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

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.

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

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

Given the investments necessary for developing the next-generation machines, many of these smaller players are looking for capital. Consolidation in the market has therefore begun. Uncertainty about which manufacturers will survive will change the face of the industry, creating risk for manufacturers investing in equipment even as improving technology holds out the promise of surmounting current barriers to the adoption of AM.

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

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

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

People tend to overestimate the short-term impact of technologies and significantly underestimate the long-term impact. Yet there is currently a lot of uncertainty about the long-term impact of AM on traditional value chains. Understandably, the issue is being raised by traditional players such as logistics companies that will be directly affected, and by governments that aim to prepare their manufacturing ecosystems and workforces for changes that may be coming soon.

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

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

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.

Its latest printer, the Massivit 10000-G is the culmination of this vision. The system crafts epoxy molds, but also enables tooling applications for thermoforming, resin transfer molding (RTM) and reaction injection molding (RIM). New features expand this output to include direct custom manufacturing of end-use parts and functional prototyping. Custom molds for composite parts can be manufactured using Massivit’s patented cast-in-motion (CIM) technology to automate isotropic mold production and decrease fiber-reinforced polymer (FRP) tooling time by up to 80%, thereby decreasing labor-associated costs by 90%.

Universities are partnering with manufacturers’ research centers to create innovation centers for applied R&D, with examples including Advanced Remanufacturing and Technology Centre in Singapore and RWTH Aachen University/Fraunhofer Institute for Production Technology. Finally, a vibrant start-up scene has arisen as most patents on existing AM technologies have run out, leaving space for new (as well as established) players from various industries to enter at all points on the value chain. New design and service companies are being set up and new technologies developed, such as by BigRep and Carbon3D.

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

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

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.

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

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

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.

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

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.

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.

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.

This 21-article compendium gives practical insights for manufacturing leaders looking to keep a step ahead of today’s disruptions.

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.

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

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

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

This 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.

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

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

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

Meanwhile, the number of materials that AM can handle is constantly expanding. A wide range of new plastics has been developed, along with processes and machines for printing with ceramics, glass, paper, wood, cement, graphene, and even living cells. Applications are now available in industries ranging from aerospace to automobiles, from consumer goods (including food) to health care (where artificial human tissue can be produced using AM) (Exhibit 1).

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

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

The AM landscape is diverse. In the plastics printing market, larger, integrated players cover the entire value chain from supplying materials to manufacturing printers to providing printing services. Several have added services by making targeted acquisitions. The larger players are also very active in creating new use cases in particular industries, driving sector-wide adoption and sale of equipment. In the metal printing market, by contrast, relatively small players focus more on certain parts of the value chain, such as in printing equipment or in printing services.

Company functions of today will also change when, for example, operators skilled for one production line will need to operate new AM production lines that produce a large variety of products. Traditional engineers will need to be trained in AM design. Marketing and sales, meanwhile, will need to learn how to market individualized products that can be produced anywhere in the world.

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

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 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.

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.

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.

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

Meanwhile, various stakeholders are accelerating the overall market development for AM. Large OEMs are investing significantly in R&D and building internal centers of competence, while other large corporations—such as HP, from the traditional printing business—are entering the market. Major governments are setting up R&D funds, including the European Union’s Horizon 2020 program, or are starting capability-building programs for their workforces, as in Korea.

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.

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.

Meanwhile, in addition to the traditional material, printing, and service businesses, fast-growing niche players are starting to arise. These companies ground their entire business models on AM, ideally combined with digital sales and service models. Align Technology, with its product Invisalign, provides an alternative to metal dental braces; there are similar examples from Sonova for in-ear hearing aids, Mykita with eyeglasses, and Shapeways with crowd design of consumer products.

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

Adoption of AM has been highest in industries where its higher production costs are outweighed by the additional value AM can generate: improved product functionality, higher production efficiency, greater customization, shorter time to market (that is, improved service levels), and reduced obsolescence, particularly in asset-heavy industries. Engineering-intensive businesses such as aerospace, automotive, and medical can accelerate prototyping, allowing them to explore completely new design features or create fully individualized products at no extra cost. High-value/lower-volume businesses see faster, more flexible manufacturing processes, with fewer parts involved, less material wasted, reduced assembly time for complex components, and even materials with completely new properties created. And spare-parts-intensive businesses in fields such as maintenance, repair, and overhaul get freedom from obsolete parts, faster time to market, more local and on-demand production opportunities, and independence from traditional suppliers.

We are also seeing an increasing availability of materials with properties comparable or even superior to those of existing ones. These materials include polymers such as nylon, PEEK, and ULTEM that are becoming more heat resistant and lending themselves to more applications, and metals and alloys within the standard range of available materials: industrial metals such as steel, aluminum, titanium, and Inconel; precious metals such as gold and silver; and new materials including amorphous, noncrystalline metals.

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

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

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

New competitors are also entering the OEM market. Large players such as Stratasys and 3D Systems are certifying an end-to-end process for producing medical parts with newly developed materials, using their own printing technology and offering printing services to customers such as hospitals, which formerly purchased from OEMs.

Massivit says its systems also make it easy to stay green, with sustainable, efficient, digital printing. Users only need to use the core material required, waste associated with CNC machining is eliminated and the need for extensive support structures is removed.

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

How will the traditional way of serving markets change, and what are the implications for traditional plant setups and value chains? As far as production and distribution are concerned, a few things seem clear. Advantages from production in low-cost countries will likely diminish. New, customer-centric plants will emerge, allowing the finishing of products according to local demand and significantly reducing the need for long-distance transport of finished goods. We may also see new production-network models—for example, production of half-finished products in low-cost countries, with finishing done close to customers to adjust for local taste, seasonality, and similar factors.

Several analyst reports expect that the direct market for AM will grow to at least $20 billion by 2020—a figure that represents just a fraction of the entire tooling market today.1 1.Nancy Eigel-Miller, Joe Jablonowski, and Steven Kline Jr., 2014 World machine-tool output and consumption survey, Gardner, February 27, 2014, gardnerweb.com. However, we believe that the overall economic impact created by AM could be much higher, reaching $100 billion to 250 billion by 2025, if adoption across industries continues at today’s rate. Most of that potential will come from the aerospace and defense, automotive, medical, and consumer-goods industries.

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.

Massivit 3D (Lod, Israel) is transforming additive manufacturing with its patented gel dispensed printing (GDP) dual-head systems, which the company says are significantly faster than other 3D printing technologies. The high-speed system is applied to print full-sized parts (4' × 5' × 6') across the entire manufacturing line. Industrial, isotropic, epoxy-based molds with high-performance materials are made possible in a matter of days instead of weeks or months.

Despite all of the optimism about AM, there are still major challenges to be overcome before the technology enjoys truly widespread adoption (Exhibit 3).

AM machine manufacturers are working on better in-process control, advanced quality diagnostics, and data storage along the entire production process for certification purposes. Large AM manufacturers, including Materialise and Stratasys, suggest that AM can achieve material properties in both plastics and metals comparable to those from traditional production techniques.

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

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

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

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

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

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.

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

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.

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.

We see little evidence of a race toward a single technology, since—because of factors including variations in cost, available materials, and surface finish—the existing technologies serve different purposes. To explore the potential of AM, manufacturers therefore often need access to more than one technology, which they can get via specialized service providers that offer all the key ones. This picture may change, however, if new entrants dramatically increase performance by improving an existing technology or creating a completely new one.

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

Additive manufacturing (AM)—the process of making a product layer by layer instead of using traditional molding or subtractive methods—has become one of the most revolutionary technology applications in manufacturing. Often referred to as 3-D printing, the best-known forms of AM today depend on the material: SLS (selective laser sintering), SLA (stereolithography), and FDM (fused deposition modeling) in plastics, and DMLS (direct metal laser sintering) and LMD (laser metal deposition) in metals. Once employed purely for prototyping, AM is now increasingly used for spare parts, small series production, and tooling. For manufacturing with metals, the ability to use existing materials such as steel, aluminum, or superalloys such as Inconel has significantly eased the process of adopting AM.

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!

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.

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.

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

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

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

CAMX 2023: The Massivit 10000-G, with gel dispensed printing offers an ultra-fast, sustainable and cost-effective way to digitize isotropic mold production for high-quality and more reliable composite parts.

Compared with traditional production methods, AM offers enormous benefits, including less hard tooling and assembly. In the long run, AM can completely change the way products are designed and built, as well as distributed, sold, and serviced (Exhibit 2).

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).

With these changes in production capabilities will come equally dramatic shifts in company functions and their relative importance on the value chain. The ability to make completely customizable products will shift the traditional manufacturing mind-set of “What is feasible?” to one of “What is possible?” Design capabilities will therefore become an even more important strategic asset.

Manufacturers of AM machines, however, are addressing these limitations with significant results. Specialized AM service companies, along with engineering and consulting firms, are now bridging the design-skills gap. In addition, regional governments are funding AM-focused production clusters for applied R&D. Several analysts predict that next-generation machines will cut current AM production costs dramatically because of factors such as patent expiration and reduced postprocessing needs. Manufacturers will also benefit from increasing economies of scale and sourcing opportunities in low-cost countries.

Founded in 2013, Massivit’s vision is to transform the manufacturing of large parts from traditional processes to on-site, ultra-fast, digital and sustainable fabrication using industrial-grade materials. Driven by a passion to solve real-world manufacturing needs, Massivit has developed a portfolio of large-scale 3D printers, enabling customers across 40 countries to automate their production, reduce manufacturing costs and minimize waste.

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).

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.

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

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.

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

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

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