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

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.

“The acquisition of this state-of-the-art facility underscores our unwavering commitment to growth and innovation, and we look forward to welcoming talented new Nexus colleagues to Lilly from the Pleasant Prairie facility,” said Edgardo Hernandez, EVP and president, Lilly Manufacturing. “We are investing boldly to serve our patients, to meet product demand and to build capabilities for our robust pipeline of the future.”

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.

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.

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.

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

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

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

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

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

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.

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

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

What about the perception that overmolding is very expensive, with high tooling costs? “Some perceive that part costs will run into the thousands,” King says, “but that’s not how we see it. It can be cost-effective, especially if you look at the complete life cycle because it removes assembly stages. You no longer need multiple different materials and inserts, but instead deliver just one integrated part to the line. We are also looking to further reduce the cost of overmolding. For example, many think the tooling will be £85,000-100,000 ($120,000-140,000) or more, but we have been able to utilize tooling that costs as little as £10,000-15,000 ($14,000-21,000) to produce complex, overmolded components. So we have made a lot of progress here.”

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.

Eli Lilly (NYSE:LLY) announced today that it agreed to acquire a manufacturing facility from sterile manufacturer Nexus.

King says this overmolding technology has provided CCP Gransden with significant benefits in the design and manufacture of high performance components:

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

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.

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.

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

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

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.

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

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.

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

The 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.

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

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

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

The demonstration part above made with carbon fiber/PPS is shown here made with unidirectional CF/PA, woven glass fabric/PEI and woven carbon fabric/PEEK. A glass/PA version has also been produced. SOURCE: CCP Gransden.

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).

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

“The process begins with a reinforced thermoplastic blank called an organosheet,” says King, “which is heated in our unique oven.” Unique? He explains that the infrared oven has some design features integrated into it to increase process control and heating speed. “The heated blank is then transferred to the press tool using a high speed multi-axis robot. When the press closes to complete the thermal press forming process, the injection molding unit simultaneously injects a shot of high-performance molten thermoplastic.” This thermoplastic is often filled with chopped fiber. “This is a super-fast, one-stage process and offers cycle times under two minutes, depending on the part size and complexity,” says King.

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.

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

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.

What about reported difficulties in overmolding PEEK onto a PEEK base laminate even in single-stage processes? “The specifics of how we achieve this is proprietary,” King replies, “but temperature control and the speed of operation are critical.”

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

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.

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

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

Sean Whooley is an associate editor who mainly produces work for MassDevice, Medical Design & Outsourcing and Drug Delivery Business News. He received a bachelor's degree in multiplatform journalism from the University of Maryland, College Park. You can connect with him on LinkedIn or email him at swhooley@wtwhmedia.com.

He points out that part volume and cost implications are key factors taken into account during tooling material selection and design, for example, whether or not to use ejector pins. “These can add in a lot of extra cost,” says King. “You can do a lot to tailor solutions to a client’s needs. We pride ourselves in this competence and also the ability to work quickly for our clients.”

He claims the single-stage process gives a far better bond between the overmolding and base laminate. “Forming at where both materials are at semi-molten stage, you then blend them, which results in interdiffusion,” King says. “So you get better mechanical properties. Otherwise, it’s a melt-melt interface. This also produces an aesthetically pleasing join/overmold, with no spillage at the side and clean, sharp edges. Though this may not affect the part strength, it certainly would convey we do not have control and precision. But, of course, we do.” He adds that CCP Gransden can also use the same polymer matrix in both the thermoplastic laminates and the overmold, something not feasible in a two-stage process.

CCP Gransden (Belfast, Northern Ireland) has been in the Advanced Engineering sector for over a century.  Forty of those years have been specifically in the manufacture of advanced composites, beginning with large glass fiber-reinforced structures (2-3m diameter) for harsh environments. In 2012, the company identified opportunities for growth through the use of new advanced technologies and the manufacture of lightweight thermoplastic composites. “There was a lot of interest from both the aerospace and automotive markets,” says Scott King, Strategic Partnership Manager. “We saw a fit where we could offer improved performance to our customers using new innovative processes.”

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.

Buying the FDA-approved facility in Pleasant Prairie, Wisconsin, further expands Lilly’s global parenteral (injectable) manufacturing network. It also supports increased demand for the company’s medicines, Lilly said in a news release. The company expects that production at the Wisconsin facility could begin by the end of 2025.

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

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 Pleasant Prairie facility doesn’t provide contract manufacturing services, Lilly said. This allows for the sole dedication of the plant to Lilly’s manufacturing efforts geared toward injectable medicines.

Many of these benefits are made possible by the single-stage process. “Previously, a two-stage process has been employed,” King explains, “where the thermal press forming process is completed in one tool. Then, a secondary operation is required to perform the injection molding cycle in a second mold.”

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.

“Each component manufactured in our cell has full process traceability thanks to our data logging capability,” he points out. “This means that we can effectively give each component a birth certificate to provide confidence to our clients that each component is manufactured via a standardized, repeatable process per AS9100 standards.”

This session is designed to demonstrate the benefits of ultra polymers for aerospace applications with real case examples of Syensqo's polymer portfolio. Agenda:  Introduction to ultra polymers (PAEK, PEKK, PEEK, PAI) key features Application of ultra polymers in aerospace: concrete examples Benefits of ultra polymers: enhanced performance, durability and cost-efficiency

The composites-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.

One of the opportunities which CCP Gransden started to explore was overmolding. It worked with Engel (Schwertberg, Austria) through the local office Engel UK Ltd. (Warwick) to install vduo 1100 workcell and develop this into a state of the art high-volume advanced composite production system. The Engel workcell combines thermal-press forming and injection molding to achieve single-stage composite overmolding.

He notes there was a challenge initially, because the aerospace industry wanted to work with polyetherimide (PEI), polyphenylene sulfide (PPS) and polyetheretherketone (PEEK), while automotive wanted polyamide (PA, nylon). “So we began working with PEEK and polyetherketoneketone (PEKK), developing a significant expertise.” He says it only took one day for the company to move from PEEK to PA. “PEEK has a narrow processing window, to get good flow from the injector into the mold tool. The appropriate heat distribution over the tool is very critical.” After succeeding in this, processing PA seemed relatively simple.

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

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

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

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

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.

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

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“We can make 1,000-1,500 parts per 24-hr shift,” he says, noting that the CF/PPS demonstration part was pressed/molded in 60 seconds. “We could probably even reduce that further.”

Powered by an 85% air/15% pure polyimide aerogel, Blueshift’s novel material system protects structures during transient thermal events from -200°C to beyond 2400°C for rockets, battery boxes and more.

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

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

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

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!

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

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 JEC Forum DACH is a business meetings event organised by JEC The JEC Forum DACH is organised on October 22 and 23, 2024 by JEC, in partnership with the AVK, gathering the composite materials community from the DACH Region (Germany, Austria and Switzerland).

CompositesWorld is the source for reliable news and information on what’s happening in fiber-reinforced composites manufacturing. About Us

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.

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.

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

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

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

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.

“We are excited Lilly is continuing our family’s mission of providing lifesaving medications to those who need them most. This milestone is a testament to the dedication of our Nexus employees in building a best-in-class injectable manufacturing facility,” Usman Ahmed, Nexus president and CEO said. “The combination of our teams and infrastructure with Lilly’s global platform will benefit patients all over the world.”

He also stresses cost-effective design and development. “It took us 12 weeks from design to finished component including tooling, process and materials development. We wanted to demonstrate that getting from a concept to a commercial product doesn’t have to take years. It can be done in weeks.”

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.

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

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.

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.

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.

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