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.

PolyOne recently collaborated with a leading global automotive OEM and its injection molder to eliminate paint from a new vehicle’s interior.

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.

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

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

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

“Many car parts are painted, not just metal and thermoplastic exterior parts, but also thermoplastic parts in a vehicle’s interior,” notes Gary Fielding, vice president and general manager, Color and Additives EMEA at PolyOne. “We have successfully helped carmakers transition from paint to MIC for many exterior applications such as skid plates and trims. This recent project is a significant step forward in reducing the cost to manufacture highly visible interior applications.”

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

The control is managed by Engel’s CC300, which provides real-time process monitoring and integrated safety systems. This is said to improve user-friendliness and enhance the efficiency of manufacturing processes.

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

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

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.

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

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

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

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).

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

Transitioning from paint to the use of MIC with Smartbatch FX helps manufacturers in the automotive, appliance, consumer goods and other industries create attractive, durable parts at reduced cost. PolyOne’s metallic-effect masterbatches can be incorporated into pre-colored compounds or dosed at a molding machine.

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 key to molding good parts is for OEMs to decide, very early on, that a part will be colored with molded-in color masterbatch; that decision will then support the development of a mold and part suitable for masterbatch.

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

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 fully integrated bolt-on-injection unit from Engel is capable of coping with both standard and high-performance plastics (including ABS, PC, ABS/PC, PEEK, PA and more) which can be processed at temperatures higher than 450°C. The consistent use of thermoplastic materials is said to enable a high degree of process integration for worry-free functionalization of the parts. Therefore, this can reduce time, raw material input and energy requirements. Langzauner and Engel are customizing and fully integrating the bolt-on injection units for the individual requirements of customers.

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

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

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

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

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!

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

Paint adds a great surface finish to automobile parts, but painting always adds cost, time, and additional logistics requirements according to PolyOne. By using Smartbatch FX metallic masterbatches, the molder was able to produce parts ready for assembly with no secondary processing required. Suitable for standard injection molding machinery, Smartbatch FX reduces the cost per part by 30 percent or more compared to painted parts. Lowered energy requirements versus painting and the reduction of VOCs also make this masterbatch a more environmentally sustainable solution.

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

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.

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.

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

Transitioning from paint to masterbatch for metallic-effect parts is not new, but it is nowhere near as widespread as one would expect according to some auto industry observers. Inertia — We’ve always done it that way — and legacy investment in paint lines, supports the continued use of paint.

To provide customers with additional information on making the switch from paint to molded-in-color parts, PolyOne has created an eBook titled, “Trend Report: Efficient Manufacturing And Molded-In Color.”

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.

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.

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.

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

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 collaboration has resulted in a combined system for processing composite semi-finished products, integrating press and injection molding technology. This technology enables the forming and back-injecting of semi-finished products in a single process step, which can make production more efficient and energy-saving for applications in e-mobility and urban air 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.

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.

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

And though the argument against masterbatch always is about these visual defects, little is said about scrap from paint lines, which can reportedly be more than 20%. Painting is not only more costly, and energy-intensive; it also generates very high levels of non-recyclable scrap.

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.

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

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).

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

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

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.

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.

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.

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.

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

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

The industry’s challenges, in light of COVID-19 and an uncertain economy, could open the door much wider to greater use of metallic-effect masterbatches, as these significantly lower cost per part. The challenge with masterbatch remains molding parts that do not have visual defects such as flow or weld lines.

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

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.

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.

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

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.

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

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

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

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.

A recent project was successfully implemented at the Technology Center Thermoplastic Composites of the Leibniz-Institut für Verbundwerkstoffe GmbH (IVW), whereby an injection unit from Engel with a screw diameter of 70 mm was selected.

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.

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and is a proud dachshund owner.

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

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.

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.

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.

PolyOne recently collaborated with a leading global automotive OEM and its injection molder to eliminate paint from a new vehicle’s interior. To support the transition to molded-in-color (MIC) parts, PolyOne provided metallic-effect Smartbatch FX masterbatch colorants for two PC/ABS side panels on the center console of a compact SUV now entering commercial production. The parts (two; one on each side of the center console) are C-shaped, 35-cm long, and at their widest point 11-cm wide.

CAMX 2024: Langzauner and Engel present combined systems for semi-finished composite processing in a single process step.

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

Langzauner (Lambrechten, Austria) and Engel (Schwertberg, Austria) have jointly developed composite processing technologies for lightweight construction, with Engel specializing in injection molding technology and Langzauner specializing in the development of hydraulic presses and custom machines.

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.

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.

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.

“Typically, you do not want a bunch of holes or sharp curves in a part if you intend to use metallic-effect masterbatch. Too often, a mold is made for molding of parts that will be painted, and then — when it is time for a facelift — the OEM decides it wants to save some money and shift from paint to masterbatch. However, without investing in a new mold, the existing mold design often makes it very difficult for masterbatch to be successfully used.

The typical process sequence is as follows: (1) Loading of a preheated reinforced semi-finished product (organosheet, GMT, LFT and so on) by hand or using an automated Langzauner transfer frame; (2) closure of the press; (3) connecting the injection unit to the mold (simultaneously to the closure of the press); (4) injection of thermoplastic material; (5) well time for cooling (composite compound); (6) disconnection of the injection unit; (7) opening of the press; (8) removal of the component.

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

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

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.