parts in terms of rendering - soft tooling for injection molding

“We knew that another company had converted a very small bracket — one that wasn’t structural — to composite on one of their truck bumpers, so that gave us a place to start,” adds Steve Perucca, FNG engineering group manager - R&D plastics/metals. FNG already had lots of experience converting structural metal parts to thermoplastic composites on passenger vehicles, and that gave the team the confidence to move forward.

“We discussed ways we could keep the bumper’s metal skin but convert hidden components to lightweight materials,” recalls Heo. “We knew this would be a challenge because you need robust brackets to hold a heavy part like a bumper, and both bumpers and brackets must perform for the life of the vehicle. Also, these brackets are key for meeting demanding offset barrier crash tests and — even in metals — those are challenging tests to pass.”

Still another issue the team wanted to address was that owing to steel’s formability limitations, benchmark brackets couldn’t be shaped to hold the vehicle’s fog lamps, which necessitated the use of yet another pair of heavy metal brackets. If it was possible, the team wanted to consolidate fog lamp support into the composite bracket.

CompPair and Composite Recycling introduce a roof scoop made of recycled fibers to an eco-efficient rally buggy, which channels airflow to the engine for optimal, sustainable performance.

Stephen Heinz, vice president of R&I for Syensqo delivered an inspirational keynote at SAMPE 2024, highlighting the significant role of composite materials in emerging technologies and encouraging broader collaboration within the manufacturing community.

“We had been growing at 40% per annum and when you grow at such a rate, productivity is always a critical concern for any and every manufacturer or machine shop. We had already started on a route to invest in the latest advanced manufacturing technologies so it was an easy decision to invest in a DMG Mori Milltap 700, the first joint development from DMG and Mori Seiki. The Milltap 700 is a compact machining centre with tool changes in 0.9 seconds and chip-to-chip times of less than 1.5 seconds, rapid traverses of 60 m/min, a 24 000 rpm spindle, and it is equipped with a Siemens 840D control,” explained Jarrad.

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

The DMG MORI Milltap 700, which was supplied by Retecon Machine Tools, allows Gantec Tool and Die to machine-to-completion precision parts in fewer set-ups and reduced cycle times. The Milltap 700 is a compact machining centre with tool changes in 0.9 seconds, and chip-to-chip times of less than 1.5 seconds, rapid traverses of 60 m/min, a 24 000 rpm spindle, and it is equipped with a Siemens 840D control

On a piece-price basis, the hybrid bracket was a wash, owing to the added cost of the injection mold. On a system’s cost basis, there were savings owing to the ability to downgauge additional components, although actual savings are difficult to quantify. The bracket has been in production for more than three years without problems.

As the project proceeded, and physical parts were produced and tested, the team was happy to learn their CAE models were fairly accurate. “Initially, we wondered if we’d be able to simulate the part properly, given that we were trying to predict high-cycle fatigue, in terms of durability, and high G loading, in crash modeling,” notes Heo. “Surprisingly, correlation between predicted and measured results from shaker testing were close, even in crash.” The final bracket design was completed in less than six months. It is approximately 41 x 46 centimeters, has a nominal wall of 3 millimeters and features ribbing for higher mechanicals.

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

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 exterior design was firmed up on the pickup, the combined team began its own design work on the brackets with a list of wants and needs. The benchmark brackets were stamped from high-strength/low-alloy (HSLA) steel, selected for its higher mechanicals and improved corrosion resistance versus carbon steel. The brackets had a nominal thickness of 3 millimeters and each weighed 4.362 kilograms. First, the composite brackets needed to fit in roughly the same package space, which was limited behind the bumper. Thus, a material with sufficient strength was needed so part thickness didn’t increase significantly.

The FlexHyJoin production cell combines surface structuring, induction and laser joining and NDT for automotive mass production.

At the same time the company introduced another CNC lathe, a spark eroder and an injection moulding machine so that they could run trials with the moulds they were manufacturing.

Tooling was produced by Integrity Tool & Mold Inc. (Oldcastle, Ontario, Canada) and featured a well-vented, 2+2 stack mold with two cavities/plate and two direct drops (cold runners) with sequential valve gating that produces four parts/cycle owing to the high build volume of the Silverado platform. FNG’s Ventra Evart division is the molder. Button-to-button cycle time is 60 seconds.

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.

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

Undaunted by the challenge, the GM team got to work and soon brought in the vehicle’s designated bumper supplier, Flex-N-Gate Corp. (FNG, Urbana, Ill., U.S.). Initially, as exterior vehicle styling was still being finalized, the joint team spent a year researching options in the industry and discussing approaches that might work. “We were waiting for the right time because, depending on final styling, that could change the design we used and the approach we took,” explains Heo.

When Anthony’s son Jarrad joined him in 2010 they decided to expand and get back into the manufacture of tools, moulds and dies.

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.

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.

New home, new machines With the increase in business the company moved to a bigger factory in the same industrial park, which is located in Spartan, Gauteng, in February 2014. The move afforded the company the opportunity to increase its machining capacity to help take the pressure off the company’s existing equipment.

Second, front bumpers typically wrap around the front corners of the vehicle to achieve styling cues the design studio wants. However, because they’re held to the frame by the stiff steel brackets, during high-speed crash events, the bumper can be crushed inward into the wheel, negatively impacting wheel orientation and locking up steering. To protect the wheel on the impacted side for as long as possible, it is desirable for bumper brackets to break away during impact. On the other hand, to avoid warranty issues, the bumper needs to stay attached during normal use for the life of the vehicle. Hence, the team had to determine how to balance these competing needs.

The company’s services now include component design, development and liaising with client to mould design and mould manufacture. We design and manufacture high-tech moulds for intricate components, including high-speed automatic unscrewing moulds, and incorporation of hot runnerless injection systems.

Suppliers of thermoplastics and carbon fiber chime in regarding PEEK vs. PEKK, and now PAEK, as well as in-situ consolidation — the supply chain for thermoplastic tape composites continues to evolve.

For the next-generation Silverado, Heo’s team plans to continue using hybrid brackets on the front bumper, but he’s already challenged team members to start thinking about how to take a hybrid approach on rear bumper brackets. That’s complicated by the fact that rear bumpers contain step-assist features on the corners to enable people to climb into/out of the pickup box more easily and safely. Additionally, more components (such as backup-warning sensors) are packaged behind the steel skin, reducing package space.

Not only did the hybrid composite bracket with metal inserts reduce mass, but its tailored geometry improved both stress and modal performance.

Figure 1. Before (top) and after (bottom) designs for the hybrid structural bumper bracket. The team used a unique method to attach composite (brown) and steel (green) portions of the hybrid bracket. Rather than bond with a structural adhesive, which would have added time, robots, curing racks and cost to vehicle assembly, they used a three-bolt/two-plane mechanical fastening system (see yellow outline) that reduces stress. Two of the bolts are applied along the front surface of the brackets and a third is positioned above it. Limiters on the bushings prevent overtightening during assembly. While it produces a robust fastening point, it is fully serviceable.

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.

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

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

“The decision was strategic but also a timely investment. It led to many more doors opening and helped improve the company’s performance and competitiveness, while at the same time increasing our customer base for design and manufacture of dies and moulds. This is after all the core focus of the business,” continued Anthony.

To balance competing needs of long-term durability with high crash performance, the team took a hybrid approach and split the bracket. The portion that joined bumper to frame would remain HSLA steel, but the outer portion would be converted to composite. This approach would permit greater design freedom to consolidate parts, reduce mass and enable the incorporation of fog lamps, but the composite portion would be designed to break away in a high-speed side crash to ensure wheel orientation remained longitudinal for as long as possible to help maintain steering capability. To meet all of GM’s requirements, some metal inserts were added to the composite side of the bracket, along with three bushings, which allow for adjustment during assembly. Designers found the material had no problems permitting the bracket’s leg (the curved end pieces shown in the composite/brown CAE design) to be extended to encompass the fog lamp, eliminating the need for a separate bracket in that location (Fig. 1).

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.

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.

Laser welding, maintenance and repairs “We also offered a service to maintain the moulds. Because of the extreme use of moulds in the plastic industry you are always going to have the necessity of repairs. But we felt that the industry standard repairs were not a good enough end result for our clients,” explained Anthony.

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

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

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

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.

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.

Flat tank enabling standard platform for BEV and FCEV uses thermoplastic and thermoset composites, overwrapped skeleton design in pursuit of 25% more H2 storage.

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

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.

On its first commercial use, GM’s hybrid approach on the structural bumper bracket (Fig. 2) brought numerous benefits. First, it achieved equivalent or superior performance in modal, stress, fatigue and crash testing (see table below).

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

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

Success comes to shops that are attentive to the changing needs of their customers. Such shops are generally willing to make fundamental manufacturing changes and process additions, when appropriate, to best meet those demands. In a growing number of cases, a shop’s customer wants to receive more than just a component that has been accurately machined.

“We could have invested in two different machines but the Milltap 700, which was supplied by Retecon Machine Tools, allows us to machine-to-completion precision parts in fewer set-ups and reduced cycle times.”

The company’s commitment to continuous improvement and its progressive attitude to investing in the future have seen Gantec Tool and Die branch out and provide moulds for other industries, including closures and packaging. In addition to investing in its equipment, manufacturing processes and systems they have also invested in their people. They recently hired two apprentices.

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

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.

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

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

Additionally, it was important to avoid a wire harness pinch point as it passed through the bracket to keep wire harnesses and wires from chafing and breaking, which would lead to short circuits of important features like headlights and fans. Avoiding those by providing a hole in the metal brackets through which wires could pass led to the use of an additional punching operation, which added more tooling costs owing to limitations in design freedom. It was, therefore, desirable to try and address this issue in the composite bracket. Of course, it also was important to avoid having to make changes in vehicle assembly to use composite brackets. And, as is often the case in automotive applications, the composite brackets would, ideally, be lighter and less expensive than the metallic benchmarks. One last concern was whether currently available CAE models could accurately predict high-cycle fatigue/durability in a discontinuous fiber-reinforced thermoplastic.

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

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

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.

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

For the 2019 model year (MY), the decision had already been made to keep styled bumper impact bars — stamped steel bumpers with styled A-side surfaces and finishes (either chrome plating or body-color paint) — on the vehicle’s front and rear. Due to styling-driven shape, and the mass of the steel shells, such bumpers typically require one or more steel reinforcement brackets to join the bumper to the vehicle’s frame and meet GM’s bumper durability, vehicle damageability, crash performance and packaging requirements. In this case, a pair of brackets wrapped around left- and right-hand corners of the bumper. Team members wondered if they could convert these heavy, complex, multipiece stampings to something lighter without sacrificing performance or durability.

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

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

It’s not easy being an OEM design engineer working on full-size pickup programs. On one hand, you want to make these vehicles as safe, feature-rich and fuel-efficient as possible. On the other hand, your customers — particularly those in the construction and farming industries — push their vehicles hard every day and have certain ideas about what is and isn’t a durable material. They know and trust steel. Composites? Maybe not so much.

“We will keep using a smart engineering approach of looking at problems, figuring out how products are being used and what their functional requirements are and then pushing the envelope,” concludes Heo.

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

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

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

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

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

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

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

“Our customers were demanding that we take control of their projects from beginning to end. So we purchased the necessary toolroom machinery including a brand new Leadwell V-40 CNC vertical machining centre.”

“This is why we looked at the relatively new process of laser welding, and purchased a German manufactured OR Laser 3300 which was supplied by Retecon Machine Tools in 2012” said Anthony.

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.

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.

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

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

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.

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

Carbon fiber composites faced much criticism in the wake of the OceanGate submersible accident. CW’s publisher Jeff Sloan explains that it’s not that simple.

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

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.

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.

GM’s 2019 model year (MY) Chevrolet Silverado pickups sport a new structural application for composites in a hidden but very effective location: on the left and right front sides behind the steel bumper. The hybrid thermoplastic composite/metal bracket reduces mass, achieves equivalent or better performance in modal, stress, fatigue and crash testing in limited package space, reduces corrosion and warranty risks and permits significant parts consolidation. All photo credit: General Motors Co.

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.

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.

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

Gantec Tool and Die owner Anthony Barnes has always been conscious of this fact since he established the company in 2008.

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

With their wish list in hand, the team got busy. An early decision was selecting the material to be used — namely one that FNG already had experience with and that had GM approvals. They chose a black 40% fiber weight fraction (FWF) long fiberglass polypropylene (LFT-PP) from Lotte Chemical (Seoul, South Korea) called Supran PP1340 GMW15890P. Since brackets aren’t exposed to sunlight and are sufficiently distant from engine heat, the tough olefin polymer would offer adequate thermal performance. The high-flow, injection moldable grade had a melt-flow index (MFI) of 40, ensuring good filling of complex geometry without the need to add extra gates; extra gates create knitlines that are weaker than surrounding material and should be avoided in a structural part, especially one that has to pass crash tests.

“I started out primarily as a design studio specialising in plastic product design and development, coupled with mould design. At that stage the manufacture of the tooling was outsourced. During my career as a toolmaker I learnt how to use and take advantage of the CAD/CAM design software available. In fact I believe that I was one of the first in South Africa to use the Vero Visi CAD/CAM software supplied by Software Development in South Africa, and I have remained loyal to the brand ever since. That was over 27 years ago,” said Anthony.

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

Second, composites’ design freedom permitted more aggressive styling in a relatively small package space. Third, mass of the pair of hybrid brackets was reduced 2.5 kilograms/vehicle versus the benchmark. And thanks to mass decompounding effects, lighter bumper corners enabled gauge reduction on the bumper mounting brace as well as other components, so total mass for the front bumper system was reduced 7.3 kilograms versus the outgoing 2016 model.

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

“We were then able to offer a total project management service. After the design phase, this service includes having development components machined or grown samples made, to manufacturing of the moulds,” continued Jarrad.

Collins Aerospace draws on global team, decades of experience to demonstrate large, curved AFP and welded structures for the next generation of aircraft.

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

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).

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.

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

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

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

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

“We also made a substantial investment in the CAD/CAM design software, which includes full 3D solid and surface modeling, presentation shading, drafting and dimensioning, intricate split line generation and mould build libraries,” added Jarrad.

As Chris Heo, lead design release engineer for full-size pickups at General Motors Co. (GM, Detroit, Mich., U.S.), and his team began work on the latest generation of Chevrolet Silverado pickups, they discussed which applications they might be able to convert from metal to composites to reduce vehicle mass.

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.

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).

Figure 2. The final design of the topology-optimized composite bracket incorporated numerous components, including the previously separate bracket for the fog lamp, plus structural ribbing to improve mechanicals and ensure nominal wallstock did not exceed 3 millimeters. Several metal inserts help increase performance in areas that will see significant fatigue or where load paths must be reinforced to ensure appropriate crash performance.

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.

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

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.

Additionally, corrosion risk and warranty costs were reduced since the composite bracket won’t rust. Mass reduction benefits consumers by contributing to improved fuel economy or enabling a heavier payload to be carried without exceeding legal road load limits.

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