Following installation of bracketry, the six-axis robot transports the finished carbon fiber composite bumper beam to a final quality inspection station prior to shipment to GM’s Bowling Green, Ky., U.S., assembly plant. Source | Randy Riksen for Shape Corp.

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

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

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

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

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

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

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

As they considered how to produce first the straight front and later the curved rear bumper beam, the team evaluated several composite-forming processes judged capable of producing a two-chamber hollow beam. Among these were:

“The parts we were looking at — some were straight, some were curved, some needed holes cut into them for one reason or another, but each one had to meet our dollars-per-kilogram target to be seriously considered,” explains Ed Moss, engineering group manager for the Corvette body structure. “Out of the 10 parts we initially considered, five moved to the next level of evaluation, although three eventually were dropped later in development. We ended up with two CFRP parts on the 2020 Corvette: the rear bumper beam and a removable underbody close-out panel for the center structural tunnel.”

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

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

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

An important post-mold assembly step performed at Shape is installation of the aluminum tow hook. Once a hole is drilled and the hardware is inserted, the tow hook is bonded into the waiting beam. Source | Randy Riksen for Shape Corp.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

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.

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

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

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

“We started seeing blisters on almost every beam we sent through the line,” Basela recalls. “They weren’t just aesthetic problems that could be refinished; the blisters were pushing fibers out of the way and causing delamination issues. Oddly enough, the issue wasn’t confined to one or two areas, but rather, blisters could show up in almost any location on any beam.” This issue led to an intensive second study of alternative resin systems from several suppliers. More PUR resins were evaluated, as was epoxy, vinyl ester and some hybrid systems. Again, candidate materials were modeled, molded and tested; promising candidates were scaled up to near-full-size beams to be sent for more crash and ELPO testing.

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

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.

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

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

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

Among the most innovative composite parts on the eighth-generation, 2020 Chevrolet Corvette sports car from General Motors Co. (GM, Detroit, Mich., U.S.) is a curved, pultruded rear bumper beam. The design team desired a beam with curved geometry that better matched rear vehicle styling and fit in the available package space, which wasn’t generous. The manufacturing team wanted the beam assembled to the rest of the body-in-white (BIW) in the “body shop,” meaning it had to have thermo-mechanical stability to survive the 238°C bake cycle after a dip in GM’s ELPO electrophoretic rust-coating bath. The beam also had to meet required low-speed impact crash requirements and engineers wanted to reduce mass versus the metal-inert gas (MIG)-welded aluminum extrusion used on the previous-generation Corvette. Given that vehicle’s history as a composites-intensive car, a composite beam was a logical starting point.

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.

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.

As Shape waited for its new radius pultrusion machine to be built, GM, Shape and engineered fabrics supplier Vectorply Corp. (Phenix City, Ala., U.S.) began evaluating and characterizing various fiber/resin combinations (See “Material Choices for the Corvette rear bumper beam”). For each candidate, the team modeled performance via finite element analysis (FEA) using GM’s beam design, then molded test plaques using Shape’s vacuum-infusion system at its Grand Haven lab. Next, specimens were cut and small-scale tests were run to correlate predictions against measured results, helping the team gain confidence with its engineering assumptions. Additional plaques of the most promising candidates were molded and sent through the ELPO line at GM’s Bowling Green, Ky., U.S. plant where Corvettes are assembled.

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

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

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

The historic Martin Aircraft factory is advancing digitized automation for more sustainable production of composite aerostructures.

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

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.

As design work for the 2020 model got underway, the Corvette team picked 10 structural parts, including the traditionally aluminum bumper beams, that could be evaluated for potential production as new, fully carbon fiber-reinforced plastic (CFRP) parts.

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).

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

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.

Powered by an 85% air/15% pure polyimide aerogel, Blueshift’s novel material system protects structures during transient thermal events from -200°C to beyond 2400°C for rockets, battery boxes and more.

The design team initially considered use of carbon fiber composites for the vehicle’s straight front bumper. However, for many reasons, chief among them the more stringent requirements to pass both low- and high-speed frontal barrier tests, the focus soon shifted to the curved rear beam, which had less demanding performance requirements and needed to lose more weight to accommodate the vehicle’s new mid-engine design.

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.

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

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

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

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.

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!

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

Among its many notable innovations, the new 2020 Chevrolet Corvette sports car from General Motors Co. features the world’s first radius pultruded auto part. The vehicle’s rear bumper beam (shown above mounted to a rolling-chassis cutaway) was produced by Tier 1 supplier Shape Corp. using an innovative process and machine developed by Thomas GmbH + Co. Technik + Innovation KG that can produce curved pultruded parts. The carbon fiber composite beam uses a variety of noncrimp fabrics in carbon fiber produced by Vectorply Corp. and infused with polyurethane-acrylate resin from Scott Bader North America. Source | Mark Richardson for SPE Automotive Div.

This bumper beam is the world’s first radius pultruded automotive part, and the first such part produced in North America in any industry.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

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.

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.

“Given that we thought we might be using new technology, and the front barrier tests have so many nuances, we decided to start with the rear beam instead,” continues Moss. “The rear beam, which frames the rear of the car, is actually more important, given the mid-engine architecture, and we were willing to pay more to get more mass out of that end of the vehicle.” A curved beam was needed both to match rear styling and to maximize rear luggage space. Given its proximity to mid-engine heat, the material needed thermo-mechanical stability, ruling out thermoplastics. The beam also needed to permit a coated aluminum tow hook to be molded in, or allow a hole to be cut in the beam to accommodate a tow hook, bonded into place post mold.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

New color masterbatches will broaden potential applications and versatility of UBQ made from unsorted organic and unrecyclable waste.

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

“I’d wanted to use pultrusion on the Corvette for at least two models, but hadn’t found the right application,” recalls Chris Basela, Corvette body structure lead engineer. Basela had worked with Tier 1 supplier Shape Corp. (Grand Haven, Mich., U.S.) on previous Corvettes and other programs, and was impressed with the company’s ability to produce complex, curved bumper beams in aluminum alloys and advanced high-strength steel. Shape designs, engineers, and produces metallic, plastic and composite products, and is known for its expertise in energy management. The company already had pioneered several metallic bumper-beam technologies that improved performance at lower weight.

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

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).

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

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.

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

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

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

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

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.

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

Offerings range from recycled, biobased, biodegradable  and monomaterial structures that enhance recyclability to additives that are more efficient, sustainable and safer to use.

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

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

“We liked the performance NCFs gave us because — since they’re stitched — fibers don’t shift during processing, which means higher stiffness and strength at the same areal weight, better drapeability, plus higher FVFs [fiber-volume fractions] in the final part,” Basela explains. “We decided to fine-tune our performance with unidirectional tows.”

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.

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

This bumper beam is the world’s first radius pultruded automotive part and the first radius pultruded part produced in North America in any industry. The profile is produced using about 75 bobbins of materials. Production speed is said to be comparable with linear pultrusion — roughly 31 centimeters per minute. To date, GM has filed one and Shape four patents for innovations on the application. The final beam is 2.2 kilograms lighter than the previous aluminum extrusions, yet met all design, engineering, and manufacturing targets. To date, the beam has earned two awards from the Society of Plastics Engineers (SPE, Danbury, Conn., U.S.): the Process/Assembly/Enabling Technologies category winner and the Vehicle Engineering Team Award (for the whole Corvette vehicle/team) at last November’s 49th Automotive Innovation Awards Gala.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

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

Teknor’s color masterbatch solution enables UBQ to be compounded with a brighter spectrum of colors beyond the initial brown, black and grey of the ‘climate-positive’ thermoplastic. Adding specialty colorant masterbatch or specially formulated colorants to UBQ  compounds allows customers to meet sustainability goals while still providing a visually appealing end-product. The new coloring capability makes UBQ a perfect sustainable material swap for applications such as point of purchase displays, pallets and more and has already been in use with major brands in both beverage and industrial industries. The masterbatch can be added to a wide variety of plastics and can be processed by injection molding, extrusion, and other processes.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

Interestingly, the resin eventually selected had not shown outstanding performance in preliminary tests, but it aced ELPO. Crestapol 1250 is an off-the-shelf, peroxide-cured polyurethane-acrylate copolymer developed by resin supplier Scott Bader Co. Ltd. (Wellingborough, U.K.) as an adhesive and later modified to become a molding resin (see side story “Material choices for the Corvette rear bumper beam” for more on this resin system as well as the NCF fabrics used). The total system of resin/reinforcement offered the best balance of crash performance, ELPO survivability and mass/cost reduction with acceptable processing times.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

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.

Next, near-full-size beams were produced on TTI’s demonstrator system in Germany for crash testing and the ELPO line, GM’s electrophoretic rust-coating bath. Things were going as expected until beams went through e-coat in Bowling Green, which is when issues were discovered.

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

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

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

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

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

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).

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

Additionally, the team evaluated many polyurethane (PUR) resins to find a candidate ductile enough to pass crash testing, thermally stable enough to survive ELPO and chemically compatible with structural adhesives used to bond the beam to the BIW.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

Shape Corp. is the first company in the Americas to own a radius pultrusion line developed and built by Thomas GmbH + Co. Technik + Innovation KG (TTI), and the first automotive supplier to produce commercial parts using TTI’s patented process, which overcomes many of the traditional limitations of conventional (linear) pultrusion. Source | Randy Riksen for Shape Corp.

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.

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

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

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

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.

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.

Teknor Apex has expanded its partnership with Israel’s UBQ Materials by creating new color masterbatches for the latter’s biobased thermoplastic UBQ which is made entirely from unsorted organic and unrecyclable household waste. This novel, worldwide patented material that has already been adopted by leading industry brands for manufacturing durable products with reduced environmental footprints. Teknor Apex has been an early adopter of UBQ developing eco-conscious TPEs made with 35% sustainable content, paving the way for other materials companies to develop more sustainable products within a circular economy.

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.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

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 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 aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

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.

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.

Cryomotive’s CRYOGAS solution claims the highest storage density, lowest refueling cost and widest operating range without H2 losses while using one-fifth the carbon fiber required in compressed gas tanks.

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.

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

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

Design work on the rear beam began in earnest even before material and process were selected. One aspect of the design that remained a constant throughout the program was the decision to bisect the hollow beam (along the length direction) via a central web, essentially creating two interior chambers. This feature was critical to keep beam thickness and weight low while providing required mechanical performance for crash testing. As would be expected, the central web’s presence affected process selection.

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

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

MTorres seeks to enable next-gen aircraft and open new markets for composites with low-cost, high-permeability tapes and versatile, high-speed production lines.

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

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

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

Extensive investigations of fabric architecture helped the team understand what would and would not work in pultrusion — particularly radius pultrusion. Numerous fabrics were studied, including weaves and non-crimp fabrics (NCFs) in fiberglass, carbon fiber and carbon/glass combinations.

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

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

While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?

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.

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

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In turn, representatives from Shape had met with German machinery OEM Thomas GmbH + Co. Technik + Innovation KG (TTI, Bremervörde, Germany — see “Curve in the road: First curved pultruded auto parts”), which had invented a  process and machine to produce curved 2D and 3D profiles via pultrusion. Shape was already in discussions with TTI to purchase a machine and license the technology when the Corvette opportunity came up.

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

“While we liked the cost of all-glass fabrics, going that route created a heavier beam to meet performance objectives, so we ended up with all-carbon,” Moss adds. Final fabric selection included a double bias, a warp triaxial and two warp unidirectional NCFs, most in small tows, and all in standard modulus with glass veils. Final FVF averaged in the mid-50% range.

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While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

Next, fasteners and brackets that will support the completed bumper’s crash cans are installed on the beam. Shape uses a multilayer barrier solution — comprised of strategically placed materials and coatings — to ensure the beam’s carbon fiber reinforcement doesn’t contribute to galvanic corrosion, while also minimizing mass and cost. Source | Randy Riksen for Shape Corp.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.