INSIDEMANUFACTURING

Aerospace

Developing repairs for thermoplastic composite aerostructures

HyPatchRepair project proves feasibility of automated process chain for welded thermoplastic composite patch repairs.

Ginger Gardiner
Senior Technical Editor, CompositesWorld

Pultrusion

Composite rebar for future infrastructure

GFRP eliminates risk of corrosion and increases durability fourfold for reinforced concrete that meets future demands as traffic, urbanization and extreme weather increase.

Infusion

Composite rotary milking platform evolves via process innovations

Infusion and LRTM-based processes and design enabled Waikato Milking Systems to bring a lighter, less labor-intensive platform to the global dairy market.

Carbon Fibers

Easy-to-use kits enable infield repair of composite structures

Portable kit enables patch repairs using UV-cure glass fiber/vinyl ester or room-temp stored carbon fiber/epoxy prepregs and battery-powered curing equipment.

RTM

Braided preforms and resin infusion for next-generation aerocomposites

Spintech shows significant cost and labor savings using its Smart Tooling, dry fiber preforms and RTM/VARTM technology on aircraft wing and inlet duct demonstrators.

Glass Fibers

Large composite covers protect a lot of water

A massive concrete water storage facility in Bogotá, Colombia, gets a much-needed makeover with the resin transfer molding of 840 large composite domes that keep the water potable.

Aerospace

Advancing the OOA infused wing box

MTorres integrates lower cover, front and rear spars into unitized flying demonstrator using one-shot, low-cost, portable production.

Core

Optimizing AFP for complex-cored CFRP fuselage

Automated process cuts emissions, waste and cost for lightweight RACER helicopter side shells.

Ginger Gardiner
Senior Technical Editor, CompositesWorld

Prepregs

Building the Museum of the Future

FR composite panels provide structure, sealing and iconic facade for pioneering architecture in Dubai.

Carbon Fibers

C-FREX exoskeleton depends on CFRP for unpowered movement

C-FREX uses a novel design and CFRP to overcome the heaviness and weakness of metallic exoskeletons.

Fabrics/Preforms

High-rate, automated aerospace RTM line delivers next-gen spoilers

At Spirit AeroSystem’s Prestwick facility in Scotland, a glimpse of the future of aerocomposites manufacturing in a resin transfer molding line for A320 spoilers.

Carbon Fibers

Compression RTM for production of future aerostructures

Automated preforming and 5-min resin infiltration show a way forward for lower-cost CFRP primary structures.

Aerospace

Overmolded hybrid parts open new composites markets

A process that combines continuous carbon fiber-reinforced PAEK with chopped fiber/PEEK overmolding is making inroads in the aerospace market. Parts that previously could not be produced cost-effectively from composites can now be made at less cost than their metal counterparts.

Glass Fibers

Automated joining of hybrid metal-thermoplastic composite structures

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

Automotive

Novel dry tape for liquid molded composites

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.

Ginger Gardiner
Senior Technical Editor, CompositesWorld

Filament Winding

Filament wound utility poles offer design flexibility

In Turkey, a utility pole manufacturer combines filament winding, automation, glass and carbon fiber composites to expand its product line.

Automotive

Composites design and process engineering form next-generation truck body panels

Glass fiber/foam preform technology is key to the all-composite refrigerated truck body panels.

Molds/Tools

Spar forming simplified

Adapting its Automated Stiffener Forming (ASF) technology to build spars directly in female molds, Northrop Grumman Innovation Systems anticipates dramatic drops in cycle time and manufacturing cost.

Epoxies

Thermoplastic overmolded thermosets, 2-minute cycle, one cell

Adhesive-free, functionalized hybrid composites enabled by industry-first, integrated molding cell.

Epoxies

Composite radar masts assembled for megayachts

Vabo Composites designs, builds and assembles 10m-tall composite radar masts, improving weight, stability and performance for modern megayachts.

Carbon Fibers

Leveraging composites for space tourism

Virgin Galactic’s WhiteKnightTwo will carry its SpaceShipTwo to launch position, then rocket passengers to suborbital space for a heavenly view of Earth.

Construction

Composites enable epic interior for Museum of the Future

For this one-of-a-kind lobby, AFI pioneered digital, reconfigurable molds to achieve organic-shaped, multifunctional panels and stairwell cladding.

Ginger Gardiner
Senior Technical Editor, CompositesWorld

Thermoplastics

Thermoplastic composites: Scenic view

First use of thermoplastic composite guide rails to replace aluminum brings many benefits to fixed-glass, roller-blind sunroof modules.

Marine

The International 14: High-tech but still accessible

Naval architect Paul Bieker and Henderson Boat Co. team take this venerable marine racing class to a more affordable performance/cost combination.

Infusion

Infused wing sheds light on aerocomposites future

In the Irkut MS-21 infused and co-cured wings, the aerocomposites industry gets a glimpse of how out-of-autoclave technologies might be applied to primary aircraft structures.

Carbon Fibers

A complete paradigm shift in aircraft construction

With its new Torreswing automated system for mold-free, fastener-free composite fuselage and wing construction, MTorres aims to revolutionize aerostructure.

Automotive

Rear wall reboot: One-stop, tow to tape to CFRP part

Audi and Voith Composites iterate the CFRP rear wall from R8 sports car to A8 luxury sedan via an automated production line able to output hundreds of parts per day.

Carbon Fibers

The future of CFRP aerostructures assembly

Metrology, robotics and inline inspection cut cost, reduce shimming and enable future automated production of three vertical tail planes per day.

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