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.

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

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

The company is also looking at thermoforming carbon fiber reinforced plastics (CFRP). “We have formed Tepex and Polystrand materials and are working on various developments with a medical customer,” says Kieffer. “We can use high-end plastic materials like Kydex and back it with CF/epoxy for aerospace, or materials like polyurethane, polycarbonate and ABS, which provide a nice exterior finish and are cost-effective. Behind these latter plastics we can use glass fiber-reinforced polyester, vinylester or epoxy laminates.”

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).

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

Back in the day, the recording industry shifted from pressing vinyl to injection molding polystyrene, especially for 45 rpm records. The Cactus Cowboy explains why and how to tell if your vintage vinyl really isn’t.

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

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.

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.

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

This combination of materials and process imparts a lot of toughness to the finished part. “We have videos of dropping concrete blocks on these parts,” says Kieffer. By molding steel fixtures, he says pull-out strength can 4-5 times that achieved with secondary bonding using industry standard methyl methacrylate adhesives.

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.

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

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

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.

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

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

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.

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

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

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.

“We do a lot R&D work with our customers,” says Kieffer. “We explore different resins, foams, laminates, layers of reinforcement and finishes, and then show them prototypes so that they can do tests very quickly. We will try to make the part more manufacturable, looking at how to reduce cost and improve performance, plus meet the various in-service requirements, such as extreme hot and cold temperatures and impact.”

Meanwhile, compared to spraying chopped fiber in an open molding process, this patented technology enables a higher fiber content, higher quality and no/low volatile organic compounds (VOCs). He points out that spraying chopped fiber onto plastics for tubs and spas is not patented. “We always use vacuum infusion to make the FRP part of the product,” says Kieffer, adding “our parts have a smooth finish, so we are more of a light RTM with caul plates. We’re always taking it to the next level. Customers come to us with a problem and we try to find a solution that works for their needs. We are very innovative, and we patent our new developments.”

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

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

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.

“We are also working with mass transit and aerospace companies,” he continues. “A lot of subway interiors are currently FRP with gelcoat plus aluminum structure behind it. They need lightweight but also a cosmetic surface finish. We’re looking at a wide range of applications, including medical, electrical and construction.”

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).

The result is a tool-less composite parts manufacturing process, which Plastics Unlimited calls Tool-less Engineered Composite (TEC). “It removes the gelcoat and tool release steps,” says Kieffer. “Also, when you thermoform, you can inspect the Class A surface and make sure it’s perfect.” In other words, the Class A surface isn’t hidden underneath a composite laminate. “All that was needed was a single thermoforming tool, and the process still made sense for our plastic parts customers.”

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

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.

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.

Editor in chief of PlasticsToday since 2015, Norbert Sparrow has more than 30 years of editorial experience in business-to-business media. He studied journalism at the Centre Universitaire d'Etudes du Journalisme in Strasbourg, France, where he earned a master's degree.

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 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.

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

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

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.

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

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

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.

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

Plastics Unlimited was started 25 years ago by Terry and Nancy Kieffer, explains their son Dakota Kieffer, sales and marketing director for the company. “They were farmers in Iowa and had started looking for a new and growing industry,” he explains, “They thought plastics would be better than welding or woodworking and they did not want to compete with their neighbors. They looked at injection molding, rotational molding and recycling plastics, but then came across thermoforming, and really understood it.” (Thermoforming uses heat and vacuum/ pressure to shape thermoplastic sheets into shaped parts.)

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.

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

Plastics Unlimited has 100,000 square feet of production space and 75 employees, including a team of three engineers.  Its 5-axis Thermwood CNC machine enables in-house tooling production and also quick prototyping, the latter important to customers as they seek to shorten development timelines.

Producing composite parts with a class A finish is not the Holy Grail — there are plenty of companies that do this on a routine basis. However, doing so using resin infusion without expensive tooling or gelcoats and at a rate of one part per hour? Well, that is something unique.

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.

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

As for the difference in sound quality, the Cactus Cowboy says it’s a toss up. In other corners of the internet, there is a raging debate. Of course there is.

CW Tech Days are virtual events dedicated to the topics impacting the composites industry today. Access past event recordings and register for upcoming Tech Days.

The 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.

Plastics Unlimited operates at the intersection of plastics, metals and composites, says Kieffer. “Our parts are typically 30 to 40 percent lighter than steel. But we find the market still needs quite a bit of education about what composites are and what they can do.” All the same, the company sees a lot of potential for future growth. “Not all materials work together, and especially not all resins work with all plastics,” he notes. “We’ve done so much testing and development over the years that we understand the landscape and possibilities very well. We have a unique expertise and offer a unique range of possible solutions.”

Kieffer notes that a composite combines two materials to make a better material than either constituent alone. “We are combining two different types of materials and two different processes to make a better product.” Notably, a product that comprises plastic, resin and glass fiber to offer a unique mix of benefits. “Plastics perform much better in impact than gelcoats,” he explains. “It is also possible to print any texture or design on the plastic, for example a camouflage pattern. The plastics also offer a lot of depth of image with no buffing afterwards, which removes secondary finishing operations.”

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

So, you’ve got a nice collection of vintage vinyl salvaged from your misspent youth, but are those records really made of vinyl? Some of them might be polystyrene (PS). How can you tell, and does it matter? The Cactus Cowboy has the answers.

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.

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

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

Efficient, high-quality, well-controlled composites manufacturing at volume is the mantra for this 3D weaving specialist.

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.

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.

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.

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.

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

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.

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

Plastics Unlimited supplies parts for a range of companies, including Harley-Davidson and Gehl telescoping lifts. “We also do soft-touch parts that look and feel like leather,” says Kieffer. The company has also made truck components for Navistar and recreational vehicle (RV) parts for Winnebago. “We prefer volume production, from 100,000 parts per year down to a few hundred.”

In a short video that clocks in under six minutes on his Youtube channel, the Cactus Cowboy explains that back in its heyday the recording industry shifted from pressing PVC “pucks” between two stamps, heating the material, and trimming flash from the edges to injection molding polystyrene. The reason, as you can imagine, was speed and efficiency, especially beneficial when it came to cranking out 45s.

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

Plastics Unlimited can make up to 2,500 of these parts per month, with some of the panels measuring 5 feet by 7 feet. “This would require expensive tooling, if not made using our method,” says Kieffer, noting that TEC can be used for quite large parts — up to 8 feet by 11 feet. “Our parts can have more shape and geometry versus steel. This is important to our customers because it lets them differentiate via styling. Our UV resistance is also better than most gelcoats.”

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

Then Kieffer’s parents came into contact with a company making glass fiber reinforced plastic (FRP) parts.  “They saw how strong FRP was, but also that it required a long, multi-step process, roughly four hours per part — so, only two parts were produced per day,” he continues. “Compared to our production in plastics, they felt that was too slow. We were turning parts every 2-6 minutes — maybe even producing 5-6 parts at once — so, thousands of parts per day.” To bridge the gap, Kieffer’s father came up with the idea of using a thermoformed plastic shell as a tool.

Flat tank enabling standard platform for BEV and FCEV uses thermoplastic and thermoset composites, overwrapped skeleton design in pursuit of 25% more H2 storage.

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.

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

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

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.

It’s fairly easy to tell the difference between a PVC and PS record. For one thing, the label is pressed into the PVC during the stamping process, whereas it is glued onto molded PS records. The appearance of the grooves is also a giveaway. And then there’s the tap test. Curious? You’ll have to watch the video for the lowdown on that.

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

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

One of the parts that Plastics Unlimited produces using this process is a grain tank extension for John Deere combines made by Deere & Company (Moline, Ill. U.S.). “This is the very top part of the combine, that is open, where the grain sits,” Kieffer explains. “Compared to the original steel tank, ours is more durable. We make it with a smooth finish inside and John Deere green on the outside with black inserts at the corners. It is the largest grain tank extension available and can fold flat. It is a more engineered product compared to our competitors, with foam and ribs added to increase stiffness.” Some steel reinforcement is also required, which is actually molded in, says Kieffer, “not secondarily bonded.”

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

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

Kieffer acknowledges that long fiber injection (LFI) and resin injection molding (RIM) are competitive processes, “but the parts are not as structural as what we do. For example, a combine grain tank holds 400 bushels, which exerts 10 tons of force. RIM parts, which are not heavily reinforced, simply can’t meet this type of load requirement and RIM tooling is very expensive.”

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.

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

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.

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

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!

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.

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

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.