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

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.

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

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.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

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.

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

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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

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 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.

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

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

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

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

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).

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

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

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.

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

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

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.

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

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

Milacron Holdings Corp., Cincinnati, is introducing a new way to take advantage of its Kortec co-injection technology for products needing a three-layer barrier sandwich structure. Up to now, Milacron has offered turnkey systems (now branded Kortec Complete) consisting of a two-component injection machine, Kortec hot runner and engineering support—including integration assistance, startup, and training. Now, molders who wish to use an existing injection machine can choose the new Kortec Connect package, which comprises a Kortec hot runner, Mold-Masters E-Multi secondary injection unit as an add-on for the existing press, and the same engineering support.

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.

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

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:

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

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

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.

NPE2024: Coinjection of postconsumer resin, in-mold decoration, LSR micromolding and bioplastics processing are just some of the machine displays at Milacron's booth.

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

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

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

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.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

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

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

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.”

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).

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

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!

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.

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

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.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

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.

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 used by composites manufacturers working in the evolving space market.

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.

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

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

AE Plast opted for tiebarless multimaterial Engel victory machines as it took on complex parts for the appliance and power tool market, including a 3K housing for Dremel’s rotary tool.

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.

Milacron claims 30 years of experience in co-injection, with over 100 systems in the field, producing 12 billion parts in 18 countries. Kortec Connect will be featured at NPE2018 May 7-11 in Orlando, Fla., at booth W2703.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

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.

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

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.

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.

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

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.

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.

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.

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.

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.

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

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

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

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.”

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

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

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?

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

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.

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).

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.

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

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.

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.

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

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

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

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

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.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

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.

Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. About Us

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

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?

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.

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

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

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

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.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

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

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

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

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.”

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.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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.

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.

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.

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.

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.

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.

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.

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

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).

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

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

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).

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

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:

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

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

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.

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

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.

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.”

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.”

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.

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.

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.

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

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

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.”

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.

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

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

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

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

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

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.

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

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

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

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

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

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.

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.