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

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

“A customer tells us they want to optimize a process,” explains Chaloupka. “We then discuss their challenges and long-term targets. Some customers want to reduce cycle times or scrap, while others just want to have transparency in the process to know what is happening and build knowledge around the parameters and material interrelations.”

“So, we started with a small team of four people that were taken out of Netzsch Analyzing and Testing,” explains Chaloupka, “and now we’ve grown to 34 people. And this team can focus on our customers because services like manufacturing, shipping and accounting are outsourced to our sister businesses that already have that necessary structure, which is another benefit of operating within the Netzsch Group.”

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

Despite the limitations of the early technology, tooling became one of the most important markets for the fledgling metal AM industry and the sector is regarded as one of the first real commercial applications of the technology. Whilst this success continues today, the use of Additive Manufacturing in the mould and die industry remains relatively niche compared to conventional toolmaking technologies.

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

Drivers for the use of conformal cooling are often application-specific, he continued, “What we see are production needs relating to the requirements of a specific product driving the decision to use conformal cooling. In some cases, moulds that have AM components with conformal cooling strategies are delivering a 30-50% increase in production at the moulding machine making the plastic parts. This dramatic increase in productivity alone will end up returning 100% or more of the entire mould’s cost over the life cycle of the tool.”

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.

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.

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.

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

“Initially, our focus was to optimize plastic and composites processes for production,” says Corneila Beyer, CEO of sensXPERT, “and sustainability was a side effect. But now the demands of customers have changed. They are faced with making significant changes to meet new requirements for increased biocontent and/or recycling, as well as reduced energy usage. But they still need a stable process and assured quality for high-performance products. Our technology enables dynamic part production where they can optimize their processes in real time. But we go one step farther, using machine learning and AI to look across all of their parts and data to make predictions. For example, the system can send an alert saying the process is moving outside the allowed window and suggest adjusting X, Y and Z to bring it back in line.”

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.

MTorres seeks to enable next-gen aircraft and open new markets for composites with low-cost, high-permeability tapes and versatile, high-speed production lines.

Rauch continued, “When other forces such as change in direction and obstructions disrupt the flow, it starts to change into what is known as transitional flow. Once the flow has become fully disrupted and a mixing and stirring action happens, turbulent flow has been achieved. This is the goal when I design conformal geometry, because once the fluid travelling inside the conformal passage becomes turbulent I know trapped heat within the steel AM part will start to rapidly dissipate. The mixing action from turbulent flow transfers heat away from the geometry it is travelling through more effectively because you are mixing the warmer fluid near the walls of the cooling passage with the relatively cooler interior fluid. It’s just like a hot cup of coffee – if you stir it with a spoon it will cool faster than just letting it sit still. If a designer takes all of these things into his thought process when designing a conformal cooling solution, they will be able to capitalise on the capabilities of what conformal cooling can do in the moulding industry.”

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As with any technology, conformal cooling can be applied well or applied poorly. Commenting on what sets a great solution apart from a poor solution, Rauch explained, “Not all conformally cooled tooling solutions are created equal. When you are designing a conformal cooling passage you are trying to achieve several different things. The number one goal when wanting to be successful with conformal cooling is figuring out how you can rapidly and uniformly dissipate the heat over the entire surface of the moulding geometry. One of the most important factors that comes into play when achieving this goal is confirming that the conformal circuit itself produces turbulent flow inside the water passage. The best way to achieve this is by using CFD analytical software that simulates the fluid’s flow through the line. The Reynolds Scale helps us determine if we are obtaining turbulent flow inside our additively manufactured waterline geometry. The Reynolds number scale is a scientific way to measure flow patterns in different situations. Fluid travels in three different ways; laminar, transitional and turbulent. Laminar flow is when the molecules are following a smooth and steady path in a parallel fashion. An example would be when you open a tap to the slowest flow you can get and the water comes crystal clear.”

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 DOMMINIO project combines AFP with 3D printed gyroid cores, embedded SHM sensors and smart materials for induction-driven disassembly of parts at end of life.

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

In 2019, Netzsch created NedgeX, a digital incubator company to work with its 4,600 employees globally and find teams with new ideas and business models for startups, as well as to support new developments and inventions at universities. “In 2019, I pitched the idea for sensXPERT along with NedgeX to our review board,” says Chaloupka. “It was like being in ‘Shark Tank’: Here’s how to use an existing measurement technology but equipped with new data science in order to combine sensors and material science for an entirely new product that really benefits the customer. This new venture was approved and we started as an incubator business in 2020.”

“Within one year, we created a minimum viable product comprising a new edge device and algorithms that can calculate quality parameters like Tg and degree of cure in real time and in a cloud environment that is connected to the device,” says Chaloupka. “Within our first year, we created awareness within large corporations.” The team also developed use cases with alpha customers ZF Friedrichshafen (ZF Group, Friedrichshafen, Germany) and Carbon Revolution (Geelong, Australia). “And we were able to show Netzsch shareholders that this is really a product that the industry values and needs,” notes Chaloupka. In 2021, Netzsch Process Intelligence was founded and sensXPERT was established as its first commercial technology product.

According to Jarod Rauch, B&J Specialty’s Information Technology and 3D Printing Manager, whilst the demand for tooling with conformal cooling is seeing strong growth, there is also some resistance to such a transformative technology in what can be seen as a very traditional industry.

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

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.

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.

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Why is this a problem? “If we had followed the prescribed process recipe generated by the material supplier from their materials lab testing, we would supposedly have ended up with 100 good parts,” explains Chaloupka. “But what happens in reality is that every single part is different. To deal with this, material suppliers and molders add time onto cycles to give a kind of safety margin. But using our Digital Mold technology, we can eliminate these safety times by having a look into the material behavior and deviations that are affecting cure. And we can calculate the degree of cure and Tg in real time.”

Chaloupka notes that the aviation supply chain, “is looking at high-pressure RTM [HP-RTM] using two-part resins for cycle times of roughly 1.5 hours for really big structures, versus current cycles of 4-6 hours.” He adds that multiple resin companies have been working in this area, including Hexcel, Solvay and Westlake, looking at high-volume production of parts for future airplanes.

“And we are working with more than just parts manufacturers,” she continues, “because there is a whole supply chain involved, including machine manufacturers, raw material suppliers and toolmakers. We are already working with material suppliers, like Hexcel, to improve their products for their customers, and machine manufacturers like KrausMaffei and injection molding specialist Wittmann-Battenfeld . The momentum is changing for us to work with our part manufacturing customers and their suppliers in collaboration. The model is ‘better together,’ and we are beginning to see even the next developments this will enable.”

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

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Supporting software is crucial to the successful and efficient development of all AM applications; however, this is especially true when it comes to the design of a conformal cooling mould. Rauch explained, “3D Systems’ Cimatron and 3DXpert packages have been phenomenal at giving me the tools needed for quickly navigating the process of designing an entire mould or just a single part for production by AM. I feel that, to be truly successful with additive, a designer has to completely change how they design – it is not a cliché that you have to design for additive. As tool designers we have all been taught to design a certain way. We had to design for how a tool would be manufactured but, with AM, all of the limitations put upon you by subtractive methods of manufacturing are almost completely removed. Cimatron and 3DXpert are very powerful modelling programs that give me the design freedom to quickly make that transition to designing for additive. The complexity of geometry I design with Cimatron and 3DXpert would be inconceivable using anything else. Tailored design tools assist me in the construction of the parts themselves and a complete suite of conformal cooling design tools automates much of the design process, allowing me to focus more on designing a part for its function rather than its ease of manufacturing. 3DXpert then takes it a step further. Once I move into build preparation I again have full freedom to design my support structures with ease because of the huge number of options I have for deciding which type of support structure will work best.”

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Concluding, Lindemann believes that increases in the production speed of AM systems, combined with a move towards increased automation, will accelerate the adoption of AM conformal cooling solutions. He stated, “Right now the direction is to make AM systems capable of manufacturing larger parts, using multiple lasers during the build process, and developing a greater degree of automation. Imagine a production floor environment dedicated just for metal AM. Conformal tooling can certainly benefit from these factors. From there, honestly, who knows where it can go? The future promises to be exciting in the least.”

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However, going from the current use of premixed RTM6 resin — which demands cold storage and has a limited shelf life — to long shelf life two-component (2K) systems that will be mixed just prior to resin injection in the RTM mold presents its own challenges (see “HP-RTM for serial production” and “2-part epoxy …”). Efforts continue to ensure mix ratios are correct throughout the injection and across the part. “We are working with CTC and an equipment manufacturer in a funded R&D project to implement sensors in the mixing heads to measure the mix ratio,” says Chaloupka. “The challenge is that operations within the mixing head are numerous and complex, such as turbulent flow, which affects measurement. We are analyzing how we can evaluate the mix ratio, what the precision is and how we can use this information to improve the manufacturing. We are also measuring the RTM’d part and directly relating that to mix ratio, and we’ve already seen trends. But we’re continuing this work with the parts manufacturers and the resin manufacturers, as there are still some open topics that need to be resolved.”

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 company has already developed a second product, sensXPERT Pipe, for in-situ analysis of cured in place pipe (CIPP) liners made with glass fiber-reinforced polymer (GFRP). It uses touchless DEA sensors that are fitted to the robot carrying the ultraviolet (UV) light source through the pipe to cure the FRP liner. These sensors use radio frequency technology to provide non-contact cure analysis as the UV light is pulled through the pipe. “Now, you can see at what velocity the UV light should be moving,” says Chaloupka, “and, in real time, if there are deviations from the optimum degree of cure.” Again, dynamic processing is now possible — the speed of the light source can be modified on the fly. “And you have a built-in record of your quality assurance,” notes Chaloupka. “You are doing QA as part of the installation, not afterward.”

Chaloupka describes one of sensXPERT’s first customers, ZF Group: “It is one of the largest Tier 1 automotive suppliers producing metal and plastic components for the powertrain, such as electronic circuit boards for vehicle control units. We have written a technical paper with ZF about electronics encapsulation, which involves transfer molding processes with epoxy molding compounds. These materials are inhomogeneous and involve a tricky process for fast curing times of roughly 1.5 to 3 minutes.”

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.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

Cryomotive’s CRYOGAS solution claims the highest storage density, lowest refueling cost and widest operating range without H2 losses while using one-fifth the carbon fiber required in compressed gas tanks.

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

B&J Specialty, Inc., based in Wawaka, Indiana, USA, offers precision machining, engineering and mould and die services to customers in the US Midwest. With the support of technology from AM technology provider 3D Systems, headquartered in Rock Hill, South Carolina, USA, the company works to offer high performance plastic injection moulding tooling for customers through the implementation of additively manufactured conformal cooling solutions.

In-mould part cooling is the most time-consuming part of the plastic injection moulding process – reduce the time for part cooling and you will increase production speed whilst achieving higher quality moulded parts with less scrap. A variety of techniques have been used to maintain even temperatures over the years, using methods such as bubblers, heat pipes and complex drilling operations using laminated blocks. These, however, are cumbersome, time consuming and can limit the useful life of a mould. Drilled cooling channels are also limited to straight lines, no matter what the part geometry.

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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.

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Chaloupka joined Netzsch Analyzing and Testing in 2016, where he worked for 2 years to advance the DEA sensor technology’s signal quality and ability to work with carbon fiber, which can create a short circuit because it’s electrically conductive. “And then in 2018, we decided to create a new business field within Netzsch Analyzing and Testing for process analytics,” he explains. “My job was to take our DEA technology into production applications around the globe and get feedback on what customers actually need. And while doing this, we doubled our revenue in both the first and second year of starting this new business.”

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Reach a truly international audience that includes component manufacturers, end-users, industry suppliers, analysts, researchers and more.

“We have seen some injection moulders and mould makers experiment with conformal cooling in that they will take an existing job that they know well and then create a version for conformal cooled inserts to use as a comparison. In some cases the difference was dramatic and the practice of conformal cooling was adopted. That is not to say it is the best or only solution for every job. It is being investigated on a subjective basis. This trend has grown in recent years and seems to be continuing to grow,” added Lindemann.

This is what the sensXPERT technology achieves, but instead of creating digital models, it collects machine and process data and combines it with data from dielectric analysis (DEA) sensor(s) in the mold that monitor viscosity and cure behavior in polymers and composites. It then applies data analytics via an edge device to let manufacturers see what’s actually going on inside the part — and control cycle times dynamically, for each part.

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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.

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

Lindemann cautioned, however, that,“there is still a resistance to embracing conformal cooling and this likely will remain for some time. Not all moulded parts are suited for conformal cooling. I once heard an AM representative tell of how he felt mistakes were made at the beginning when metal AM began taking on popularity. He explained about how mould makers especially were being told that this technology would replace them and what they were doing. That has proven far from the case. Good mould making and mould design practice remain essential to the industry and, if anything, AM has proved to be another tool in the tool kit to getting the overall job done well, and not a replacement for everything.”

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The sensXPERT technology has been developed by Netzsch (Selb, Germany), a company founded in 1873 that developed into three divisions: Pumps & Systems, Grinding & Dispersing and Analyzing & Testing. In 2000, Netzsch bought Holometrix Micromet (Bedford, Mass., U.S.) and its DEA technology, which was spun off from MIT.

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

Conformal cooling moulds have curved cooling channels that conform closely to part geometry and their use for an injection mould can reduce cycle time by anywhere from 10% to 40%. The low range gains are possible with little to no engineering analysis; the higher estimates reflect the use of flow analysis, computational fluid dynamics and finite element analysis.

The sensXPERT edge device on the factory floor is connected to the customer’s intranet, giving them access to the system. Ideally, says Chaloupka, it is also connected to the internet, allowing data to be sent into a cloud environment for advanced analytics. “We have developed the necessary data security infrastructure and are accustomed to working with risk assessment frameworks for large corporations as well as providing the assistance necessary for smaller companies,” he adds. This final part of the installation is then completed working together with the customer.

Additive Manufacturing has been used to build moulds incorporating conformal cooling channels since  the 1990s when the first metal powder-based AM systems came to market. The AM process in those early days used CO2 lasers and required metal powders coated with polymer binder, which would evaporate out after the part was built. The part would then be infiltrated with a second metal to remove the porosity. Today, the technology has moved on considerably, and the new generation of AM systems uses significantly more precise fibre lasers, high purity metal powders and an oxygen-free manufacturing environment.

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

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).

Commenting on what attracted B&J Specialty to 3D Systems’ technology offer, Rauch explained, “When we decided to invest in Additive Manufacturing, we looked at several different machine manufacturers, but when we considered what 3D Systems had to offer we were drawn to the fact that they not only focused on the printers themselves but also a complete line of design software that streamlines the conformal cooling development process. Having a good workflow simply makes good business and 3D Systems provides that with its end-to-end solutions for the tooling industry. From the start I can transition from design to build preparation and manufacturing, all from within the same piece of software. This is a huge time saver. We all talk about how AM can affect the supply chain because we can now take a digital design file and, in a matter of hours, have a finished product. 3D Systems seems to understand this, having the same mindset when developing its products. Other companies that we looked at had good machines but fell short when it came to having that smooth flow from the digital to the physical.”

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

“We then analyzed what our next step should be,” Chaloupka continues. “We had a good measurement technology and some customers who could analyze the dielectric data, but it wasn’t necessarily easy for them to translate that data into added value. We therefore decided that what we really needed was a new level of data science — a way to match material science from the lab with the production environment, to combine the information from the sensors with the machine parameters and the influencing factors that can affect the material behavior as the part is being produced.”

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 has written a lot about sensor technologies and how they can be used to improve composites manufacturing. See our Sensors microsite, which discusses sensor types and data, and includes CW articles and videos from technology suppliers. Dielectric sensors, or dielectric analysis (DEA), is one of the main technologies we’ve covered because it offers the ability to assess the actual state of a polymer or composite material in situ, during molding, including its degree of cure and Tg — which then enables managing processing on the actual state of the material, instead of legacy time and temperature recipes.

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

“And then, from the edge device, we send all the data into a cloud environment,” he continues, “and our software uses the historic data to recalculate the machine learning models going forward, which will further enhance these models running on the edge device and increase the ability to identify areas for improvement. Meanwhile, the data is also fed into dashboards for everyday monitoring and operations.”

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

Rauch is also confident that we are just seeing the start of what conformal cooling using AM can do for the plastic injection moulding industry. “Right now, the technology is constantly evolving as new materials and better machines become available. But I think we are still scratching the surface of what AM can truly do for the moulding industry. The big changes won’t begin to happen until the people accept change. Designers must learn to think differently and design differently. Applying system level thinking into the engineering process has the power to change everything. Engineers with an open mind will become innovators overnight, and tooling companies willing to use AM in the production environment will become pioneers in what I believe is going to be the next industrial revolution.”

“We are also talking to companies working with thermoplastics who want to increase their recyclate content,” says Chaloupka. “Due to new EU regulations, there is no way for the plastics industry to avoid using more recycled content, even post-consumer material, which makes it harder to characterize every batch of material before you mold it. Therefore, new technologies are needed that can deal with material deviations and help to ensure proper manufacturing. Those deviations can happen from one batch to another, and you may need to change many different parameters in different directions to be able to produce good parts. We are looking into that because we can see and evaluate those deviations in real time.”

Chaloupka says sensXPERT can work with a range of materials, including adhesives, coatings, preceramic polymers and thermoplastic composites. “We have grown within the thermoset resin market, and 95% of our existing customers are thermoset-oriented,” he concedes, “but we are reaching out to more and more thermoplastic customers. Yes, we can measure crystallization in semi-crystalline thermoplastics [e.g., PEEK, PEKK, PAEK] and also solidification in amorphous thermoplastics. We have a use case, but it is for in-situ polymerization of caprolactam into polyamide 6 [PA6] in Six Sigma product manufacturing. We have a series installation at a German company that is manufacturing volumetric semi-finished products where we have to optimize the manufacturing processes for different materials and with adapted chemistry (mixing ratio and additives) for different plate thicknesses.”

Cured in place pipe (CIPP) can use UV light to cure FRP pipe liners for trenchless repair without having to dig out old, corroded pipes. Photo Credit: Lightstream LP, “Cured in place pipe”, CW Dec 2012.

By applying machine learning algorithms, sensXPERT can enable material behavior characterization in real time and adapting processes for improved quality control and dynamic cycle times. This then improves efficiency and reduces energy consumption, giving composites material suppliers and parts manufacturers a new tool to improve sustainability. For more details, watch the Sep. 28 webinar on CW.

Whilst conformal cooling solutions can significantly reduce the total cost of production by lowering mould cycle times, they also require sophisticated mould designs. A well-designed conformal cooling mould typically has a wide variety of unconventional curves, twists and shapes that must be precisely placed. Once designed, these complicated moulds must be manufactured to the same standards as any other mould.

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Once the initial scope is finalized with the customer, sensXPERT then works with them to install the sensor(s), edge device and software/IT infrastructure. Parts are made and the machine learning models are built. “We then start the data analytics and evaluation process,” says Chaloupka.

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Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Rauch stated, “Most customers are eager to listen but very hesitant to make the decision to use AM. Mostly because you are telling them you will be changing both the established processes and the materials used to make the AM parts. Customers like to hear about new technologies but don’t seem to like it when they hear they will have to change. My best tools to convince them that this change is for the best are our own case studies, mould flow simulations and CFD analytical tools. These allow us to show things in black and white for them, so they can see first-hand what could be achieved if they decide to go down the path of change. After seeing the results, customers often think it’s too good to be true.”

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

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

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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.

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.

Rauch believes that the sector’s growth is coming from both a combination of customers who are demanding faster process times and from innovative toolmakers looking to gain a competitive advantage in terms of their technology offering. “At this point it has been almost a 50/50 split between these drivers, however I am starting to see a change as AM has become a real game changer in the moulding industry. Now I am seeing larger companies wanting to ‘go additive’ without a company such as ours trying to sell the technology. The door has opened and we are beginning an industry-wide transition.”

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

“We then discuss their experience from their manufacturing environment,” he continues. “This is very important to develop the machine learning models so they aren’t focused in the wrong direction — not necessarily measuring every parameter but instead targeted to solve the customer’s challenge and provide real value. We create these machine learning models using material science that originated in the lab but that is now getting matched with real-time process information from sensors. And that lets us analyze how the material performs under different circumstances. We then combine that data with the machine data to bridge the gap between what we know from the original lab testing and what we see is actually happening with the material in the mold under different circumstances. This then allows us to relate all that information to each other.”

“This industrial PC edge device is also equipped with software developed by sensXPERT, which includes machine learning algorithms,” he continues. “The system can perform a lot of analytics and machine learning model execution at the edge device, but enabling the machine learning training and retraining requires working in the cloud. For this, we need an IT infrastructure that we will verify together with the customer. And when the first data has been generated and the first parts manufactured, we will then create the machine learning models for the customer and use case, based on the material science and the real-time process information.”

Lindemann believes that it is crucial to understand the limits of the technology and to apply it only as appropriate. He stated, “There certainly are many ‘upsides’ but this is when the conditions are right. There has to be a realistic expectation. Mould builders making extremely large muolds look at the additive process and say that it is not for them. Their moulds are simply to large. There is however a trend in applying additive in a limited degree by creating mould inserts that are of printable size for key areas of the mould where conformal cooling would be beneficial. This requires some creative engineering but many are getting good results.”

SensXPERT uses in-mold DEA sensors, an edge device and software to convert the data from the DEA (and other) sensors plus the machine data into useful, actionable information. Photo Credit: sensXPERT

Using a sensor, an edge device and machine learning software, sensXPERT sees into processes and is improving quality and cutting scrap, cycle time and energy use for composites customers like ZF and Carbon Revolution.

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

The sensXPERT technology has four basic components: sensors, an edge device, software and an IT framework for data analytics. “The DEA sensors are typically installed in the mold and create information about material behavior,” explains Chaloupka. “The edge device is a small industrial PC where the sensors are connected, receiving information from the material in the mold. The edge device is equipped with the dielectric measurement unit that can also connect to other sensors, such as pressure or temperature sensors from other companies. Thus, the customer can have just one edge device that is receiving an array of different signals/data streams. The edge device also communicates with the machine/molding control system so that we can exchange parameters and process data with the production machines. We not only receive machine data, but we can also send information back to the machine to initiate process actions or if a customer wants to see one of our signals directly on an HMI at the machine.”

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

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

For years, the Netzsch Analyzing and Testing business unit developed and marketed the DEA technology for laboratory use. However, as digital technology began to advance, “the decision was made to move beyond the traditional business of lab-based thermal analysis, and out to the manufacturing environment in order to achieve real benefits in production,” says Alex Chaloupka, managing director of Netzsch Process Intelligence.

SensXPERT worked with ZF to analyze transfer molding of epoxy molding compound materials for EV control unit circuit boards (top left) using in-mold sensors (top right) to provide data on cycle time and material deviation (bottom). Photo Credit: ZF, sensXPERT

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.

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

This Digital Mold technology can be used in a wide variety of plastic and composite processes including injection molding, compression molding, resin infusion and resin transfer molding (RTM), as well as autoclave curing of prepreg. It enables manufacturers to stop the curing process, for example, when the desired degree of cure/polymerization or glass transition temperature (Tg) has been reached. It also enables tracking material viscosity and flow front position, as well as deviations in materials, helping to identify how to adapt processes to prevent scrapped parts.

“Roughly 20% of the tools we are currently producing have some type of AM component. So far, all tooling we make with AM has conformal cooling. The other 80% of our conventionally manufactured moulds would all benefit from the use of conformal cooling in certain areas due to the shape of the geometry and the inability to get a cooling passage into the location needed. AM is slowly gaining traction in the moulding industry and it’s just a matter of time before all of the moulds that B&J Specialty builds will have AM parts with conformal cooling passages.”

B&J Specialty uses a portfolio of dedicated software solutions from 3D Systems to develop its conformal cooling solutions, including Geomagic® Design X™, Cimatron® and 3DXpertTM. The tool parts are then built on a 3D Systems ProX® DMP 300 Laser Powder Bed Fusion system.

SensXPERT is working with the aviation supply chain and various resin manufacturers to reduce cycle time for RTM and enable higher volume, faster parts manufacturing by using two-component resin systems for HP-RTM parts. Photo Credit: sensXPERT

ZF was getting ready to start series production for an OEM’s next generation of electric motor control systems. “We looked at the material behavior within their manufacturing process and found potential for a cycle time reduction of around 21%,” says Chaloupka. “We could also see the material in the process was deviating, even when we worked with ZF to ensure all process and material parameters were the same for 100 parts in a row made using a single batch of material.”

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

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The importance of digital tools and simulation for successful composite parts design is well established, whether for aircraft wings, automotive bumper beams or bicycle frames. Over the past decade, these digital tools have extended into simulation and modeling of the processes as well, to explore materials-process interactions and address problems before production begins.

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.

SensXPERT uses an edge device to collect data from its DEA sensors as well as third party sensors and then analyzes these data with software to track degree of cure/polymerization/crystallization, Tg, material viscosity and more (top), which helps to achieve a range of benefits that increase sustainability. Photo Credit: sensXPERT

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 sensXPERT, Netzsch has advanced DEA technology into the rapidly growing field of material informatics, enabling dynamic material behavior prediction in real time based on sensor data combined with process data from machines and the sensXPERT machine learning algorithms.

–  Netzsch buys DEA technology, pushes outside the lab –  NedgeX incubator, sensXPERT venture –  Alpha customers and use cases –  Basic components –  How does the installation process work? –  Process transparency and optimization –  Use with thermoplastic composites? –  Further applications, collaboration with supply chain

Another alpha customer is an aircraft manufacturer, which is using sensXPERT technology in series production of carbon fiber/epoxy beams and panels. “After several years of working together, they have now completed a sensXPERT installation for RTM processes in a cascaded manufacturing line,” notes Chaloupka. “Here, we have identified a potential 30% reduction in cycle time. But there is also interest to apply this technology in different manufacturing environments, future development programs, where new materials are presenting new production challenges.”

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

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.

Lindemann concurs with Rauch in that there are two drivers behind the growth of AM for conformal cooling, stating, “Right now the momentum is coming from end-users who want better quality parts at reduced cycle times. The end cost may be such that it is an economical advantage even if the mould with conformal costs more to make initially. In some cases we see mould makers wanting to have the option of offering this technology to their customers, the end-users, as they see a need to be more competitive. With this they can, in some cases, also offer a quicker turnaround time in mould repair. Now they can print replacement cores overnight or in a few days, harden and finish them and have the mould back up and running quicker than with a traditional process. I have to again use the disclaimer ‘in some cases’ – wisdom dictates that each part or mould be considered on a case by case basis and it is not a fair statement to suggest this is a blanket statement for everything.”

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

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.

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 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, says Chaloupka, is the real value of sensXPERT because, “As humans, we are not really capable of taking 10 process parameters and relating them to the material behavior and to the material science in order to know that if I change this parameter, then this is what to expect. That’s just too much for our brains to do quickly, much less in real time.” There are some experts with decades of experience who can quickly assess manufacturing irregularities and adjust the right parameters, he adds. “But not every company has these experts and there are simply less of them around, which emphasizes the need for technology tools that can provide this type of assistance.”

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

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.

Whilst conformal cooling opens up a world of new possibilties for tool designers and plastic injection moulders, it brings a new level of complexity and its own unique requirements. Rauch explained, “If a designer has good design skills and a good understanding of fluid dynamics, additively manufacturing conformal cooling passages can dramatically improve cycle times and also improve part quality. However, it’s not that simple. People tend to have tunnel vision and focus solely on designing an optimised conformal circuit, but one thing that will cause AM tooling with conformal passages to fail – and fail rather quickly – is the quality of water that is circulating inside. Most people don’t initially think about this being an issue, but you have to remember that most moulding facilities’ water systems consist of open-loop systems, with large cooling towers outside that carry the water through pipes to each moulding machine. Large amounts of debris and deposits build up which end up inside the mould waterlines. Eventually these build-ups cause catastrophic issues during the moulding process and you have to remove deposits.”

Providing 3D Systems’ perspective on the broader industrial use of conformal cooling, David Lindemann, Cimatron Application Engineer at 3D Systems, told Metal AM magazine, “The driving forces seem to be coming from automotive, aerospace, and medical. The reason is mostly to improve overall part quality and reduce warpage, this in turn improves part fit and functionality. As previously stated, another crucial reason is to reduce the cooling cycle time and thus reduce overall part cost.”

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.

A speed gain of 1,000 to 10,000 times greater than traditional FE models has been achieved using machine learning models, enabling near real-time simulation for large composite components.

Commenting on the increasing demand for injection moulding tooling with conformal cooling, and expectations of growth in the near term, Rauch stated, “Seeing the demand increase for AM with conformal cooling in the moulding industry has really been exciting. As with all disruptive technologies it takes some time for a new solution to become the new ‘norm’ and I believe we are still just scratching the surface of what Additive Manufacturing can do for the moulding world. B&J Specialty has seen the results and we know that conformal cooling is a huge game changer. I would say in the next five years almost all of the moulds we build will have some type of AM components with conformal cooling in them.”

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

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.

The correct software, believes Lindemann, is fundamental to achieving success in this sector and the designer needs support in ensuring both functionality and manufacturability. “Not all conformal cooling lines are good waterlines for their intended function or even good to be printed. There are design standards associated with all of this and having the right CAD software that works with these standards is invaluable. We recommend using Cimatron software for the mould design software that has dedicated functionality for conformal cooling that allows for consistent use of ‘printable’ waterlines and waterlines that are checked for consistent distance from the mould surfaces to hold the conformal effect.”

Commenting on how 3D Systems is helping toolmakers embrace AM in order to develop their conformal cooling capabilities, Lindemann stated, “We have the software to assist and can work with the customers on a job by job basis and prove out the design. The customer may naturally hesitate to jump in with both feet and buy a metal AM system that he knows little about. We have services where we can print the mould core and prove out its viability and best case situation for printing. Once it is seen as a success, then the customer can move forward using this proven process on their own. They will be trained to use the software and the machine and start manufacturing their own cores per the proven process.”

“We see the most resistance to AM with customers that know nothing about it. It’s a major change and people will normally fear change. I believe they dig their heels in because we are disrupting the status quo. The moulding industry is mostly based around a set of standards that have been in place for decades and now, when you tell a customer we are throwing most of the manufacturing limitations out the window because of what AM brings to the table, they find it very hard to believe. Education is the key. You need to educate your customers on what they can gain through AM – and also help them realise that if you want major improvements things just have to change. Once a customer can accept this, you will then be heading down the path of success with Additive Manufacturing,” explained Rauch.

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!

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

“Up until now, most waterline passages were machined with some type of a drill bit – as all water circuits travelled in a straight line. So a blocked waterline just meant you had to run a drill bit back through the straight drilled hole to clear it out and everything’s good to go. With conformal cooling, it’s not so easy. The conforming line that follows the three-dimensional shape of the geometry makes it impossible to clean out in this way. I therefore urge all of our customers to invest in a closed-loop system so you have filtration options and much better control of the quality of water you are using. Once you have water quality in check you can then view conformal cooling as a perfect technological solution for injection moulding.”

Today, most manufacturers use a variety of sensors to collect machine and process data (e.g., temperature, pressure, molding time) which can be fed into these simulations, but what if this modeling could be done in real time to adapt the molding process to each individual part?