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

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

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.

“The ROBIN end effector comprises a C-frame made of carbon fiber composite and on the outside you see an aluminum frame,” explains Stegelmann. “The frame contains the lightweight locking system, which handles up to 12 tons of loading forces during injection molding, brought from the upper side to the lower side of the mold.” ROBIN can also reach out to a 1-meter cantilever across large structures. “This is our know-how within ILK — how to use carbon fiber and lightweight materials in the right way.”

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

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

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

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

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.

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.

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

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?

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.

Plasteurope.com is a business information platform for the European plastics industry. It is part of KI Kunststoff Information and PIE Plastics Information Europe, one of the leading content providers for the European plastics industry. We offer daily updated business news and reports, in-depth market analysis, polymer prices and other services for the international plastics industry, including a suppliers guide, career opportunities, a trade name directory and videos.

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

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 latter is why Anybrid assists its customers with testing. “We get customers that are not sure if their materials will bond to each other,” notes Stegelmann. “We ask them to send us some of the material and we then make some small, simple structures to test. We have a small mold for a stiffening rib that we can injection mold onto different plates. For example, if the customer sends us samples of some composite plates, we can overmold onto these with their injection molding materials. That's the first step, that we have a feasibility study of the bonding behavior of the different materials. After that, we can do some analysis and offer suggestions for optimization.”

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.

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

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

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

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

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

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).

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This reduction in size does limit the area that can be overmolded. “At the moment, we are limited to 50-60 grams for the injection shot,” says Stegelmann. “We developed ROBIN to weigh just 140 kilograms, which makes it possible to use smaller, more affordable automation. We are focusing right now on functionalizing pipes and profiles and adding smaller elements to larger structures.”

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.

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

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.

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.

For example, in the overmolded tube shown below, Mitsui Chemicals Europe (Dusseldorf, Germany) supplied the carbon fiber-reinforced polypropylene (PP) unidirectional (UD) tapes and INOMETA (Herford, Germany) used these to produce composite tubes, which Anybrid then overmolded. “The functionalization was the same material as the pipes are made of,” says Stegelmann. “We overmolded it with both unreinforced and carbon fiber-reinforced PP material, but also with glass fiber reinforcements as well. With ROBIN, you can manufacture with any thermoplastic material that is on the market.”

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

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.

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.

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

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

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

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

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

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 traditional approach to injection molding requires large presses and expensive molding tools. Thus, it has been limited to large-series/high-volume production. In contrast, ROBIN enables manufacturing of small series or multiple, different moldings on larger components. “The principle is that we have such a flexibility in the machines that we can functionalize almost any composite material or structure,” notes Stegelmann.

Anybrid’s mobile injection molding approach provides an affordable means for a wide variety of functionalization — e.g., inserts for fasteners and LED lights, localized stiffeners and customized end-fittings — to composite pipes, tubes, profiles, plates and even larger structures, providing the flexibility needed for future manufacturing.  Photo credit: Anybrid GmbH

“We try to minimize the size of the molds to reduce costs, so you just need a few thousand euros to build the mold,” Stegelmann explains. “This allows an integrated quick change-out system because only a small mold area has to be changed. The idea, for example, is that you have an assembly line with the possibility to quickly change the mold and do a different part on two different sides of the line. You can either use two Robin systems or one Robin system and quickly change the mold. So, you have high flexibility.”

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

ROBIN, short for “robotized injection molding”, was first presented in 2019 at the K show in Dusseldorf, Germany. “We then founded the company last year and are now working with customers to establish pilot production lines using the equipment,” says Stegelmann. The concept, he explains, is to reduce the mass of the injection molding machine by using small injection units and compact, inexpensive molding tools that can be quickly exchanged.

Anybrid GmbH (Dresden, Germany) is a spin-off from the Institute for Lightweight Engineering and Polymer Technology (ILK) at TU Dresden. ILK works with industry to develop new lightweight technologies, with a focus on reinforced polymer composites. “We developed this robotized injection molding machine two years ago for producing hybrid components,” says Michael Stegelmann, chief commercial officer at Anybrid. Hybrid components refers to functionalizing a structure — for example, a composite tube or metal electric vehicle chassis — with injection-molded plastic to create local attachment points, stiffening ribs, etc.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

“We are still exploring applications, but we are initially working with pipes and profiles,” says Stegelmann. “One of our ideas is to sequentially bring different structures onto these continuous, potentially very long shapes,” says Stegelmann. “So, elements can be applied directly to pipes. Such concepts are already being used by INOMETA and Herone (Dresden, Germany) to integrate axial connection systems and form-fitting gears. This also might be interesting in the aviation industry, where you need various stiffness enhancements and perhaps want to add functions such as attachments. Also, you may have a stringer or frame, for example, but many variations in length. With our technology, there is the possibility to maintain a high level of automation and just vary the elements that you are functionalizing from one part to the next.”

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 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.

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).

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

Award-winning motorcycle brake disc cover showcases potential for KTM Technologies’ Conexus joining technology and flax fiber composites.

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

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.

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

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

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.

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

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.

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

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

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

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

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

“There is also potential with large components,” says Stegelmann. “Working at ILK for the last years, we developed many different hybrid components using steel, plastic and composites. We could see that overmolded clips on structural frames and chassis makes sense for assembly. And with the move to electric vehicles and hydrogen systems, we see that it is important to make assembly lines and processes as flexible as possible, to prepare for a variety of different components that may be needed in the future. With ROBIN, you can easily adjust local enhancements for assembly but also for stiffness of the structure, for example. However, we want to extend this capability beyond just automotive and aerospace. Our idea was to make this more affordable for small companies and enable this hybrid technology for smaller quantities in other fields and other applications.”

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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.

Light weight, simplified/cost-effective manufacturing, passenger comfort and safety informed materials and process innovations and won awards for the 2022 Toyota Tundra‘s second-row seat frame.

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

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

“This is actually our background,” says Stegelmann, referring to Anybrid’s four co-founders. “We did this in a lot of projects over the last 10 or 15 years, combining different materials and finding the right bonding, I did my PhD on extrusion processes, and it's always challenging when you are combining different materials. You always need some additional preparation for bonding like plasma treatment or laser treatment, to alter the surface structure, especially when bonding plastic or reinforced plastic onto metal. Composites are a bit easier, because you can match the polymer matrix in the injection molding material and the substrate.”

Combining braided tape, overmolding and form-locking, herone produces one-piece, high-torque gear-driveshaft as demonstrator for broad range of applications.

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.

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

This process, referred to as overmolding or hybrid injection molding, has gained a lot of attention over the past 5-6 years, but in a more traditional form — steel molds in a molding press with an attached injection unit. Anybrid has essentially miniaturized this setup into the red and black, C-shaped end effector shown on the Kuka robot in the image above and video below. The result is revolutionary, enabling pultrusions or extrusions to be overmolded as they exit the molding die or large structures to be functionalized as they move down an assembly line.

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

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.