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.

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

New robotic and digital technologies are enabling advanced in-house capabilities for small companies and innovative suppliers willing to embrace the move toward more affordable, sustainable composites.

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.

In 2021, Al-Sheyyab and his team began an extensive study with Anybrid on thermoplastic extrusions, composite profiles and molded parts. By late 2022, they had successfully overmolded profiles offline but also integrated a ROBIN unit into a production line at the REHAU technical center, where profiles were overmolded in-situ.

“We developed this robotized injection molding machine in 2019 to produce hybrid components,” says Michael Stegelmann, managing partner at Anybrid (see “Robotic injection molding for functionalize composites”). “Hybrid components” refers to functionalizing a structure with an injection molded polymer to create local attachment points, stiffening ribs, etc. This overmolding process has gained traction in composites, but typically uses a traditional injection molding machine.

“Dongnam sent us some of their pelletized materials and we did overmolding tests using ROBIN,” says Stegelmann. “The materials processed really well and create a whole new possibility of generating functionalized biocomposites for furniture or consumer goods that eliminate the need for petroleum-based plastics. We see a lot of potential for using ROBIN with these cellulose polymers in the future.”

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

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.

Stegelmann notes the tests with CQFD produced a monomaterial system with excellent adhesion. Overmolding was also demonstrated using Mitsui Chemicals’ PP material. “I was surprised by the great adhesion quality of the first trials using PP,” says Stegelmann.

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

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.

Chauzu adds, “Due to the great flexibility of the Anybrid technology, the combination with our thermoplastic pultrusion leads to many interesting applications to develop together.”

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).

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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

As explained on the REHAU Germany website, when Dr. Stephan Sell, research chemist in Al-Sheyyab’s team, first saw Anybrid’s ROBIN technology at the K trade fair in 2019, he could see many opportunities for it at REHAU. “They have succeeded in transforming the otherwise stationary injection molding machine into a mobile machine that can be moved freely in space,” says Sell. “This means that functional elements such as seals, metallic inserts, connecting elements or ribs can be retrofitted to existing molded parts, profiles, semi-finished products and metal hybrid composites.”

“Summit’s leading customer base includes some of the largest and most recognizable players in the medical and packaging spaces,” said Matthew Puglisi, Partner of Core. “This acquisition significantly enhances Fathom’s domestic injection molding and tooling capabilities, and we’ll continue to actively pursue acquisitions, similar to Summit, that simultaneously broaden our customer base, enhance our service offering, and deepen our presence in attractive, recession-resistant end markets.”

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

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

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.

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

Fig. 1. Functionalized automotive profiles. Anybrid worked with REHAU Innovation Group to integrate threaded inserts into GF/PA6 profiles by overmolding with GF/PA6 compound, including functionalization such as anti-twist features (top). The small size of the mold enables ROBIN to reach in between the walls on the rear side of the omega profile (bottom).

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

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.

Chicago-based private-equity firm Core Industrial Partners announced today the acquisition of Summit Tooling Inc. and Summit Plastics Inc. by its portfolio company Fathom. The precision tooling and injection molding supplier is the fourth add-on acquisition to the Fathom platform since Core made its initial investment in 2018.

In a separate trial, Anybrid was able to demonstrate the potential for ROBIN in combination with a new type of sustainable bio-based material. “We met Dongnam Realize [Daejeon, South Korea] when they won the JEC startup competition at last year’s composites show in Paris,” says Stegelmann. “Their CXP material uses a cellulose-based polymer made from waste wood products.” The Dongnam Realize website notes that cellulose cross-linked polymer (CXP) can be made from sawdust, wood chips, discarded vegetables and even invasive species like certain reeds and water hyacinth, for example.

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

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

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

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.

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.

Fig. 2. Inserts aid assembly. A metal insert can be placed inside the mold (red circle, top) and then ROBIN is positioned over the profile, the mold is closed and the insert overmolded. Such functionalized profiles enable quick assemblies, such as this shell demonstrator using ULTEM PEI composite profiles with integrated aviation-certified Böllhoff inserts.

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.

Fig. 4. Hybridizing reactive thermoplastic composite pultrusion. Anybrid demonstrated ROBIN’s ability to overmold onto high-fiber-content (up to 85% by weight) GF/PA6 panels (bottom) made by CQFD using its reactive thermoplastic pultrusion process (top). Photo Credit (top): CQFD

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.

GKN Aerospace has spent the last five years developing materials strategies and resin transfer molding (RTM) for an aircraft trailing edge wing spar for the Airbus Wing of Tomorrow program.

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).

“Summit’s focus on customers during the design, prototyping, and low-volume production stages of a product’s life cycle perfectly aligns with Fathom’s unique customer-value proposition,” Fathom CEO Ryan Martin said in a prepared statement. “We’re excited to work with the Summit team to explore opportunities to even better serve its customers through Fathom’s comprehensive digital manufacturing platform while also providing Fathom’s existing customer base expanded domestic quick-turn precision tooling and molding capabilities,” added Martin.

Founded in 1996, Summit provides plastic injection mold design, precision mold making, and close-tolerance injection molding with a specialty in small to medium prototype injection molds. Summit primarily serves long-tenured customers in the medical and packaging end markets with its fleet of more than 30 machines, said Core's announcement.

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 expertise of both teams was important in these developments. “The parameters from extrusion have to be brought together with those from injection molding,” says Sell. “It is important to match the speed of the production line to that of the part to be overmolded. For example, the cooling time of the overmolded element must be taken into account.”

In-house metalworking capabilities include engineering design, sheet metal shearing, punching and bending, roll forming, hardware integration, welding, grinding, polishing, painting, and assembly. Summit’s thermoplastics engineering expertise allows the company to process multi-shot and bi-injected tooling and perform insert overmolding. Pad printing, hot stamping, ultrasonic welding, and assembly are also offered by the company, which operates a 26,000-square-foot facility northwest of Chicago in McHenry, IL.

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.

Although the print bead is constant for each print, it could be 4-24 millimeters wide and 1-5 millimeters tall. That rough surface creates issues with achieving a good seal for the ROBIN mold and runout of the injection material during overmolding. “Thermoforming provides a smooth surface, and we also achieve a good connection between the overmolding and substrate materials,” says Stegelmann (Fig. 3).

Computed tomography (CT) scan of overmolding on 3D-printed panels showing diffusion and interlocking of polymer systems.

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

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.

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.

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

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

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

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

“Mobile injection molding allows us to apply recurring elements as needed with a high degree of flexibility to profiles or large-scale components,” says Stegelmann. He points out a shell demonstrator (Fig. 2), “where we show that with overmolded omega profiles, you can achieve a very quick, simple construction to achieve light-weight, high-strength assemblies.” REHAU and Anybrid plan to continue development, looking at processes beyond extrusion and joining technologies for composite parts.

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

“The use of composite materials in structural applications creates specific challenges for joining,” explains Stegelmann. “ROBIN can be added to production lines to integrate inserts that enable attachments and facilitate assembly [Fig. 1]. Anybrid has demonstrated this in two projects with the Innovation Group of REHAU Industries [Rehau, Germany]. REHAU produces polymer-based solutions for construction, automotive and industrial applications including window profiles and components for car exteriors, bumpers and air duct systems. REHAU is also researching a variety of innovations using composites, including natural fiber and bio-based composites.”

Core Industrial Partners’ portfolio company Fathom acquired the precision tooling and injection molding supplier serving customers in the packaging and medical markets.

Anybrid and ILK performed demonstrations using the 8 × 2 × 2-meter-high “Supertooler” LFAM developed and built in-house at ILK onto an eight-axis Kuka Robotics (Augsburg, Germany) system. Materials included bio-based polylactic acid (PLA) reinforced with cellulose fibers supplied by UPM Biocomposites’ (Helsinki, Finland) UPM Formi (Lahti, Finland) division. The printed structure was then overmolded using polypropylene (PP) with 30% glass fiber supplied by Mitsui Chemicals (Tokyo, Japan). “The black PP compound allowed us to see the material flow onto the 3D-printed PLA substructure,” says Stegelmann. “We quickly preheated the 3D-printed surface using an infrared heater and then closed the ROBIN mold onto the panel, thermoforming the part surface. This thermoforming is needed due to the large bead size of the printed materials.”

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

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

Collins Aerospace draws on global team, decades of experience to demonstrate large, curved AFP and welded structures for the next generation of aircraft.

Anybrid has miniaturized the process to fit within a robot arm end effector, enabling, for example, pultrusions to be overmolded inline or molded structures to be functionalized within a robotic cell. Anybrid has recently completed a series of demonstrations to highlight new capabilities its technology can offer including:

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.

“We see great potential to use Anybrid’s mobile injection molding in a variety of continuous process lines,” says Sell, “such as thermoplastic extrusion, pultrusion or CCM, for the production of composites parts for transport or industrial applications, for example. It enables monomaterial systems — products that consist of the same polymer matrix. Steps such as gluing are eliminated. This makes production faster and the products easier to repair or recycle.”

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

Anybrid’s ROBIN demonstrates inline/offline functionalization of profiles, 3D-printed panels and bio-based materials for more efficient, sustainable composite parts.

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.

CFRP pultrusion and pullwinding specialist Epsilon Composite combines thermoplastic overmolding with traditional thermoset processes, demonstrated through aircraft struts and industrial applications.

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

He notes that ROBIN also saves costs. “Using the small injection molding robot makes it possible to dispense with large, expensive tools. The logistical effort is also reduced since profiles no longer have to be moved to injection molding machines. We have shown that costs can be reduced and productivity and flexibility increased in our extrusion lines.”

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

Stegelmann and Chauzu also emphasize that it is possible to use the process heat during reactive pultrusion instead of preheating the profile for overmolding, as is typically necessary. This would enable even better process and energy efficiency, they explain. “For example, a PA composite might be heated to 180 to 200°C,” says Stegelmann, “instead of allowing the profile to cool, we can overmold as the pultrusion exits the system to achieve a good connection, saving time and process steps. Again, overmolding is not new, we are just enabling it to become directly part of the process line, but with increased flexibility and lower cost.”

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.

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.

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.

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.

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.

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

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.

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

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

Branding these materials as Supercore, CQFD claims other advantages, including a modulus of 50-62 gigapascals — roughly 1.5 times more stiffness than conventional glass fiber composite profiles — and a density of 2.0 grams/cubic centimeter. CQFD profiles made using unidirectional (UD) glass fibers (GF) offer a higher specific rigidity versus profiles made using aluminum (2.7 grams/cubic centimeter). Also, because these profiles are thermoplastic composite, they can be thermoformed, reshaped and overmolded.

Dan Martin, President of Summit, commented: “Since my wife, Michelle, and I founded Summit 25 years ago, we’ve been committed to providing outstanding quality and customer service to build the business into a leader in the design, engineering, and construction of molds and molded components. We’ve now reached an inflection point in our growth trajectory, and we believe Fathom is the perfect fit in terms of both culture and customer-value proposition to help take Summit to the next level.”

This connection was investigated using computed tomography (CT). “We can clearly see diffusion between the two polymer systems, which creates a mechanical interlocking,” says Stegelmann. “There are still some challenges in optimizing the processing temperatures, but we see a real opportunity for in-situ functionalization of 3D-printed parts with local inserts, sealings, clips, etc. Our next step is to demonstrate this potential with a technical component from the marine industry. We can see a future where large-volume 3D printing facilities will be equipped with our mobile injection molding system as standard due to the possibilities it opens for their parts.”

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

Stegelmann explains the steps involved: “First, we position the metal insert inside the small injection mold within the ROBIN machine [Fig. 2]. Next, the ROBIN system is aligned with the profile, and then the mold is closed and the fastener is overmolded. Because the mold is very small, ROBIN is able to reach even between the high walls on the back side of this profile and overmold fasteners with anti-twist resistance or integrated sealing, for example.”

Functionalized PEI profiles made using CCM. Anybrid worked with REHAU Innovation Group to demonstrate use of its ROBIN robotized injection molding system to overmold Böllhoff Hitsert metal inserts into Xelis glass fiber/PEI omega profiles made using its CCM process, aimed toward possible aerospace applications. Photo Credit for all images: Anybrid

For automotive applications, demonstrations used Lanxess Bond-Laminates (Brilon, Germany) Tepex 102-RG600 PA6 with 47% glass fiber roving for compression molding. Resulting composite profiles were then overmolded using Lanxess’ (Cologne, Germany) PA6 flame-retardant Durethan BKV60 and BKV30 with 60% and 30% chopped glass fiber, respectively. For this application, ROBIN was used to integrate threaded fasteners from Böllhoff (Bielefeld, Germany) into a narrow omega-shaped profile (Fig. 1).

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

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

“Due to the innovative composition of CQFD’s composite materials and the right process parameters, it is now possible to obtain excellent adhesion with the overmolded PA6 inserts even when using a highly fiber-filled composite,” says Frank Chauzu, founder and CEO at CQFD. “Supercore profiles are also available with compatibility for other material combinations such as PP. To reach that compatibility, the profiles go through a specific treatment developed by CQFD that promotes adhesion between the PA6 and PP materials.”

Although Anybrid works with a wide range of standard materials, the innovative nature of the technology makes it attractive for companies developing new materials and processes. One such partner is CQFD Composites (Mulhouse, France), a supplier of structural thermoplastic composite profiles. Founded in 2006, CQFD Composites has developed a reactive thermoplastic pultrusion system. This technology uses in-situ polymerization of low-viscosity caprolactam monomer to produce, in this case, PA6 pultruded profiles with high glass fiber content, up to 85% by weight.

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

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

Anybrid overmolded panels made of the natural composite wood (cellulose fibers in lignin matrix) with cellulose cross-linked polymer (CXP) from JEC award winner Dongnam Realize.

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

As global industries and markets demand increased sustainability, novel automated systems such as Anybrid’s (Dresden, Germany) robotized injection molding (ROBIN) offer a means to functionalize composite components, eliminating bonding and facilitating lightweight assemblies.

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.

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.

Dr. Ahmad Al-Sheyyab, manager of the Composites Technologies Department of REHAU Innovation Group, notes, “Our mission is to check every idea for relevance and make what sometimes seems impossible possible.”

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 a second set of demonstrations, the teams used continuous glass fiber/PEI profiles produced by Xelis (Bermatingen, Germany) using its CCM process. Similar to omega-shaped stringers used in commercial aviation, Hitsert threaded inserts from Böllhoff were integrated via overmolding with glass fiber/PEI materials fom SABIC (Riyadh, Saudi Arabia). “These parts demonstrated our ability to overmold using high-temperature materials approved for aerospace,” notes Stegelmann.

The opportunity for Anybrid’s ROBIN technology to produce a variety of more sustainable composite parts seems, if not limitless, then at least very broad. “The issue is convincing companies to move beyond the known and familiar,” says Stegelmann. “Overmolding has been well proven and is gaining use in composites. We are just making that process mobile and more flexible to provide really futuristic solutions that can generate value for manufacturers now.”

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

In 2018, Teijin broke ground on a facility that is reportedly the largest capacity carbon fiber line currently in existence. The line has been fully functional for nearly two years and has plenty of room for expansion.

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

“We wanted to demonstrate a process chain where CQFD’s reactive pultrusion process could be combined with our robotized injection molding inline,” says Stegelmann. The first demonstration used CQFD’s in-house GF/PA6 profiles and a black-tinted PA compound with 30% glass fiber supplied by Lanxess for overmolding. The overmolded feature (Fig. 4) is a shape Anybrid created to demonstrate the complexity that is possible with ROBIN. It also provides a good basis to test for adhesion between the overmolding and the substrate.

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

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!

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’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.

To demonstrate the ability to functionalize 3D-printed parts, Anybrid worked with the Institute of Lightweight Engineering and Polymer Technology (ILK) at Technische Universität Dresden in Germany. “The use of large-scale/large-format additive manufacturing [LSAM/LFAM] is growing,” notes Stegelmann. “The technology has been proven to be quite capable and cost-effective, but the problem with these big machines is they can print with high deposition rates but not with high resolution, and thus, fine details are impossible. This is where we can help, because ROBIN can overmold detailed functional elements during the print process.”

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

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

Monroe Capital LLC provided financing for the acquisition. Winston & Strawn LLP provided legal representation to Core and Fathom in the transaction.

Fig. 3. Overmolding and 3D printing. Anybrid demonstrated ROBIN’s ability to overmold GF/PP features onto a cellulose fiber/PLA panel made by a large-format 3D printer.