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

The DCIM process combines injection molding and compounding in a single process. A single-screw extruder handles the material preparation, making the process particularly cost-effective for smaller components with a shot weight of 50-2,000 grams. Material savings of up to 50% per kilogram can be achieved.

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

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.

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

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.

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 Corporate Average Fuel Economy (CAFE) standards, set by the National Highway Traffic Safety Administration and the Environmental Protection Agency (EPA), established a goal that model year 2025 vehicles will attain an average of around 50 miles per gallon (mpg). This is an approximate 40% increase in fuel efficiency over current levels. Auto manufacturers are keenly focused on creating lighter vehicles to meet this standard.

The push for lightweighting is likely to continue far beyond 2025. Consumers and governments alike will continue to demand increased energy efficiency in transportation and we in the polyurethane industry are already looking for more ways we can help reduce the weight and, by proxy, the footprint of automobiles on our environment.

The inherent flexibility of polyurethane chemistry allows automotive designers to make their dream models a reality. Sleeker, more aerodynamic designs also have an impact on fuel needs.

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

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

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.

Fiber Dynamics has been developing and manufacturing highly complex articles from composite materials for 40 years. Its customers come from a wide range of industries, including aerospace, defense and automotive. The company is open to new economical manufacturing processes; when designing the right solution, Fiber Dynamics focuses not only on component-specific properties such as weight reduction or higher strength through integrated structures, but also the elimination of secondary assembly processes, a higher degree of automation and shorter cycle times.

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.

Both auto manufacturers and polyurethane producers are looking beyond the seats and soft surfaces to other applications of polyurethane-enabled lightweight materials in the automotive industry.

Storage compartment flap for truck interior produced via fully automated continuous fiber thermoplastic sandwich molding technology shows suitability for series manufacture.

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.

Efficiency, resource optimization and environmental responsibility are key focuses behind the seamless switch between flat and round jet nozzles, used for spraying polyurethane onto composite components.

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

For interior design, molded polyurethane panels can be treated to have the appearance of hand wrapped leather. Polyurethane also adds "warmth" to soft touch surfaces such as steering wheels and gear shifts.

In seating, polyurethane is moving into the seat frames with the use of reaction injected molded (RIM) polyurethane parts. Similarly, one of the newer applications is the use of polyurethane in the actual frame of the car. While bumpers have long incorporated polyurethane, the frame remains mainly steel. Some manufacturers have begun using polyurethane foam in the B pillars. These are the vertical support between a car's front door window and rear side window and the area that is vulnerable in a side impact. Hollow steel tubes can be filled with polyurethane foam that hardens into an incredibly rigid barrier for impact.

Lee Salamone is the Senior Director of the American Chemistry Council Center for the Polyurethanes Industry (CPI), a value chain organization that represents companies that manufacture the raw materials and machinery used to make all kinds of polyurethanes materials including those used in automotive applications. CPI promotes the use of polyurethanes in many end use markets and provides information on safe use of these materials. For more information: www.polyurethanes.org and www.incrediblepolyurethane.com.

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

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

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.

“When we discovered the potential to produce our LCTS materials by thermoplastic injection molding, we were able to use the laboratory machine at ATLAS to carry out important validation processes,” adds Teeter. “The results were excellent, so we quickly decided to purchase the DCIM system.”

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

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.

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.

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).

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.

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

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!

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

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

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.

Composites solutions specialist Fiber Dynamics Inc. (Wichita, Kan., U.S.) has invested in KraussMaffei’s (Parsdorf, Germany) GX 1100-4300 direct compounding injection molding (DCIM) machine as the company moves to thermoplastic injection molding and compounding. Fiber Dynamics chose this equipment for its recipe sovereignty, enabling greater flexibility as well as faster cycle times and improved cost-effectiveness.

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

Composites using graphene is not a new concept — but what is new is that the industry now recognizes "graphene" as an actual family of materials with different properties and promise. A new and exciting form of graphene is made from reclaimed methane, which uses new technologies to create green carbon materials. While showing great sustainability promise, functionalization is needed to unlock graphene's full range of properties for the next generation of composites to make these carbon materials useful. In this webinar, graphene manufacturer Mito Material Solutions will discuss how to bring functionalization and multifunctionality to these new "green" graphenes to enable a stronger, more robust and sustainable world.

Prior to the purchase of the DCIM machine, Fiber Dynamics was looking to expand production. It was also facing challenges with the production of propeller blades for the advanced air mobility (AAM) market. The company’s existing lost core tooling system (LCTS) took too long, had formulation limitations and was too costly using traditional methods. Injection molding was an obvious solution, but producing its proprietary and highly customized formulations posed an additional challenge.

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

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

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

“KraussMaffei was able to quickly understand our problem and offer us a solution with its DCIM technology,” says Darrin Teeter, CEO of Fiber Dynamics. “In addition, KraussMaffei was able to demonstrate and implement the solution quickly.”

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

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

Fiber Dynamics highlights the DCIM’s cycle times — reported to be eight times faster compared to the LCTS — but also the technology’s recipe control. “The ability to test a variety of different formulations and quickly develop new ones is crucial to the success of our program,” says Teeter. “Externally compounded formulations are generally not practical for our work and jeopardize the proprietary nature of our solutions. The ability to also produce technical thermoplastic molded parts and thermoplastic composites also opens up a whole new dimension of versatility and added value for the company.”

Polyurethane has long been a staple for seating foam. Polyurethane foam offers high performance over a wide range of firmness while adding only nominal weight to the car overall. The foam holds its shape over long periods of time and heavy use. In addition to the seats, foam is also widely used in headrests, arm rests, headliners, and even instrument panels.

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

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

Moreover, the entire process takes place in one go, as the compounded melt enters the plasticizing process of the injection molding machine without any intermediate stops or cooling. This reduces polymer degradation, saves energy costs and reduces the CO2 footprint.

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

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.

The Corporate Average Fuel Economy (CAFE) standards, set by the National Highway Traffic Safety Administration and the Environmental Protection Agency (EPA), established a goal that model year 2025 vehicles will attain an average of around 50 miles per gallon (mpg). This is an approximate 40% increase in fuel efficiency over current levels. Auto manufacturers are keenly focused on creating lighter vehicles to meet this standard. In response to this need for lighter yet durable parts, the polyurethane industry is responding with new ways to incorporate polyurethane into different vehicle components.

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

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.

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.

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.

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.

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

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

CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

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

Eco-friendly natural fiber range of decking, cladding, fencing, railing options ensure durable and long-lasting structures.

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.

An important partner in this project is the National Institute for Aviation Research (NIAR, Wichita, Kans., U.S.) Advanced Technologies Lab for Aerospace Systems (ATLAS). With 1,400 employees and an annual research budget of more than $240 million, NIAR is a leading research institute in the field of U.S. aviation. Since mid-2023, ATLAS has been operating a GX 450-1400 from KraussMaffei in its 150,000 square meter research pilot plant, which is also designed for the FiberForm and ColorForm processes.

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.

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.

Demonstrator’s upper, lower shells and assembly prove materials and new processes for lighter, cheaper and more sustainable high-rate future aircraft.

Plastics and composites manufacturers will benefit from Roctool’s heat and cooling induction for molding processes, with increased technical service support and capability demonstrations on a global scale.

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.

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.

Direct compounding injection molding (DCIM) enables the composites company to develop, test and protect its own recipe formulations, while increasing cycle times by eight times and reducing energy consumption.

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

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

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

The GX 1100-4300 DCIM system, with a clamping force of 11,000 kilonewtons, is scheduled to start production in Wichita in May 2024. Initially, it will produce tooling mandrels for composites articles in aircraft, such as propeller blades, wings and landing gears. Fiber Dynamics also sees future potential for DCIM technology in the automotive and sporting goods industries.

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

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.

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

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

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

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

At one time, sound proofing in automobiles just focused on keeping road noise out. Today, with in-car wireless technology and global positioning systems (also known as GPS) in cars across all price points, the acoustic needs of cars have become even more important. Many components impact the sound quality within a car. Headliners, for instance are an important part of how automakers can keep the interior of the car quieter. Some manufacturers use open-cell acoustic polyurethane foam made with some soy-based polyols. This product also features permeable thermoplastic adhesives and permeable felt fabrics in the headliner construction. The result is delivery of excellent noise / vibration / harshness (NVH) performance and lower weight.

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.

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

CMC is expanding, with new fiber production in Europe, faster processes and higher temperature materials enabling applications for industry, hypersonics and New Space.