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.

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

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

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).

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.

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

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.

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

The composites 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.

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

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

“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.”

HHI developed the platform with a view to storing 400,000 t/yr of CO2 in South Korea’s East Sea gas field from 2025 onwards.

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

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.”

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!

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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.

It will offer options including hydrogen liquefaction, ammonia and methanol conversion to hydrogen power systems, to cover various hydrogen sources and transportation methods.

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

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.

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

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

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

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.

“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.”

“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.”

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.”

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.

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

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

This 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.

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

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.

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

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.”

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.

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.”

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

“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.”

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

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

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.”

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

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.”

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.

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

Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.

“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.”

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

“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.

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.”

“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.”

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.

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.

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

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.”

–  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

ABS has also issued AIP to the offshore green hydrogen production platform, which will be linked to renewable power sources on land as a near-shore concept, as well as a variety of offshore wind power.

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.

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

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.

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

This is designed to store carbon dioxide that has been captured on land, liquefied at high pressure and then transported to the sea via a subsea carrier or pipeline.

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.

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.

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.

“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.”

“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.”

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

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.

The other concerned developing technical guidance for green hydrogen production from offshore platforms as a first step towards design and construction of a facility by 2025.

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

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.”

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

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

“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.”

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.”

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.

This was one of two joint development partnership signed by two parties for the gas field project at the 2021 United Nations Climate Change Conference, COP26.

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

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.

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.

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.

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

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

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

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

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.”

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

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.

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

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).

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

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.

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.

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

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.

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.

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.

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

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.

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

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

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

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

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.

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.

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 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.

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 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.

HOUSTON – ABS has awarded Hyundai Heavy Industries (HHI) Approval in Principle (AIP) for its carbon-dioxide injection platform during OTC.

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

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?

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.

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.

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.