoset molding,that enable both. These technologies also open the door to further hybrid processes, such as laser processing to augment injection molding. “By integrating the developed laser tool in the molding cell, you now have the possibility to perform laser ablation, cutting, pretreatment or heating before, between or after polymer processes inside the injection molding machine,” explains Schares. “This enlarges the functionality of future parts.”

During this CW Tech Days event, sponsored by Composites One, experts will offer presentations to review and evaluate the composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

“Factories (in the developed world) are regulated, regularly inspected and usually employ high tech scrubbing technologies on their emissions.”

The first project is underway to recover carbon fiber used in an A330-200 aircraft, which will then be regenerated for other end uses by HRC.

The molded CFRP shells would then be overmolded with 30-percent short glass fiber-reinforced polyamide 6 (GF/PA6) using Lanxess (Cologne, Germany) Durethan BKV 30 H2.0 901510. A KraussMaffei CXW-200-380/180 SpinForm injection molding machine was chosen as the foundation for the OPTO-Light manufacturing cell and installed at AZL. It features swivel platen technology developed to enable multi-component injection molding.

OPTO-Light has developed different process routes for achieving epoxy CFRP parts functionalized via thermoplastic overmolding. Both process route 1 using laser ablation and process route 2, which eliminates the laser in favor of co-curing, have been validated via 50 demonstrator parts.

CompositesWorld’s Tech Days: Design, Simulation and Testing Technologies for Next-Gen Composite Structures is designed to provide a multi-perspective view of the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

On another note, the above comments in this section prove exactly what is wrong with the sustainability community, people spend so much time talking about what’s better or worse that no one actually does anything. Emissions in X vs. emissions in Y. Frankly, no one cares about emissions and the big companies and starts ups that use these materials don’t wait around calculating if one options emits 0.00001 CO2e than another. They start, the fail, they redo, they prototype and the achieve success. That’s why I love precious plastics, they have launched a community and I guarantee the product in 10 years will be so much more advanced than the current MVP. If he had sat around having conversations like the above he would probably still be calculating the lifecycle analysis and debating the difference between boat vs. truck logistics costs to the environment….. but I guess a lot of people are paid to chat and not to do.

How many factories are in the developed world and have these high standards. I live in China and work in the area of plastics recycling and I can tell you right now that many factories are not meeting standards and there is no “formal” recycling system in place. Since the plastic import ban (which btw makes localised solutions even more important) this is beginning to change in more economically thriving areas of the country e.g. Shanghai, Shenzhen etc. but there is a lot of work to do. Note: Very good and highly developed factories do exist in China and if navigated correctly it is a wonderful place to produce.

Over the last 8 months, Archer Aviation has completed a total of 402 test flights with its composites-intensive aircraft, adding to key milestones.

Available as filament and granules for extrusion, new wood composite matches properties yet is compostable, eliminates microplastics and reduces carbon footprint.

The greater cost to produce the item then translates into greater energy and resource use as translated through the economy, which means by recycling the object you actually consume more than you save.

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.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.

CompPair and Composite Recycling introduce a roof scoop made of recycled fibers to an eco-efficient rally buggy, which channels airflow to the engine for optimal, sustainable performance.

Explore the technologies, materials and strategies used by composites manufacturers working in the evolving space market.

Even as the benefits of the initial process were being documented, the OPTO-Light team realized it was possible to eliminate the laser pretreatment. This two-step process would only partially cure the epoxy prepreg shell and use remaining reactivity in the epoxy resin to achieve attachment with the thermoplastic overmolding. Three potential mechanisms exist for bonding between uncured epoxy and PA6:

In these sessions, experts will discuss the emerging hydrogen economy and the opportunities for composites in this lucrative space.

Indeed, the project’s April 2018 final report asserts that this technology can reduce automotive CFRP part cost by up to 30 percent versus current production using wet compression molding and adhesive bonding of single onserts for clips (see Fig. 2).

The initial idea was to make the epoxy CFRP parts using C-RTM, a kind of high-pressure resin transfer molding (HP-RTM) also known as gap impregnation, developed by the IKV Institute of Plastics Processing. However, during this time, automated tape-based processes began to challenge liquid molding of noncrimp fabric (NCF), offering a reported 30 percent reduction in cutting scrap. Snap-cure liquid epoxy resins were also expanded into prepreg materials, making compression molding attractive, with a potential cycle time of one to two minutes.

A combination of Airtech’s 3D printing materials and Ascent’s production capabilities aim to support increased use of composite additive tooling in spaces like defense and aerospace.

Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.

This project reminds us of the tiles made of HDPE plastic with nothing more exotic than what you’d find in the average kitchen. Projects like these really drive home the idea that with the right hardware individuals can turn trash into usable products.

Suppliers of thermoplastics and carbon fiber chime in regarding PEEK vs. PEKK, and now PAEK, as well as in-situ consolidation — the supply chain for thermoplastic tape composites continues to evolve.

Continuous fiber-reinforced thermoplastic composite targets full circularity in aircraft interior applications, with FST, impact resistance and toughness features.

Advanced Engineering is the UK’s largest annual gathering of engineering and manufacturing professionals. The event will help you to source new suppliers, network, build connections and learn about the latest industry developments all in one place. Get involved and exhibit alongside 400+ exhibitors offering solutions and products across all industries and sectors to help improve your productivity and inspire creativity. With over 9,000+ of your peers due to attend and ready to network with and inspire you, this is the event you can’t afford to miss!

Once you’ve designed your mold on the computer, you need to turn it into a physical object. If you’ve got a CNC capable of milling aluminum then you’re all set, but if not, you’ll need to outsource it. [Precious Plastic] found somebody to mill the molds through 3DHubs, though they mention in the video that asking around at local machine shops isn’t a bad idea either.

He, that’s me! Thanks for sharing :D Feel free to ask questions here or here: https://davehakkens.nl/community/forums/topic/make-a-plastic-phone-cover-using-cnc-milling/

The process, beginning with fixation of the prepreg preform inside the mold and ending with ejection from the injection overmolding cavity, is described by the DCR/DEA sensor signals. These data are crucial for determining the optimum cure time in compression molding before the pivot to injection molding for cure completion and overmolding. The sensors help to characterize the material during processing for optimal part quality. In the future, the process may be adaptive and intelligent, with process pivoting triggered by the DEA and DCR sensor signals.

The pretreated shell rotates on the swivel platen for back injection molding with short glass fiber/reinforced PA6 compound.

Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.

The plastic waste have to be sorted, PE, PET, etc. so the right temperature can be used and you don’t mix chlorated plastics in there like Nylon. Undyed PE, like used in plastic Jerry cans and the likes, is quite pure. Black plastics have usually already been recycled once. So the trick is to find the right mix of undyed higrade and lower grade plastic to grt satifactory properties. The problem with plastics, even if they are not heated to more than their recomended temperature for casting, is that some of the polymers breaks up, and the material gets a little more brittle. If a correct amount of virgin material is used and time and temperature is observed, satisfactory results can be achieved.

That the question that [Precious Plastic] asks, and by providing a centralized resource for individuals and communities looking to get into the plastic recycling game, they hope to put a dent in the worldwide plastic crisis. One of their latest projects is showing how plastic trash can be turned into functional iPhone cases with small-scale injection molding.

Also the Aluminium oxides are the same as the raw material used to make it in the first place. If you just chuck all your scrap Aluminium into the smelter it goes through the process much faster using less energy. The purity doesn’t matter that much.

That’s because, you need to make money to cover the time and upkeep of yourself and the tools. You make that money through the economy. Since the economy is services-based (>80%) it means your efforts are largely not producing new value but consuming it, because the way you make money is by helping other people consume resources.

An overview of ASTM Standard Guide D8509, and its coupon-level mechanical testing of design properties for analyzing composite bolted joints.

The idea of combining multiple manufacturing processes into a single work cell is gaining momentum in composites. For example, many of the CNC machine manufacturers now offer cells that combine additive manufacturing and subtractive CNC machining. MF Tech (Argentan, France) has combined 3D filament winding and CNC machining, and co-founder Emanuel Flouvat confirms further hybridization, with robots able to switch out end effectors to an ultrasonic or laser welder for joining thermoplastics, or an automated fiber placement head to apply local patches of unidirectional tape. “By integrating a robot-guided laser system, the ‘tool box’ for the definition of further inline combination technologies is extended,” says Schares. This is another significant step forward in this advance toward automated, multi-process composites manufacturing that will no doubt soon integrate electronics into finished products.

The DOMMINIO project combines AFP with 3D printed gyroid cores, embedded SHM sensors and smart materials for induction-driven disassembly of parts at end of life.

Low-melt polyaryletherketone (LMPAEK) unidirectional tapes provide outstanding thermal and fire protection, demonstrating their effectiveness through rigorous testing. These tapes are fire, smoke and toxicity compliant with FAR25.853 and meet OSU Heat Release Rate standards. The tapes were tested under ISO 2685/AC 20-135 Change 1, meeting the fireproof criteria. Additionally, they met UL 2596 requirements for battery thermal runaway tests. These tapes are crucial for high-temperature applications showcasing their resilience and safety in both aerospace and automotive applications. Part of a broader range that includes films and compounds, Victrex LMPAEK materials are valued for their excellent processability and weldability. They offer versatile solutions for complex needs beyond traditional structural parts, such as: thermal runaway and lightning strike protection, heat sinking, and intricate bracketry. Victrex LMPAEK materials facilitate automation and high-rate production while addressing performance and sustainability challenges. With reduced environmental impact, lower weight and cost-efficiency, they meet the evolving demands of the transportation industry and support innovative design solutions. Agenda:  Introduction to LMPAEK ecosystem, highlighting unidirectional tapes Thermal and fire protection performance: applications and benefits Material forms and processability Sustainability and efficiency Conclusion and future innovations

One more thing – you can identify the aluminium alloy with an XRF machine (expensive, but labs have them), good luck IDing what the composition of a plastic polymer is :P

Six U.S. companies have proven their recycling technologies for composites and rare earth elements, and will be supported for relevant scale demonstration and validation.

This session is designed to demonstrate the benefits of ultra polymers for aerospace applications with real case examples of Syensqo's polymer portfolio. Agenda:  Introduction to ultra polymers (PAEK, PEKK, PEEK, PAI) key features Application of ultra polymers in aerospace: concrete examples Benefits of ultra polymers: enhanced performance, durability and cost-efficiency

With the mold completed, all that’s left is to bolt the two sides together and inject the liquid plastic. Here [Precious Plastic] shows off a rather interesting approach where they attach the mold to a contraption that allows them to inject plastic with human power. Probably not something you’d want to do if you’re trying to make thousands of these cases, but it does show that you don’t necessarily need a high tech production facility to make good-looking injection molded parts.

The JEC Forum DACH is a business meetings event organised by JEC The JEC Forum DACH is organised on October 22 and 23, 2024 by JEC, in partnership with the AVK, gathering the composite materials community from the DACH Region (Germany, Austria and Switzerland).

The advantage of this two-step process, says Schares, “is that you can skip the pretreatment, but the required process control is much more challenging and the surface quality is not as high-gloss. However, further reduction in part cost by simplification of production is very attractive.”

Powered by an 85% air/15% pure polyimide aerogel, Blueshift’s novel material system protects structures during transient thermal events from -200°C to beyond 2400°C for rockets, battery boxes and more.

A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

There are many problems with plastic recycling. I wanted to make 3D filament from recycling and that is when the problems hit you in the face. 1)Our current system for identifying the type of plastic is totally inadequate. #5 plastic is a wide variety of plastics 2)Unlike Consumer food grade Aluminum, most plastics are blends. The same additives that give plastics some very beneficial properties also cause problems when you try to recycle them. 3)The plastic degrades when you heat it. The additives cause problems when you heat them and as a result you don’t always end up with what you start out with. 4)Outgassing from the heated plastic is a real crap shoot. What chemicals are you subjecting yourself to when you heat these up?

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.

Analyzing structural resonance of the aircraft under various loads becomes a critical step in obtaining flight certification.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

New aircraft is expected to deliver wind turbine blades from 105 meters up to expand the reach of wind energy and achieve global climate goals.

Best bet is to gather a bunch of them and drop them off in the entryway of your nearest Wal-mart. They have a collection bin.

Arguably small scale aluminum recycling has similar drawbacks to plastic recycling w/o virgin material added. Cans/thin sheet are notoriously bad since they have all that surface area to oxidize without some process controls most backyard foundries ignore. It’s just that aluminum impurities are insoluble in the melt making it easier to retain material properties if you’re willing to accept comparatively high waste losses.

Kennametal will cover the influence of different composite materials characteristics on drilling performance and how to optimize the process. Agenda:  Who is Kennametal? Hole making challenges in composite materials Innovations for hole making applications Upcoming events and academic partnerships

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.

Because the overmolded ribs must match the pretreated areas, the ablation process requires high positioning accuracy. Subsequent placing of the overmolded glass fiber/PA6 composite material is strictly defined by the mold tool. Thus, a necessary part referencing methodology was developed by AZL. “The offset between the pretreated geometry and overmolded compound should be less than 300 microns. Thus, accuracy for the central point of the laser scan field (tool center point) must be within 150 microns relative to the reference point. This was achieved, as well as a cycle time of less than two minutes for the laser pretreatment. “Very important was the preliminary work by Fraunhofer Institute for Production Technology (IPT) to develop path generation for the robot and laser beam — this was not trivial,” says Schares. The system did indeed prove its mettle — test results showed a shear strength of 27 MPa between the GF/PA6 overmold and epoxy CFRP substrate.

The mold attached to the swiveling platen was used to form two different molding cavities for two different processes — expoxy prepreg compression molding and thermoplastic injection overmolding. “No one has created such a tool before,” Schares points out. BMW and KraussMaffei spent many weeks finalizing all of the requirements for both processes, including tolerances due to different temperature zones, turning accuracy and sealing for the thermoset resin, as well as the standard details for injection molding tools.

Base Materials introduces a high-performance, toughened epoxy tooling board designed for thermoforming and vacuum forming processes, direct-to-part applications and more.

We imagine you’ve heard this already, but waste plastic is a problem for the environment. We wrap nearly everything we buy, eat, or drink in plastic packaging, and yet very little of it ends up getting recycled. Worse, it doesn’t take a huge industrial process to melt down a lot of this plastic and reuse it, you can do it at home if you were so inclined. So why aren’t there more localized projects to turn all this plastic trash into usable items?

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.

How the predictive tool “CZone” is applied to simulate the axial crushing response of composites, providing valuable insights into their use for motorsport applications.

None of the above is a big problem for commercial foundries because they use electric arc furnaces with inert gas and synthetic cryolite flux to keep the aluminum from oxidizing.

While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?

Aerospace manufacturer joins forces with composite materials company to achieve sustainable manufacturing practices that overcome traditional composite layup tooling.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

EU project will develop bio-based, repairable and recyclable vitrimer composites and advanced sensors for highly reliable, sustainable wind blades.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.

This is what the three-year project OPTO-Light, which ended in 2018, set out to answer. It was funded by Germany’s Federal Ministry of Education and Research (BMBF) as part of its strategy to develop photonics — light-based technology such as lasers — for mass production of lightweight constructions. The project was awarded to the Aachen Center for Integrative Light Construction (AZL) at RWTH Aachen University (Aachen, Germany), which provides a single campus for companies to collaborate with eight research institutes to develop lightweight materials, production technologies and applications.”

The video after the break goes into intricate detail about the process involved in creating the 3D CAD files necessary to make the injection molds. Even if you don’t plan on recycling milk jugs at home, the information and tips covered in the video are extremely helpful if you’ve ever contemplated having something injection molded. The video even demonstrates a neat feature in SolidWorks that lets you simulate how molten plastic will move through your mold to help check for problem areas.

But… before I can be convinced that home plastic recycling can be a useful tool for helping the environment I would need to have a couple of questions answered. First, how does the energy efficiency of some guy in his garage recycling plastic compare to that of a high volume factory? I suspect it’s pretty poor. Second, how about emissions? Factories (in the developed world) are regulated, regularly inspected and usually employ high tech scrubbing technologies on their emissions. The garage maker who blows air through a box of aquarium charcoal is probably ahead of the curve when it comes to non-professionals.

Thus, the objective was defined, but the issue was how to combine both materials in a single molding cell. Schares explains how the industry partners were selected. “BMW had the most experience with serial production of CFRP parts. KraussMaffei was very proactive in creating combination technologies, such as its ColorForm multi-component injection molding machine and FiberForm hybrid molding machine.”

Herone, Spiral RTC, Teijin Carbon Europe and Collins Aerospace Almere recycle A350 thermoplastic composite clips/cleats waste into rods for the all-thermoplastic composite Multifunctional Fuselage Demonstrator’s crown.

Program will focus on sustainable, next-gen wing solutions, including in wing design and manufacturing and advancements in carbon fiber-reinforced composite materials.

Why join thermoplastic overmolding to a thermoset composite part? “Thermoset CFRP components made with epoxy resin offer the best characteristics for car body applications,” asserts AZL research engineer Richard Schares. Overmolding thermoplastic composite ribs increases the part’s design stiffness (section modulus), thus reducing the amount of carbon fiber required. “Using a rib thickness equal to that of the CFRP shell, the specific bending stiffness of the OPTO-Light demonstration part can be tripled,” he adds. Overmolding can further reduce part cost by providing molded-in attachment clips or bosses for screws while simultaneously providing isolation to prevent galvanic corrosion between the carbon fiber and metallic fasteners.

A section of the BMW i3 Life Module floor panel demonstrates a serial production hybrid composite molding cell which uses a central swivel platen to accommodate both thermoset prepreg compression molding and thermoplastic overmolding while photonics provides essential part referencing and more.

An on-demand mapping tool for anisotropic materials and polymer material fracture prediction model, i-Lupe, aims to help predict impact, crash behaviors.

The key to this process route is process monitoring. “You must look inside the prepreg compression molding process because knowledge about the state of cure must be sure in order to achieve a good join with the thermoplastic overmolding,” he explains. This cure state monitoring was achieved by using in-mold pressure and temperature sensors, as well as in-mold direct current resistivity (DCR) and dielectric analysis (DEA) sensors.

The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.

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Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

Celebrating National Composites Week 2024, CW looks at how composites are being used to provide the next generation of energy.

So again, I am all for encouraging people to do this. I just don’t think selling the idea as ‘saving the environment’ is necessarily honest or correct.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

American Bureau of Shipping (ABS) certifies use of jointly developed CFRP repair technique on FPSO and FSO industrial systems, addressing traditional steel restoration challenges.

In order to reclaim the value of the plastic, it’s often not even useful to collect it, because the collection costs resources. That’s a good way to gauge whether the recycling is worth it: if they pay you money, the material must be worth more than the money. If they demand you to sort/collect/return the items for nothing, it’s probably not worth recycling and should be burned with regular trash.

We regularly buy H2O2 for the pool and several other stuff in blue ones (we had also acetone and HCl in blue ones). I have uncolored for water, one also contained H2O2 before. I also have black and orange ones for gasoline. So there seems no color code.

Closed mold processes have many advantages over open molding. In this knowledge center, learn the basics and vital tools needed to produce parts accurately.

Nope. The UK and the rest of the EU has the same color/usage regulations as us. Red for leaded gas, green for unleaded, etc.

Automated preforming of thermoplastic tapes and subsequent hybrid molding — thermoforming and injection overmolding ribs, clips and bosses onto part surfaces — have been heralded as the future for composites manufacturing in high-volume applications such as automotive. But what if it was possible to combine the toughness of thermoplastics and functionality of injection molded features with the high performance of carbon fiber-reinforced epoxy parts?

The multifunctional laser scanner emits a laser beam with a wavelength of 1.064 nanometers in nanosecond pulses. “You need high intensity, and pulsing achieves this most efficiently,” Schares explains. “We tried a continuous wave laser, but it introduces too much thermal stress into the composite laminate below the joining zones, reducing the fiber-epoxy adhesion. Finding a process-suitable beam source that can be used for remote-processing in an industrial environment was not easy.”

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Prior to placing in the OPTO-Light molding cell, towpreg and prepreg tape materials are converted into net-shaped, 2D tailored blanks using automated preforming equipment, such as Broetje-Automation’s (Rastede, Germany) STAXX tape placement cell.

The Marservis PROeco is a mass transportation marine vessel using Bcomp natural fiber for interior parts in place of standard materials.

Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.

DCR and DEA are well-established for cure monitoring in composites.In OPTO-Light, the DCR/DEA process control comprises an Optimold system from Synthesites (Uccle, Belgium) including a durable 16-millimeter DCR sensor and Optiview software. Optimold monitors the resin’s electrical resistance and temperature up to 210°C and pressure of 90 bar with a sampling rate of 1 Hz. The DEA288 Epsilon analytic device from Netzsch Gerätebau (Selb, Germany) includes a 4-millimeter ceramic monotrode and Proteus software. Kistler Instruments (Winterthur, Switzerland) DataFlow software for injection molding optimization is another key component.

Reliable news and information on where and how fiber-reinforced composites are being applied — that’s just the start of what you get from our team here at CompositesWorld.

The ITHEC 2024 will take place from the 9 to 10 October 2024 in Bremen, Germany. At the 7th International Conference, more than 300 participants from around the world will be presenting and discussing newest scientific results, meet leading international specialists, share their expertise and start business co-operations in the field of thermoplastic composite technologies. The international exhibition will feature 40+ exhibitors showcasing all steps of the supply-chain. Be it materials, machines, testing, processes, or solutions. By combining the exhibition and the conference ITHEC is further fostering the inter-connectivity between science and industry.

The final four OPTO-Light partners are German photonic systems suppliers. The first, Arges (Wackersdorf), is an expert in 3D scanners used for laser machining. “It typically develops innovative laser scan systems, positioning and deflecting laser beams in industrial materials processing and medical applications,” says Schares. “An Arges double-beam unit was developed for ablation and heating. Precitec (Gaggenau) supplied the interferometric sensor for measuring distance used during ablation and part referencing throughout the process. Sensortherm (Sulzbach) provided the pyrometer (temperature sensor) which aided process control, and Carl Zeiss Optotechnik (formerly Steinbichler, Neubeuern) contributed the T-scan laser scanner for QA. “It measures part geometry and detects potential deformation,” explains Schares. “It will show defects, such as the overmolded rib not completely bonded to the CFRP shell.” All of these systems are integrated into the multifunctional laser scanner (Fig. 2), which is mounted on the end of a six-axis Kuka (Augsburg, Germany) robotic arm.

Also, lets not forget the duality of sustainable vs durable. On the one hand you have biodegradable plastics, which wont last hundreds of years if left in the environment, but these are also much more prone to falling appart during heating. And on the other hand you have the plastics that you can recycle, but which will last forever in the scrapheap.

A section of the BMW i3 Life Module floor panel was selected to demonstrate process scalability for serial production. Four different epoxy prepreg materials were evaluated for compression molding of the part shell.

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.

etc etc etc. the jist of most of the articles I’ve seen posted around here is that what you’ll end up with is some pretty inferior stock. if you where concerned about upcycling the materials you’d be doing so at a loss because you’d have to mix in higher quality stock and properly mix it in with the mulch so it blended adequately. with all the inks pigments and general discrepancies between any two shopping bag though you’ll end up with densities that wouldn’t be very good for much of anything- well aside from a plastic mallet made of milk jugs but that’s already covered.

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.

The final lesson OPTO-Light offers in hybridization is in its partnership. “The most interesting challenge in managing this project was how to take all of the different partners, each with their unique expertise — for example, photonics, reaction polymers, injection molding, metrology — and have them develop and advance a common understanding of the effects of each operation in order to make this single process chain successful,” says Schares. He stresses the importance of the expertise and support contributed by five partner institutes — IKV injection molding, IKV reaction polymers, ISF for welding and joining, Fraunhofer IPT for laser integration and Fraunhofer ILT for alternative laser sources. “This project demonstrated the ability of such interdisciplinary development to efficiently solve technical challenges for reduced-cost composites production,” says Schares. It has also laid the groundwork for even further disruptive innovation.

This sidebar to CW’s August 2024 feature article reviews this technology for more efficient composites manufacturing and why it aligns with Koridion active core molding.

Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.

Initial tests show a pull-off strength of 9 N/mm2 and an even higher shear strength for the epoxy-PA6 join using this second, shorter OPTO-Light process route. Work is ongoing to improve this join strength, including further use of process monitoring. The team is also exploring a one-step process in which horizontal prepreg compression molding is no longer a separate process, but is instead achieved simultaneously with overmolding.