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.

As its product line has expanded, so too have the markets in which these materials are used. In addition to long-desired automotive business, the company now serves medical device (both durable and disposable), small appliance and consumer electronics (metal replacement cases/covers). Aviation/aerospace is still important, as is the sporting goods industry, which has grown to include applications on racing bikes, mountain bikes, golf clubs, firearms, compound bows and other archery parts. With several products offering coefficient of linear thermal expansion (CLTE) values similar to those of metal injection molded (MIM) aluminum and magnesium — albeit with better toughness, lighter weight and lower cost — the team finds itself replacing metals in an increasing array of applications.

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.

Among the new injection moldable CFRTP compounds specifically developed for automotive use is KyronMAX ES 4240, a 40 FWF short carbon fiber-reinforced PPA said to be the first to break the 414-MPa (60,000 psi) tensile strength barrier.

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

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

Keyland Polymer's R&D chemist will demonstrate the UV powder coating application process followed by UV curing on a carbon fiber water bottle holder. (Sponsored)

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!

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

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.

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).

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

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

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

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

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

The materials are formulated and sold by Mitsubishi Chemical Advanced Materials Inc. (MCAM, Tokyo, Japan). MCAM combines several previously separate businesses acquired by the parent company over the last decade. These include the former Quadrant AG (Lenzburg, Switzerland), a producer of glass mat thermoplastic (GMT) and organosheet composites as well as thermoplastic engineered shapes, and what had been Piper Plastics Inc. (Chandler, Ariz., U.S.), which started life as an injection molder and producer of precision machined parts, and later expanded into custom CFRTP compounding — first for its own use and later for other molders.

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 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

Other automotive grades introduced at the 2019 SPE AutoEPCON include a high-temperature carbon fiber-reinforced PPA grade specifically developed for underhood applications. That grade is said to have a glass transition temperature (Tg) and continuous-use temperature (CUT) rivaling that of PEEK, but is easier to mold. Given the cost sensitivity of high-volume industries like automotive and small appliances, it comes as no surprise to learn that the team also is working on a polypropylene (PP)-based KyronMAX product.

As formulation expertise grew, the company came to the attention of Mitsubishi Chemical Holdings Group (MCHC, Tokyo, Japan), which acquired Piper in 2016. MCHC immediately made a substantial multi-million dollar investment to increase the size of the compounding line in Arizona, automate operations and bring in its own carbon fiber sizing and chopping technologies to enable KyronMAX compounds to be produced faster and with greater consistency and efficiency. Subsequently, a second compounding line was set up in Michigan and a third in Japan. This expanded capacity meant that KyronMAX grades could compete for automotive business in North America and in Asia. Other markets have followed.

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.

During the Process Qualification phase, you will move on to establish the range of process parameters. This involves conducting a selection of statistical and dimensional studies, enabling you to identify and investigate any deviations in the process. A process is not considered as validated if the variations have negatively impacted the finished product in any way.

The final validation phase - Continued Process Verification - focuses on demonstrating that your process is consistently stable. It involves simulating different production runs using the same production equipment and the processes that you will be routinely using, ensuring repeatability of the set-up conditions throughout the machine’s full lifecycle.

With fiber weight fractions of up to 50% and an array of thermoplastic matrices available, injection molding compounds are expanding composites’ capabilities.

Going back to the basics of why validation exists, it’s to ensure that injection moulders have a stable and dimensionally centred process that consistently produces high quality products. Validation is basically providing the scientific evidence that the machine and tool is repeatedly doing everything you expect it to do, every minute of every day.

Finally, last summer MCAM acquired carbonNXT GmbH and sister company CFK Valley State Recycling GmbH and Co. KG (both Wischhafen, Germany), bringing a complete line of carbon fiber recycling technology into the group’s product offering. The MCAM team is said to be testing multiple formulas using recycled carbon fiber ahead of qualifying commercial products.

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.

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

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

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

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

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.

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

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.

Last year the European Commission issued its first update since 2001, causing more confusion. The new version of Annex 15 now requires manufacturers to ensure that “critical aspects” of their operation are validated throughout the product lifecycle. This includes any changes that could impact a product’s quality. Effective 1st October 2015, the amendment to EurdraLex Volume 4, Annex 15: Qualification and Validation closely mirror the FDA’s (U.S. Food and Drug Administration) lifecycle approach. There’s also a greater emphasis on risk management to reflect today’s manufacturing and regulatory environment.  So, how do these changes impact manufacturers?

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

The first problem was solved by applying a focused R&D effort on various base resins and fiber sizing technologies, which led to the development of a family of high-performance, injection moldable CFRTP compounds called KyronMAX. These materials feature matrices such as polyamide 6/6 (PA6/6), polyphthalamide (PPA), polyetherimide (PEI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK) and polyaryletherketone (PAEK) reinforced with short chopped carbon fiber. The compounds — most of which offer high thermal performance, broad chemical resistance, good mechanicals and low flame/smoke/toxicity (FST) values — were formulated not only to replace short glass fiber-reinforced and mineral-filled injection molding grades, but also LFT compounds (with average starting fiber length of 13 millimeters) and even metals.

Unsurprisingly, because these compounds were initially formulated by a molder for a molder, they were designed to provide properties that made them easy to process and to consistently yield higher quality, better performing parts. “We formulated our KyronMAX product line to provide higher flow and fiber interaction, lower internal stresses, less anisotropy, stronger weld lines, fewer sink marks, less tendency for warpage and greater dimensional accuracy — regardless of whether wall sections were thick or thin,” notes Dave Wilkinson, MCAM R&D director. “In addition to our formulation work and unique sizing technology, we also made our own press modifications to run these materials more efficiently.”

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

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.

While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?

The validation process requires a step-by-step approach, working with each customer to break down each element of each injection moulding cycle and documenting every stage. Conducted by an engineer, the actual validation usually takes longer than actually building the tool itself. For this reason, the validation is often partially completed at the toolmakers’ facility by a senior engineer from the company as this allows issues to be addressed there and then on site, rather than shipping the tool back and forth. Ultimately, the final phases of the validation will be completed in-house on the specified equipment.

Wheel brand Parcours reveals composite bike wheels using Hypetex colored carbon fiber to achieve aesthetic, lightweight and performance goals.

“It’s not so much that we set out to create a broad range of CFRTP compounds but that each one was developed to meet the specific needs of a particular customer,” adds Clint Newell, MCAM global composites technology manager. “As our formulation capabilities grew, we entered new markets, met with new customers, asked what they needed and set about creating a perfect compound to meet those needs.”

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.

Circa 2012, Piper was a midsize custom injection molder serving a customer base in aerospace and sporting goods/recreational equipment. Company leadership wanted to grow its parts-making business but had two challenges. First, it was having trouble sourcing the kinds of compounds the team felt would enable the company to compete in higher performance market segments. Second, the company wanted to enter the automotive market, but didn’t have enough available molding capacity to compete on major programs.

In accordance with ISO 13485 standards, ongoing documentation of the injection moulding process needs to be maintained. This is a continuous process, which is a significant change under the new directive.   From time to time, machine settings may have to be adjusted to compensate for changes in the environment or to address moulding issues, such as pulling, distortion, or aesthetic defects. The key areas that might impact a stable process include changes in pressure, temperature, flow rate and cooling rates, any of which may trigger a re-validation exercise.

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.

Now, with greater production capacity and access to a broader array of polymer and carbon fiber materials, the MCAM team has been busy developing an array of new products — several of them specifically formulated for the automotive market. One of the most interesting is KyronMAX ES 4240, said to be the world’s first short carbon fiber injection molding compound to break the 414 MPa (60,000 psi) tensile strength barrier. That grade, which was introduced at the 2019 SPE Automotive Engineered Plastics Conference (AutoEPCON) in the Detroit suburbs, is a 40% fiber weight fraction (FWF) carbon fiber-reinforced PPA that also offers tensile modulus values of 41.2 GPa, flexural modulus values of 34.5 GPa and flexural strength values of 552 MPa. PPA is a specialized form of polyamide with better thermal and broader chemical resistance and far lower tendency toward hydrolysis than conventional PA6 and PA6/6.

“On a datasheet, LFT compounds look stronger, but often they’re unable to fill the kinds of part geometry we can fill with short carbon fiber technology,” explains Alex Wojtysiak, MCAM key accounts manager – composites. “Because our flow is so much higher, we’re better able to fill intricate geometry, so our compounds produce parts that are dramatically stronger.”

Why the unusual product name? “In ancient Greek myths, Kyron (also spelled Chiron) was part centaur and part human,” explains Randy White, MCAM chief innovation officer. “Kyron used his unique personal skills to rise above his beastly nature. We likened that to our compounds, which are half carbon fiber and half resin, so as strong as a horse and as smart as a human for ease of processing.”

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

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

When it comes to product quality in injection moulding, machine and tool validation is fundamental to creating a stable manufacturing process and de-risking the project. Yet, it’s often bureaucracy rather than methodology that drives companies to validate. James Hines, Process and Training Engineer at Sumitomo (SHI) Demag goes back to the basics of why we validate and why this complex process shouldn’t be just regarded as a tick-box exercise to get the FDA or other regulatory bodies off your back.

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

What’s next? With access to the broader Mitsubishi organization globally, the MCAM team can access technology representing a  broader composites portfolio that spans thermoplastic as well as thermoset chemistries, with a range of reinforcement types and lengths. For example, another Mitsubishi group produces split and chopped tow carbon fiber-reinforced forged molding compound (FMC), an advanced form of sheet molding compound (SMC) that helps bridge the performance and processing gap between short glass or carbon fiber-reinforced SMC and continuous carbon fiber-reinforced prepreg. Still another group produces woven and nonwoven carbon fiber reinforced prepreg and rapid-cure prepreg compression molding (PCM) materials.

Although not a prerequisite for the automotive and packaging sector, validation can be good business practice for a large number of mass manufacturers of injection-moulded components. Think of it as a long-term investment. Essentially, it’s a risk assessment which, when executed professionally, can deliver efficiency gains and save your business time, money and resources by ensuring product integrity and reducing scrap volumes.

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

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.

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

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

The ITHEC 2024 will take place from the 9 to 10 October 2024 in Bremen, Germany. At the 7th International Conference, more than 300 participants from around the world will be presenting and discussing newest scientific results, meet leading international specialists, share their expertise and start business co-operations in the field of thermoplastic composite technologies. The international exhibition will feature 40+ exhibitors showcasing all steps of the supply-chain. Be it materials, machines, testing, processes, or solutions. By combining the exhibition and the conference ITHEC is further fostering the inter-connectivity between science and industry.

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

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

From a business perspective, validation will also address profit-driven challenges and design out production weaknesses. Functional tests can help operatives better understand what drives the machine, how fast it goes and the consequences if manufacturing procedures are not correctly followed. In some instances, ramping up to a faster cycle time won’t always be the most optimised process.

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.

An MCAM customer wanted to replace metal injection molded (MIM) magnesium with a composite on a performance mountain bike’s suspension elements with the goals of reducing mass and avoiding processing concerns with the reactive alkaline earth metal. Given the complexity of the part and the production volumes involved, only injection molding could meet the customer’s price point. MCAM formulated a 30% FWF short carbon fiber-reinforced polyphenylene sulfide (PPS) composite (KyronMAX S-8230) that met all mechanical requirements — including challenging fatigue targets — and successfully replaced magnesium in this application. Photo Credit, all images: Mitsubishi Chemical Advanced Materials Inc.

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

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

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.

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.

Ohio-based Canvus Inc. upcycles fiberglass wind blades, car tires and post-consumer plastics to create outdoor furniture that amplifies sustainability messages in community spaces.

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

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

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

Major repairs, changes, or improvements to the mould tool may require changes in the set up, and this would mean re-validating the process. This is also true of the moulding machines. Significant repairs or machine exchanges if not carefully managed and controlled may trigger a full validation of the process, which takes time and costs the moulder more money.

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.

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.

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.

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

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.

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.

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).

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

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.

A family of short carbon fiber-reinforced thermoplastic (CFRTP) compounds specifically formulated for injection molding is being used to extend the capabilities of thermoplastic composites in a variety of part sizes and complexities. Interestingly, these materials have been shown to outperform long fiber thermoplastic (LFT) composites (in fiberglass or carbon fiber) as well as metals in a growing range of applications — from sporting goods and car parts to medical devices and aerospace 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

Within MCAM itself, another technology that’s nearing commercialization is a new family of textile (nonwoven, woven and unidirectional)-reinforced dry prepregs with thermoplastic matrices called KyronTEX. These products are currently being strategically sampled.

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.

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

Collaboration aims to deliver the next generation of thinner, lighter, stronger and more sustainable composite materials used in consumer electronics and automotive industries.

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

At the Process Design stage you are looking to see if you have the proper sized machine - shot size and tonnage - and that the equipment is properly calibrated.

For any plastics manufacturer, zero defects remain the target. In the medical industry, for example, there’s no wiggle room. You can’t shift the parameters to suit.  If you’re producing a medical device or a sterile implant, nothing less than 100 percent quality is acceptable.

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 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.

Like before, there are three key phases to process validation, only now the FDA categorises them as Process Design, Process Qualification, and Continued Process Verification. These reflect the focus on the manufacturing lifecycle and the need to provide scientifically sound data to verify that your injection moulding processes start and continue to remain stable.

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.

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

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

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.

To demonstrate the performance capabilities of KyronMAX composites to aerospace customers, MCAM designed and produced a generic quarter-turn retaining latch for use in aircraft galleys. The parts are currently produced in aluminum owing to high load requirements. A 30% FWF short carbon fiber/PEI grade (KyronMAX S 6230) was selected both for its mechanical performance as well as its flame/smoke/toxicity (FST) listing. The composite parts meet the performance requirements of aluminum at half the weight and are currently being evaluated by several customers. They also permit painting to match aircraft interiors.

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

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

This idler wheel that is part of a performance compound archery bow was originally produced in machined aluminum. The customer wanted to convert to composites, so initially tried 50% FWF long glass PA6/6. However, that material had challenges filling the complex geometry, which led to premature failure of the part. MCAM formulated a 20% FWF short carbon fiber-reinforced PA6/6 composite (KyronMAX S 2220) for the application. Not only was the new composite able to be molded in the same tool as the LFT grade without modification, but failures were eliminated and weight was reduced 21% versus the LFT material and 50% versus the original aluminum.

Before you start validating, it is vital to be clear on your expectations. If it’s to provide a documented source of evidence to satisfy a regulatory body, you need to do it. But that shouldn’t be your sole motivation. Validation is not purely about procedures and scrambling to put the correct documentation in place. The objective of having an efficient process and repeatable high product quality should never be overlooked, as this is ultimately how you can avoid costly product recalls and cosmetic product defects.