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

In contrast, injection molding of neat thermoplastics produces complex components in minutes, but limits the molder’s ability to optimize part functionality. “What’s great about this hybrid process,” Kneath points out, “is that you can put the material where you need it, vs. standard injection molding, where you can’t really selectively reinforce parts easily.”

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

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

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.

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

Equally importantly, the internal container can be reused by up to five years, providing a cost-effective means of transporting and storing chemicals while delivering an improved carbon footprint.

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

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

A new polymer and a hybrid process enable production of complex, high-load-capable, fiber-reinforced brackets and clips in minutes.

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

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

RPC Promens is introducing its proven Varibox IBC into the UK and Ireland, offering the ideal solution for the safe and cost-effective handling of hazardous chemicals.

To meet the specific needs of the UK and Irish markets, the standard two-way secured entry pallet has been augmented with the availability of a four-way secured entry version, allowing even greater flexibility in the4 movement of the container by a forklift or pallet jack without compromising on safety.

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

The strength and sturdiness of the Varibox ensures maximum protection so that product quality is maintained throughout the logistics chain.

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 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.

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.

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

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.

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

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

“We see real opportunity to significantly expand PEEK applications in aerospace,” says Herr. And, says Kneath, “We are also exploring applications for other industries as a next step.”

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

The easy-to-clean design prevents product contamination and large recessed label areas provide plenty of room for all required product information, and a built-in RFID tag enables the Varibox to be tracked at every stage of its journey.

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

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

To demonstrate the process, Tri-Mack needed a part that would deliver the message. “There are so many brackets used in aerospace,” says Kneath, “and we’ve made a simple bracket with thermoplastic composites, so we decided to design a complex bracket shape that would also bear significant load.” The design is loaded in three axes and incorporates four mounting points that rely on co-molded metal inserts in the PEEK overmold, the latter a typical feature of Tri-Mack’s unreinforced thermoplastic brackets. “We load the aerospace-grade, carbon fiber-reinforced PAEK substrate and four metal inserts into a standard injection mold,” describes Kneath. “We use a standard process to inject VICTREX PEEK 150CA30” — 30% carbon fiber-reinforced compound — “over the substrate, and minutes later, we have an integrated assembly that marries the performance of PEEK composites with the cost efficiency of injection molding.” (See photo at left.) Initial testing shows a very robust bond between the PAEK and PEEK matrices. “This will build confidence in the engineering community as they start to design parts exploiting this technology,” Kneath asserts.

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

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.

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.

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.

Victrex also proved fiber orientation can be maintained during forming and that there is the potential for variations in substrate laminate thickness, which enables local tailoring of stiffness in the final part. The process requires less energy than anticipated, with substrate preheating typically maintained at 200°C.

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.

“This is an enabling technology, offering so many opportunities beyond brackets,” says Kneath, adding that, given PEEK’s mechanical and elevated-temperature performance and chemical/corrosion resistance, there are few areas where it’s not a suitable solution. “We could be talking more complex housings or different types of panels with very thin, overmolded fiber-reinforced ribs.” Tri-Mack also sees opportunities in the process for imparting multi-functionality. “We have evaluated technologies that would add lightning strike protection (LSP) paths or EMI shielding. This is typically done with secondary coatings or by adding a metallic layer to the layup,”  Kneath says, but Tri-Mack is now exploring how to do this via the compounds used in the hybrid processing.

Overmolding offers aerocomposites molders the advantages inherent in both molding “worlds”: Complex aerospace thermoset composites can provide desired functionality and strength at low weight but “require hand layup and autoclave processing, resulting in parts production that takes hours to days,” comments Kneath.

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

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

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 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.

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

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

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.

“We’re getting a resounding response from airframers and others in the market,” claims Herr. “This technology gives engineers the flexibility they want to design a very robust yet lightweight, load-carrying part.” He explains this is one reason why Commercial Aircraft Corp. of China (COMAC, Shanghai) is fully engaged and actively looking at where PEEK can replace heavy, costly metals.

In the composites industry, use of polyetheretherketone (PEEK) has recently experienced an uptick in thermostamped aircraft fuselage clips and brackets made from preconsolidated blanks with woven and/or unidirectional reinforcements (see “Thermoplastic composites "clip" time, labor on small but crucial parts" and "Inside a thermoplastic composites hotbed," under "Editor's Picks,” at top right). But those who use and those who make the blanks recognize their limitations.

Best performance at least weight: The hybrid molding process uses a flat, lower temperature VICTREX PAEK composite substrate overmolded by short fiber-reinforced PEEK with co-molded metal inserts. The resulting finished bracket is as much as 60% lighter than comparable metal components. Source: Tri-Mack

As production of the A350 XWB ramps up, so does manufacture of the thermoplastic fuselage clips the plane requires. HPC sees how it’s done.

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

Preconsolidated carbon fiber/PPS and PEEK and automated thermoforming enable six-figure production of connectors for the Airbus A350 XWB.

“The industry needed overmolding,” he explains, like the organosheet process now common with polyamides and polypropylene in the automotive industry (see “CAMISMA's car seat back: Hybrid composite for high volume,” under "Editor's Pick's"). Aerospace parts manufacturer Tri-Mack (Bristol, RI, US) already had begun exploring this type of PEEK processing as part of its thermoplastic composites development. The two have now demonstrated a new hybrid molding process for PEEK that uses a lower temperature continuously-reinforced Victrex polyaryletherketone (PAEK) composite as a substrate, overmolded with short fiber-reinforced PEEK, to produce a high-performance loaded bracket that is as much as 60% lighter than comparable metal components.

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

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

JEC World 2024: Bally Ribbon Mills is displaying film-infused 3D woven joints, woven thermal protection systems (TPS) and woven composite 3D structures.

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.

Low-melt polyaryletherketone (LMPAEK) unidirectional tapes provide outstanding thermal and fire protection, demonstrating their effectiveness through rigorous testing. These tapes are fire, smoke and toxicity compliant with FAR25.853 and meet OSU Heat Release Rate standards. The tapes were tested under ISO 2685/AC 20-135 Change 1, meeting the fireproof criteria. Additionally, they met UL 2596 requirements for battery thermal runaway tests. These tapes are crucial for high-temperature applications showcasing their resilience and safety in both aerospace and automotive applications. Part of a broader range that includes films and compounds, Victrex LMPAEK materials are valued for their excellent processability and weldability. They offer versatile solutions for complex needs beyond traditional structural parts, such as: thermal runaway and lightning strike protection, heat sinking, and intricate bracketry. Victrex LMPAEK materials facilitate automation and high-rate production while addressing performance and sustainability challenges. With reduced environmental impact, lower weight and cost-efficiency, they meet the evolving demands of the transportation industry and support innovative design solutions. Agenda:  Introduction to LMPAEK ecosystem, highlighting unidirectional tapes Thermal and fire protection performance: applications and benefits Material forms and processability Sustainability and efficiency Conclusion and future innovations

The 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.

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.

Recycled fibers, in-situ polymerized PA12 and steel inserts combined in one-shot process to cut weight 40 percent at competitive cost, cycle time and safety.

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.

Because the substrate blanks are multi-ply composite layups, they are easily tailored for specific properties and/or load handling. For example, Tri-Mack has the ability to place and orient UD tapes in the blanks, using in-house automated molding cells. In fact, the company’s Advanced Composites Center, adjacent to its main plant, was designed specifically to enable automated layup, consolidation and thermoforming of composite materials in conjunction with its legacy injection molding capabilities, to replace both metals and thermoset composites in aerospace applications.

“About 3-4 years ago, we recognized that compression-formed laminates did not offer the design flexibility and manufacturing efficiency being sought by aircraft designers,” says Tim Herr, aerospace strategic business director for PEEK supplier Victrex Polymer Solutions (Cleveleys, Lancashire, UK). Drawing on the high-temperature-capable, high-performance resins’ 25-year history in the aircraft industry in both filled and unfilled injection molded plastic parts, such as mounts and spacers, tubing, housings and electrical connectors, Herr’s Victrex team and aerospace parts manufacturer Tri-Mack (Bristol, RI, US) began to explore the concept of injection overmolding as a means of overcoming the limitations inherent in thermostamping of preconsolidated blanks.

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.

“Our idea was to combine the chemical resistance and moldability of thermoplastics with the high performance and light weight of composites,” says Tri-Mack director of sales Tom Kneath. “Only then can thermoplastic composites penetrate into new applications where plastic alone cannot go because of the mechanical properties required.” But the organosheet process is not without issues. Traditional steps include preheating a preconsolidated thermoplastic laminate to remelt temperature, transfer to an open injection mold, closing the mold to thermoform the blank to shape and then injection overmolding with fiber-filled melt to provide the finished three-dimensional surface. As presented by Alan Wood at the 2nd International Conference and Exhibition on Thermoplastic Composites (ITHEC 2014, Oct. 27-28, Bremen, Germany), Victrex had to work through an array of issues, including support of the substrate during preheating, control of fiber orientation during forming, potential restriction to a uniform blank thickness to ensure matrix melting, and the development of polymers that would indeed fuse together during overmolding.

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

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

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

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

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!

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).

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

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

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 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).

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

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

“The design flexibility is huge,” he adds, noting the same bracket made with forged metal would require a significant amount of machining. “That’s easy to beat with a 2-3 minute injection molding.” Kneath concedes there is a tooling cost, but says the payback is usually pretty quick. “Most aerospace companies will say they don’t have the volumes for injection molding, but we’ve been injection molding aerospace parts for 40 years, and know how to design tooling that balances cash and performance requirements.”

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.

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“We could mold PEEK over PEEK, but it doesn’t fuse together,” says Herr. Fusion of the matrices requires a substrate with a lower melt temperature than the overmold. “If you don’t fuse the two, you don’t consolidate the part,” Herr points out. “So, we needed a low-temperature processing PAEK that has PEEK properties.” Think of PAEK as the polymer family — Victrex can make different formulations, each with a specific molecular weight, melt temperature and Tg — with PEEK being one species. Thus, Victrex developed the PAEK A250 polymer, with a melt temperature of 305°C (see Table 1, at left). “We have enabled not only overmolding with PEEK,” claims Herr, “but also the ability to achieve PEEK-type properties at processing temperatures similar to PPS or PEI with current equipment.”

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.

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

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

Roto moulded in polyethylene, the robust construction of the Varibox features an inner container enclosed within a strong outer cover, and incorporates a special discharge valve for easy dispensing of product with no need to remove a cap.

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

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.

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.

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

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

Hybrid over molding design: This CAD image shows a continuous-fiber-reinforced PAEK composite (red) with a PEEK overmold (green). Source: Tri-Mack

Integrated vents automatically open for safe dispensing and a pressure release system is available for products that cause a product build-up.

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.

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.

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.

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

CAMX 2023: Startup Weav3D will be demonstrating its two collaborative automotive demonstrator parts and present two conference papers.

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.

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

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.