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

The goal was a fastener strong enough to fasten a composite part, but also be cost-competitive and amenable to high-volume production. “Attachment to metal floors can be easily industrialized using fully robotic processes,” says Bernard. “So the idea for IMTEC HR was an industrialized solution for composites with no manual operations.” IMTEC HR fasteners can be placed into the mold for a composite floor structure and integrated during the molding process. Bernard cites IMTEC HR as compatible with thermoset and thermoplastic molding processes, including resin transfer molding (RTM), compression molding and injection molding/overmolding.

A special version of IMTEC® HR has been developed with Cetim which is compatible with the QSP production line. Cetim is the French research organization that has developed the Quilted Stratum Process (QSP) for highly automated production of composite parts.

I asked Bernard about the shape of these fasteners, explaining they looked similar to others I had seen, including Big Head and Spida Fixings. He said the shape is reminiscent but different, developed to allow the gradual release of energy during crash conditions. “It is strong enough to provide a high mechanical performance but can absorb energy in crash test conditions to avoid catastrophic brittle failure,” he explains. “It enables elastic then plastic deformation without breaking. Without this behavior, the composite floor at the attachment would deform and break or the metallic fastener would break. This was one issue with adapting fasteners for composite structures.”

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

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.

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.

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

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.

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.

Another aspect of the shape is the petals. “These are designed to embed in the composite material during molding,” says Bernard. “You must design this fastener to embed in the part and not be left in the mold.” He also notes that the fastener flange is behind the composite part and does not reduce the part section thickness. “This is important to achieve an embedded fastener while maintaining the part section, which gives structural properties.”

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

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

According to an article published by Cetim, the patent pending IMTEC HR fastener developed for QSP shows a 30-75% increase in pull-through performance and 60-75% improvement in lap-shear performance compared to conventional fasteners.

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

Böllhoff’s IMTEC HR fastener developed for molding process embeds into the composite part without reducing section thickness. SOURCE: Böllhoff.

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

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!

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.

CW’s tour of Cetim and the QSP line which preforms multi-thickness thermoplastic materials in 40-90 seconds for composite parts with cycle times of 1-2 minutes.

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.

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

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.

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.

To resist galvanic corrosion, IMTEC HR is available in zinc-plated steel and in stainless steel, the latter used mainly for carbon fiber reinforced plastic (CFRP). Different fastener versions are also available, including bolts (studs), nuts and spacers. “We can also change the size of the holes and dimensions of the fastener to meet specific requirements,” says Bernard.

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.

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

This 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

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.

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

Developed to resolve tilting and close-off issues, SmartValves eliminate cutting through vacuum bags while offering reduced process time and maintenance.

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

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

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.

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

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

For compression molding, the process is essentially the same except the pin is a plastic screw-off “cap” and also serves to push the material aside for inserting the fastener into the composite, thereby eliminating the need for hole drilling. This not only saves time, it avoids cutting the fibers. The pin cap again protects interior threads during molding and is removed after the part is demolded.

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.

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

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

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.

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.

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

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

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

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

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

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).

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

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.

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

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

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

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

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

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

ALPLAinject manufactures roughly 60 billion injection-moulded parts per year at 43 plants around the world. The division has more than 600 high-performance machines and systems. As a specialist in packaging solutions and recycling, ALPLA also relies on technological innovation. ALPLAinject scores highly with its decades of experience in lightweighting, alternative and recyclable materials; and energy-saving production facilities.

For injection molding, the fastener is robotically placed first onto a pin fixed on the mold. The pin locates the fastener and protects the threads inside of it from being coated with resin. Next, the composite material is robotically placed into the mold. The mold is closed, the plastic injected and the part demolded with fastener integrated.

Placed into the mold prior to RTM, compression or injection molding/overmolding, this specially-shaped fastener enables composites to be fastened with standard methods used for metal parts.

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.

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

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

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.

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.

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 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).

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.

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.

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.

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

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

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.

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.

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 global ALPLA Group is setting the course for further growth in injection moulding by establishing the ALPLAinject division. By strategically concentrating all injection moulding expertise and capacity under this brand, the plastic packaging specialist is increasing efficiency, speeding up the market launch of new products and unlocking new market segments.

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

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

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

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

ALPLAinject stands for high-quality injection-moulded parts such as closures, caps, jars and multi-part packaging components such as pumps or deodorant sticks. With this new division, the international ALPLA Group is setting the course for further growth. The ALPLAinject brand brings together all human and technical resources in this area in one central organisational structure. It comprises a total of three core technologies – injection blow moulding and compression moulding in addition to injection moulding – as well as global toolmaking, development and sales.

Standardised processes, centralised product and technology development; and shorter distances will ensure greater flexibility and efficiency in the future. "With ALPLAinject, we are focusing on the specific requirements of the dynamic injection moulding market. We combine technological expertise and regional market knowledge, promote the global roll-out of innovative processes and enable our customers to bring new products to market faster," emphasised the new ALPLAinject managing director Michael Feltes, who had already been business development director in the injection moulding section of the Group since October 2022. The global headquarters of ALPLAinject are located at the ALPLA headquarters in Hard. There are also global teams in all nine regions of the ALPLA Group.

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

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

“There are no extra operations once the floor is produced,” notes Bernard. “We believe this technology helps to make composite floors or any other structural parts with an affordable production cost. It replicates the used of blind rivets with metal floors because the fastener is already there in the molded composite part. You now attach the seat with standard methods. This equals the playing field because parts can be attached to a composite floor the same as to a metal floor.”

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.

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.

"The injection moulding sector offers enormous potential and is one of our strategic growth drivers. The competitive market environment requires maximum cost effectiveness and flexibility. As its own injection moulding division, ALPLAinject will continue to ensure our competitiveness in the future," said ALPLA CEO Philipp Lehner with conviction. The new division reports directly to the CEO.

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

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

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

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