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.

Control of shrinkage was critical to maintaining board dimensional stability. “Neat polypropylene shrinks 20 mils per part inch, but with the glass loadings we’re using, at 40-50%, and with the molded ribs and bosses, shrinkage is reduced to 2 mils per inch,” Mazula explains, pointing out, “We will need minimal to no secondary operations to control part flatness and to facilitate efficient assembly.” ICP also designed beveled bottom boards to allow for easy access by material handling equipment, such as “walkies.” To address the tendency for pallets to become trapezoidal in shape when dropped or impacted repeatedly, ICP has factored in design elements to resist shape change, which also aid assembly.

ABS is the most-used home 3D printer filament after PLA. Check out our guide to the best ABS filament brands on the market.

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.

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

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

“Many people have tried to commercialize heavier-duty composite pallets. All have struggled and many have failed,” says Derek Mazula, CEO of Integrated Composite Products Inc. (ICP, Winona, MN, US). “We thought, how can we selectively reinforce a composite pallet, and do it in a way that meets all of the industry’s requirements, but allow the customer to save money and supply chain partners to make money?” ICP’s answer, advanced fiber reinforcements (AFRs), combines a unique technology, robust design and a vertically integrated group of partners, including customers, who are ready to eliminate wood and corrugated cardboard from their plants.

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

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

AFRs are of three types (for background on AFR development and their types, see CW's previous coverage of this subject, titled "Selective reinforcements boost 'commodity' composite properties"):

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

ICP’s pallet would look like a GMA-standard wood pallet, with the same 1m by 1.2m (40- by 48-inch) dimensions, to integrate seamlessly into existing handling systems. But the pallet would be made from compression-molded polypropylene (PP) composite “boards” — sized almost identically to a wood pallet’s boards, at 1m to 1.2m long, 100 mm wide and 19 mm thick (40 or 48 inches by 4 inches by 0.75-inch). These would be mechanically fastened to eight injection-molded, high-density polyethylene (HDPE) blocks at the corners and along the pallet’s centerline (see the detail in the drawing, above).

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.

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

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!

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.

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.

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.

Mazula and ICP’s chief science officer and long-time industry innovator Ron Hawley deliberately avoided previous composite pallet design missteps. They knew their product would need to pass myriad performance tests under ISO 8611-1:2011, Pallets for Materials Handling. One test, for example, is deflection under load when edge-racked (when all the load is located on one edge). Beyond high strength and stiffness, the pallet would have to offer good durability and impact resistance (often at odds
 with flexural strength), yet weigh less than 50 lb (22.7 kg) — a US Occupational Safety and Health Admin. requirement — clean
 up well, repair easily and meet National Fire Protection Assn. (NFPA) fire retardance requirements.

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

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.

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.

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.

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

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

Built-to-spec prototype passes muster. This composite pallet offering from Integrated Composite Products Inc. (ICP, Winona, MN, US) is built to US-based Grocery Manufacturers Assn. (GMA) specifications. It is the first of many transportation packaging offerings in development at ICP, including bins and totes. Source (all photos): ICP Inc.

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

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.

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.

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

ICP and design partner Inform Product Development (Sun Prairie, WI, US) developed a proprietary advanced materials model for finite element analysis (FEA), using leading programs, including HyperWorks’ platform, a division of Altair (Troy, MI, US), to assess the behavior of the molded pallet under static and dynamic loads as well as typical uses, with AFRs and without, and with varying glass loading percentages in the resin. Adds Mazula, “ICP’s proprietary model evaluates true ‘composite interactions’ of each ICP AFR and the base resin/glass matrix.” Ultimately, Hawley and Mazula found good correlation, ±5%, between the model’s predicted performance and the experimental results.

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.

Lightweight carbon fiber construction, Formula 1-inspired aerodynamics and high-performance hybrid powertrain technologies hallmark this hybrid vehicle, serve as a springboard for new race cars.

The composites-intensive VTOL platform is next expected to undergo a series of test flights in various conditions to validate its performance, safety and reliability, leading up to eventual certification.

The 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.

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.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

The JEC Forum DACH is a business meetings event organised by JEC The JEC Forum DACH is organised on October 22 and 23, 2024 by JEC, in partnership with the AVK, gathering the composite materials community from the DACH Region (Germany, Austria and Switzerland).

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

Mazula says one of the US’s largest protein suppliers and packers, along with a variety of produce suppliers, are prepared to adopt the pallet in multiple plants or even system wide. ICP’s partners, including Smart Logistics LLC (Minneapolis, MN, US), have pioneered a model for assembling, cleaning and servicing of pallets that further reduces the projected cost per use (or turn, the term used in the leased pool market).

The keys to weight and cost control would be ICP’s (pat. pend.) AFRs, manufactured by ICP and partners that include Saint-Gobain ADFORS (Grand Island, NY, US). The AFRs would be placed only in pallet regions that demand higher performance. is would allow ICP to use materials, including long fiber-reinforced thermoplastic (LFT), provided by partners that include Mafic (Toronto, ON, Canada), elsewhere to optimize the pallet.

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

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.

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

Concludes Mazula, “Our ... AFR technologies are the prerequisite allowing for lighter, less costly and higher performing solutions. Concurrent with the pallet’s 2017 introduction, we will continue design work on ICP’s Universal Assembled Platform (UAP), which will allow for integration of pallets, bins and a variety of smaller totes later in 2017 and into 2018."

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

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.

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

“This was essentially an impossible set of requirements for the composite pallets that had gone before,” Mazula notes, “but we had ICP’s advanced technologies, a savvy design approach and confidence gained from three years of R&D.”

In the ubiquitous and growing transportation packaging market, valued by some reports at more than US$15 billion, 2 billion pallets are made and used each year in the US alone. The vast majority of pallets are made of wood. Those used to transport food products typically follow the Grocery Manufacturers Assn. (GMA, Washington, DC, US) design. Although wood is strong and renewable, it presents problems for pallet owners and lessors of “pooled” pallets. It absorbs water and spilled product, becoming unsanitary, difficult to clean and attractive to insects and fungi. Critical to the food 
industry, wood pallets are easily damaged, hard to repair and often 
fail in such a way that wood splinters and foreign material can enter the food being processed or transported. As a result, the pallet market is facing regulatory pressure and even bans on wood pallets in some countries and US states.

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.

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

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

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

Strategically placed advanced reinforcements reduce weight, cost while dramatically increasing mechanical performance and dimensional stability.

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

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.

ICP pallet proves durable at critical in-use impact points. ICP has tested its own pallet and a number of competing wood and composite pallets by impacting their lead boards with a 100 ft-lb force, simulating lift-truck fork impact. Here, a lead board on an ICP pallet (see top sample in photo) shows no damage at the point of impact, in sharp contrast to the competitors’ lead boards arrayed below.

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.

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

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.

Although ICP knew exactly where it should place its AFRs to achieve the maximum effectiveness, the question of how the ICP team would optimize each AFR type and each base resin/glass matrix for the design proved to be far more involved. Says Hawley, “The sheer number of design factors/combinations with AFRs — types, sizes, formulations, etc. — base resin matrices — percentage glass, melt flows, formulations, etc. — and the interdependent impact of part designs — rib depths, rib heights, wall thickness, etc. — for each board and block as well as the entire pallet system was staggering!”

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

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

Durable and dimensionally stable. A used wood pallet (left) fails under a 1,273-kg load. An early developmental version of the ICP pallet (right), by comparison, passes the ISO 8611 test, even without final HDPE blocks.

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

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

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

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

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

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

The low-cost PP resin, either a long-fiber thermoplastic (LFT) or reinforced with short glass fiber, would flow around and encapsulate the specially designed and formulated AFRs. “Our goal was to custom-design the pallet elements for the required performance, with full knowledge of their likely failure modes, and make them virtually indestructible,” says Mazula, “by strategic placement of AFRs that would make up only 5-10% of the pallet.”

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

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

The use of polybrominated diphenyl ethers (PBDEs) as a fire retardant is a concern for many retailers and shippers. ICP partnered with Arbor Plastic Technologies (Sterling Heights, MI, US), to provide a non-halogenated, non-brominated food-contact-safe fire retardant that is compliant with US Food and Drug Admin. (FDA, Washington, DC, US) directives. It has passed all required flame tests, and can be added at low loading levels with minimal performance impact.

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.

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

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

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

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 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 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.

Selective reinforcements paired with commodity materials, plus long-term partnerships, make this pallet concept a winner.

The key AFR technologies and ICP’s method of pallet design are proven and ready for market introduction. The pallet has passed all ISO 8611 tests with flying colors, and Underwriters Laboratories (UL) and FM approval certications are underway. The company says it is collaborating
 with several molding
 partners, all followers
 of best practices used in 
the automotive industry, who have dedicated production capacity to meet committed orders from a variety of large end-customers, beginning this year.

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).

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.

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

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.

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.

Hawley designed a single mold that could produce the variety of boards needed to prove out ICP’s conceptual design: “With 
just a single board mold and wood blocks, we could make a wide variety of prototype pallet components that could readily be tested at the ICP Center. We relied on our team’s experience, coupled with rigorous designs of experiments (DOE) on prototype parts to narrow the solution set.”

Pallet “lead” boards (those in contact with lift-truck forks) were designed for harsh use, including impact forces of 100 ft-lb or more from fork-lift truck masts. Pallet blocks would experience even harsher impacts from the “business end” of the fork tines, because they are routinely speared or “pinwheeled.” Lead boards, flat on top, were molded with several, small lengthwise ribs on the underside, each rib containing an AFR-TM rod (with the appropriate number of filaments) at its bottom (see drawing). Boards also incorporated SM-AFR mesh and PP resin reinforced with LFT (higher glass percentages required for performance) to provide structural support. The selectively placed IM-AFR mesh, which is formulated with a resin coating incompatible with the PP molding resin, doesn’t co-melt completely with the molding resin, but retains some flexibility to better absorb big impacts. Top center pallet boards also have unique and proprietary features factored into their design. The underside of select boards offer molded-in bosses to receive conventional fasteners that attach the boards to the HDPE blocks.