Manufacturing - plastic prototype manufacturing

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

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.

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

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.

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

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).

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

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.

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.

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

Nowhere is this more apparent than at Plastek UK’s 18,000sqm factory in Mansfield, Nottingham, where 41 injection moulding machines work round the clock to produce the intricate components that make up aerosol assemblies and closure systems for laundry, personal care, cosmetic, pharmaceutical, food and baby formula products.

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.

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!

Under press reversing reject belt conveyors are operated via the SPC control system, ensuring only good product continues on to the swan neck belt conveyors.

“Typically, conveyors consist of two rollers with a belt stretched over them, but there are inherent problems with this design, as the belt can start to wander,” says Fowler.

Key to Plastek’s business model is minimising manual intervention in its processes – not only for speed, but also quality purposes.

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

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.

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

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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.

The conveyors are fitted with cooling tunnels, as well as search coils under the belts to detect metal, and ionisers to remove static, preventing dust from clinging to the products, or the products from sticking to one another or equipment.

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

Sophisticated automated product handling systems, with fail-safe features, have enabled plastic packaging manufacturer Plastek UK to expand its business with blue chip brands. Lynda Searby looks into the project

Products must also be cooled along the way – essentially it is this that dictates line speed, according to Warboy. “The speed of the conveyors is set to allow enough cooling time to bring the products down from about 60-70°C to ambient temperature,” he says.

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

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.

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

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

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

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.

“Products are transferred to the fully automatic assembly and packaging machine without any manual involvement.” It is, in part, thanks to product handling systems from UPM Conveyors in Langley, Berkshire, that this is possible.

The fast moving consumer goods business is, as the name suggests, fast. And this time pressure is felt right back through the supply chain.

The systems also incorporate a number of fail-safe features, as it is crucial for such a high volume business to keep downtime to a minimum.

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

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

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

Plastek now has three production cells, all manufacturing aerosol assemblies, that use UPM equipment to transfer parts from the injection moulding process to the point of assembly. Two of these cells consist of four injection moulding machines feeding two assembly stations, and the third links eight injection moulding machines to two assembly stations. Moulded components are discharged from the well of the injection moulding machine onto belt conveyors, transferred onto swan neck type elevator conveyors, and lifted five metres to high level conveyors to minimise floor area occupied. They then pass through a firewall to the assembly area, where there is an over-capacity storage facility fitted with height level detectors.

UPM installed its first system at Plastek UK in 2005, and has since supplied two further systems – the latest investment went in last October.

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

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

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.

The fabrication of the proposed thermoplastic uses hybrid overmolding where thin sheets of carbon fibers are combined with Victrex’s LMPAEK polymer, creating a unidirectional (UD) tape. This material is then stacked and consolidated into one panel with the application of heat and pressure, with small pieces cut from the panel. Finally, the short fiber-reinforced PEEK compound is injection molded onto the insert. A fusion bond similar to a weld forms between the PEEK compound and LMPAEK composite insert as the molten PEEK melts the surface of the insert. As the part cools, the PEEK compound and LMPAEK composite solidify as one piece.

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

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.

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

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

“To minimise damage and distortion to components, we don’t really handle any semi-finished products,” explains Darren Warboy, engineering and site services manager at Plastek UK.

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

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

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

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 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.

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

To this end, all UPM equipment is centrally controlled via a HMI touch screen which interfaces with UPM’s statistical process control (SPC) system.

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

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

Each robotic assembly cell builds 360 aerosol systems per minute, enabling Plastek UK to honour its existing client contracts. Based on the performance of the three UPM systems already in operation at its factory and on the back of being awarded a new major contract, Plastek UK has just put in an order for a fourth system, to be installed later this year.

Who Plastek UK Aim To automate the transfer of components from injection moulding to assembly at its Nottingham site What Three product handling systems from UPM Conveyors Spend Undisclosed When 2005 to present

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.

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

“If there is any deviation from the set process parameters, SPC detects this and diverts out of specification product to a holding bin,” says Warboy.

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.

To eliminate the need for belt tracking and tensioning, UPM developed plastic conveyors with the side frames produced from High Molecular Weight Polyethylene which are cut on an in-house router together with the machining of channels  either side of the frames to locate the belt. This makes the belts particularly suitable where there are changes of angle or swan neck conveyor arrangements – as was the case at Plastek UK.

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

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.

“Turnover has increased considerably in the last few years. We’re now at 41 injection moulding machines and 18 robot assembly packing cells, and we’re looking to continue this growth in 2014 and beyond,” says Warboy.

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

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

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.

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.

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.

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 factory doesn’t just mould the components, it also assembles them – complex four or five part assembly processes – before packing them for delivery to blue chip customers who are well known household names. It is a high volume business for a customer base with exacting demands, and Plastek has to strike a balance between being competitive and maintaining profit margins.

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.

But there is far more to it than this. To give an idea of the scale of these projects, Roy Fowler, sales director of UPM Conveyors, explains: “From leaving the injection moulding machine, components travel about 100 metres through different heights and levels to the assembly area.”

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

Tool Gauge (Tacoma, Wash., U.S.), a U.S. manufacturer of complex, high-value plastic and metal assemblies for global aerospace OEMs, and Victrex (Lancashire, U.K.). a company offering polyetheretherketone (PEEK) and polyaryletherketone (PAEK) based polymer solutions, are collaborating to develop a new co-molding technology for the aerospace industry. This solution will use formed carbon fiber composites combined with carbon-filled thermoplastics.

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

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

Carbon fiber-reinforced PA12 thermoplastic launched by CRP Technology is a 100% recycled high-performance material derived from the Top-Line range for 3D printing.

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.

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).

“As a solution provider, Victrex firmly believes that the path to innovation lies in understanding customer needs and pioneering solutions where PEEK and PAEK deliver a strong advantage,” adds Jonathan Sourkes, head of market and business development for Victrex. “Through this, we continue to redefine what is possible, delivering transformative solutions that address pressing, unmet industry needs. Our commitment to innovation and strategic collaborations enables us to be at the forefront of technological advancements, driving progress and creating a more sustainable future for industries worldwide.”

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.

Novel hybrid overmolding technology achieves novel thermoplastic composite parts to replace machined aluminum components on commercial aircraft, as well as reduce manufacturing costs and timeline.

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

“The aerospace industry continues to increasingly adopt thermoplastic materials as they lower aircraft weight, reduce time and waste from machined metals and provide sustainable goods for our future,” explains Jim Lee, general manager of Tool Gauge. “As part of this collaborative project with Victrex, we aim at replacing machined aluminum components used in commercial aircraft that are currently expensive and take months to produce with new thermoplastic composite versions.”

The hybrid overmolding process creates a part that is reported to be mechanically stronger and stiffer than a part only made with PEEK compound due to the continuous fiber used in the composite insert. The hybrid overmolding combines injection molding with thermoforming to create a finished part that is lighter, cheaper, produces less waste, can be produced faster and has optimized fatigue performance.

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

The design of UPM’s conveyor belts, which won a Queen’s Award for Innovation, also contributes to Plastek’s zero maintenance goal.

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 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 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

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.

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

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.

“We’re in the fast moving consumer goods business; we need to keep maintenance, downtime and manual intervention to a minimum,” says Warboy. “With the customers we’ve got, we can’t exactly pick up the phone and say we’re going to be late with their order.”

In addition, if there is a problem with one of the assembly machines, the product flow can immediately be diverted to a different assembly machine, eliminating a potential source of downtime.