One of the main innovations in the 3DiTex system is the way its winding process works to create a multilayer textile preform without the time-consuming, back-and-forth motion of a typical filament winding system. Laine explains, “The first point of the technology is to build preforms in a continuous way. That was the start. But of course other technologies can also do that, with braiding, for example. So then the challenge became how to lay down all of the layers at once. We also didn’t want to reinvent pultrusion. We wanted to be able to do complex geometries, and for the preform to be bendable to different shapes, not just straight profiles like you get with pultrusion.”

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

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.

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.

Exatec plasma coating technology from SABIC can make it possible for PC-glazed windows, where regulations allow for their use, to meet legislated driver visibility requirements. For larger PC-glazed surfaces like backlights and sunroofs, weight savings of up to 50 percent can be possible, helping automakers to improve fuel efficiency and lower emissions.

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

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

What’s the maximum length part that 3DiTex’s process can produce? “The limit is more about the tooling, and that’s based on the customer and their requirements,” Laine explains, “but the longest part we’ve produced so far is about 2 meters.”

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

The 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.

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?

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

The team has developed what Laine calls “a process that is similar to plastic injection overmolding” for molding an additional piece of continuous fiber material — potentially a specialized fabric produced by sister company Nobrak — over the tube joints to connect the two pieces without other bonding or fasteners. “This allows you to connect the tubes and also adds geometry to reinforce areas that need additional reinforcement with continuous fibers,” Laine says.

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

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.

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

CFRP pultrusion and pullwinding specialist Epsilon Composite combines thermoplastic overmolding with traditional thermoset processes, demonstrated through aircraft struts and industrial applications.

3DiTex’s first customer in this market is bicycle manufacturer Caminade (Ille-sur-Têt, France), which specializes in high-end, custom-made bicycles assembled from its modular designs and components to fit a customer’s specific measurements and needs. Currently, most of the company’s bicycle frame components are straight, hollow tubes made from titanium, aluminum or short fiber pultruded composites, joined to build the full frame with injection molded plastic or titanium connectors. 3DiTex introduced Caminade to the idea of using its technology to incorporate the higher rigidity of continuous, unidirectional fiber and the possibility of molding the frame components into more complex or curved shapes.

Getting ready to ride. Pictured here, a full Caminade bicycle frame undergoes strength testing while the company prepares the product for rollout to customers. Photo Credit: Caminade, via 3DiTex

High-volume manufacturing capability, easily recycled materials and design freedom are three increasingly important requirements for a material to be adopted for many end markets and applications, from high-performance sporting goods to commercial and defense aerospace parts.

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

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

Optimizing the design. Using its process, 3DiTex was able to optimize Caminade’s typically straight bicycle frame components (one of several pictured here) into more complex curves or shapes.

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

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

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

Currently, 3DiTex collaborates with resin supplier partner Arkema (Colombes, France), developing its parts and process for use with Arkema’s polyamide 11 (PA11) and polyphthalamide (PPA) products, among other materials.

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

Continuous winding. The 3DiTex process is said to combine the continuous production capability of pultrusion with the ability to wind tapes at optimal orientations and angles.

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

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

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

The resulting 3DiTex system is a series of winder modules — Laine calls them “discs,” referring to their round shape — that are mounted along a fixed mandrel or support structure onto which the filaments or tapes are wound. Each module works independently, positioned at equal distances along the system and programmed to rotate around the mandrel and deposit one specific layer. The preform moves continuously through the system at a specified speed, typically a meter or more per minute, with modules laying down successive layers. The modules are highly customizable, programmed to rotate at a specified speed and lay down the materials at a specified angle for each layer of each part.

A program from the U.S. Air Force Research Laboratory adopts automated braiding and phase-change tooling for a complex geometry unmanned aircraft part.

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

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

Starting with the sporting goods and bicycle market, French startup 3DiTex targets its continuous preforming system for thermoformable, thermoplastic composite tubes in complex geometries.

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!

“When we started Nobrak, we modified an existing TFP machine and we made flat preforms that could then be stamp formed or put through some other process to form a more complex geometry,” says Laine. While the company has seen success with this technology, he adds that it was quickly apparent that one market gap Nobrak was not able to serve was the need for hollow, tube-shaped preforms common to many applications and end markets, from bicycle frames to aerospace struts. To fill this need, Laine and Azran began investigating methods to produce hollow preforms that could then be molded into tube-shaped composite parts.

Toyota’s special edition 86 GRMN sports car is the first production vehicle to feature a rear quarter window in polycarbonate (PC) material with a plasma-coat solution designed to deliver the highest level of durability performance. The vehicle, exclusive to Japan, was exhibited earlier this year at Tokyo Auto Salon 2016.

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.

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.

In summer 2023, Caminade provided 3DiTex with the design parameters needed for several different styles of tubes: diameter, length, shape and mechanical properties. 3DiTex then came up with a compatible design for each of the needed tube shapes and lengths, using a carbon fiber thermoplastic tape. Laine adds that not only does the company’s process enable more complex shapes, but also variation in tube thickness, flexibility or rigidity in specific areas along the part.

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.

Laine and Azran leveraged this method into a second startup in 2018, 3DiTex. Today, Laine serves as CEO of 3DiTex, and Azran as CEO of Nobrak. In the last few years, 3DiTex has been raising funds, filing patents on its technology and has grown to a team of 32 employees. With plans to open its first official pilot line in 2024 and first production plant in 2025, the company is already using its initial pilot machine to produce prototype and commercial parts for customers.

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.

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

The car’s rear quarter window is injection molded with Lexan polycarbonate (PC) resin from SABIC. The optically clear window is about 50 percent lighter compared to a conventional glass solution.

He adds that the company is also working to develop joining methods to be able to produce more complex finished parts (more on this below).

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.

Currently, 3DiTex’s initial pilot machine is capable of producing prototypes and commercial parts in small volumes, up to several hundred per year.

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.

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

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

As the advanced air mobility market begins to take shape, market leader Joby Aviation works to industrialize composites manufacturing for its first-generation, composites-intensive, all-electric air taxi.

Moving forward. Each disc-shaped winder along the line is programmed independently, laying down one material layer at a time while the preform moves continuously forward, eliminating the typical process of a filament winder going back and forth over a mandrel.

Once the preform comes off the 3DiTex line, it is ready to be cut and then molded into a final part, either by 3DiTex or by the customer.

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).

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

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.

3DiTex has targeted sporting goods as its entry-level end market, with first prototype parts produced for a customer that manufactures ski poles. Laine notes that the poles are “quite simple, but not completely straight, so you cannot make them with pultrusion.” 3DiTex is also working with customers on various other sporting goods applications, like tennis rackets, hockey sticks and baseball bats.

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.

“Typically with winding, it’s a one-shot process with the winder going back and forth, right and left, over the support,” says Laine. “But in our case, it never goes back to the right, it just goes one way all the way through continuously, so each disk has to apply the full quantity of material that we want for each layer.”

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

As of October 2023, Caminade is working toward qualification tests for the new frame components, with the goal of launching them as an option to customers for its custom bikes by the end of the year.

Thanks to recently acquired funding, the company’s pre-industrial pilot line is in the works and is expected to be online by summer 2024. By mid-2025, the company plans to open its 3,000-square-meter production plant, and to double its workforce. Laine explains, “In our current space, we have the capacity to produce a few hundred parts. In our pre-industrial facility, we’ll be in the mid-volume range, with a capacity from about 1,000 to 10,000 parts per year for a customer. And then by 2025 we’ll reach our goal for high-volume capacity, between 10,000 and 100,000 parts per year.” He adds, “There’s a lot of investment involved in this process. It’s a highly optimized process and textile, with a lot of investment for the mandrels or supports, tooling for the thermoforming process and design work that goes into each part. So high-volume production runs ultimately will make the most sense economically once we have the capacity.”

Six U.S. companies have proven their recycling technologies for composites and rare earth elements, and will be supported for relevant scale demonstration and validation.

The company’s founders, Bertrand Laine and Aymeric Azran, earned Ph.D. degrees in materials science and the mechanics of materials, respectively, and worked for a number of years in composites and technical textiles. They met while working on 3D knitted preform technology at R&D company RT2i (since acquired by Saint-Gobain), and in 2016, decided to leverage their experience to found startup company Nobrak specializing in innovations related to tailored fiber placement (TFP) technology.

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.

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.

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

Adhesive- and fastener-free joining. As a next step, 3DiTex has developed a modified injection overmolding process to join its components together to manufacture full bicycle frames or other products. Shown here is a 3D model of 3DiTex’s bicycle frame concept.

Thermoplastic composite preforms for tubes, bicycle frames and beyond. French startup 3DiTex has developed a continuous process for winding complex-shaped, hollow, thermoformable preforms from thermoplastic composite tapes or other materials. The company’s first target market is sporting goods, including bicycle frame components and, soon, fully integrated bicycle frames like those shown here. Photo credit, all images: 3DiTex

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

Because Toyota wished to achieve regulatory requirements at a global level, the Japan-based OEM turned to Exatec plasma technology from SABIC. This flexible glass-like coating is deposited on top of a base wet coat to enhance performance. Applying this advanced coating made it possible to meet Toyota’s high quality requirements.

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

Laine notes that several methods could be used to manufacture these parts, and 3DiTex has mostly used thermoforming or compression molding. For each part, 3DiTex designs and orders an open or closed mold, and a bladder to fit inside the preform. The thermoplastic preforms can be bent by hand to insert into the mold, and final parts are molded under heat and pressure.

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.

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

Laine explains that many different materials can be used — carbon, glass or flax fiber; dry filaments or prepreg tapes; thermoset or thermoplastic resins, including bio-based resins; even rolls of paper or metal filaments — but the process was designed around the use of thermoplastic tapes or commingled yarns with thermoplastic filaments. “Thermoplastic tapes are a perfect fit. They’re easy to work with but also fit our strategy to use recyclable materials, and to have the ability to go toward large-volume manufacturing in the future,” he says.

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.

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

To demonstrate this technology, 3DiTex is building a full bicycle frame demonstrator, which will combine the original preforming technology, thermoforming of the tubes and 3DiTex’s modified injection overmolding process to join the tubes together into one final part.

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

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

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

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

For the next few years, the sporting goods market, including bicycle frames, will continue to be 3DiTex’s main focus. Further in the future, Laine says the company is in conversations with potential customers in the aerospace industry, and is also considering the possibility of expanding its business to sell machines to customers who need to produce parts on-site for confidentiality or geographical reasons.

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.

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

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.

Bendable, thermoplastic preforms. While other materials can also be used, the process is primarily designed for use with thermoplastic tapes. One of the benefits is the ability to bend the preforms by hand to insert into the mold for forming.

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

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

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 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.

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

Until now, manufacturers have produced rear quarter windows in PC using wet-coat only solutions. Depending on vehicle type and passenger position, wet-coat solutions can meet industry requirements for weatherability and abrasion resistance at that window location. In some cases though, a higher level of performance is required to meet driver visibility needs.

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.

From infrastructure solutions to consumer products, Polish recycler Anmet and Netherlands-based researchers are developing new methods for repurposing wind turbine blades and other composite parts.

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

Laine explains that as a next step for the technology, the company plans to offer not just preforms or thermoformed composite tubes, but also the capability to join its tubes to create a more complex finished part without the need for either separate connectors, fasteners or adhesive.

In terms of performance, Laine sees this technology as a good fit for medium-volume electric city bikes, for example — where both light weight and strength to carry batteries and electronics are needed.

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

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

He adds that there are two options for the mandrel or support structures used in the 3DiTex system. “You can either push a mandrel — with the preform being formed on top of it — continuously through the system, or pull the preform itself, sliding along a fixed support.” This depends on the material used as the base preform.

Laine notes that the process enables different types of materials to be laid down on the same part in one shot — a mix of glass and carbon fiber layers, for example, or to apply a core layer such as cork or foam in between by the different independent modules.

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

3DiTex (Canéjan, France) is a startup company aiming to provide all three with its process for producing hollow, tube-shaped, thermoplastic composite preforms and end-use parts, with the ability to mold into complex shapes and be manufactured from easier-to-recycle thermoplastic or even bio-based materials as well as the potential for production in large volumes.

“The goal is not to compete with fully injection molded plastic bike frames, or high-volume aluminum frames,” Laine notes. “We’re only planning to use injection molding in small areas where needed to combine parts of the frame. We’re competing with fully monocoque carbon fiber frames, which right now are often hand-built and custom-made, and providing a higher-volume option for that.”

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

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.

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

“We are proud to have supported Toyota and its Tier suppliers with this first-to-market, plasma-coated rear quarter window on a very special car,” said Scott Fallon, SABIC’s automotive business leader. “No other technology is available today with the same level of durability for PC-glazed windows than this plasma solution. It is a good example of the superior value that we can deliver to today’s automakers as they strive to build light, stylish and well-finished vehicles.”

The resulting technology is a continuous, modified winding process (more on this below) designed as a modular system for manufacturing highly material-optimized, tube-shaped thermoplastic composite preforms that can then be molded into final parts — including those with complex shapes and curves.

The 3DiTex system is, essentially, a continuous production line consisting of a series of winders laying down tapes or filaments onto a mandrel or support to manufacture the preform layer by layer as it is pulled through the system. The process is said to be something of a cross between a continuous pultrusion line and filament winding, combining the speed and continuous production of pultrusion with the ability to wind tapes or filaments in various orientations and angles.

The system operates via design and control software developed in-house by 3DiTex. For each part, inputs such as the radius of bending, diameter and more are used to create 3D models of the part “that allow us to predict trajectories for bending to accommodate all the variation,” says Laine. The preform is designed via in-house simulation software. He adds that it was a trial-and-error process at first, requiring the manufacture of physical preforms to compare to the values predicted by the simulations, in order to perfect the software.

Currently, the company can offer customers preforms or hollow composite parts. Laine explains, “When we first launched the company, we didn’t know exactly what we wanted to do yet — sell the machines? Sell the preforms? Manufacture composite parts? We decided to start with selling the textile preforms, but quickly realized that because it’s a new process, if we sell only the preforms then there’s a lot of educational steps to explain to the customer how to manufacture with our preforms. So we realized the best method for now is to build the composite parts ourselves so that we can control all the steps.”

Looking to the future, the company sees the most potential in bicycle frames. Laine notes, “We’re targeting bicycles in particular because the frames are complex, so we saw a good opportunity for our process and products.”

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.

In addition, compared to other material solutions for windows, new combinations of style and function are possible with PC glazing. For example, rear quarter windows can smoothly integrate an aerodynamic spoiler, roof pillar, airflow separators, door handle scallops and even rear lamps.

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.

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