This initial project under the Space Act Agreement is focused on studying and developing high-performance battery cells, as well as performing safety testing, to achieve purpose-built solutions for electric aircraft.
AeroZero TPS, applicable for metals and composites, will protect critical battery housing and parts in the Lilium Jet eVTOL aircraft from burn through and risk of thermal runaway. Placing Boom Pump
V-tail, five-passenger aircraft builds on the vison of the S-A1, designed with a priority on safety and a focus on sustainability.
Agreement with green hydrogen producer extended for 2024, investment will support ongoing global capacity expansions including CFRP cylinder production.
Multifunctional four-axis winding system offering fiber flexibility will underpin the NCC’s work in testing and manufacturing pressure vessels leading to commercial production.
The EHang unmanned aerial vehicle (UAV) complies with approved type design, safety and quality requirements, with deliveries to customers now underway.
The new alliance will broaden National Composites’ capabilities in SMC and BMC and tooling, while providing customers with comprehensive solutions, from initial design to final delivery.
A new ASTM-standardized test method established in 2022 assesses the compression-loaded damage tolerance of sandwich composites.
Composites automation specialist increases access to next-gen technologies, including novel AFP systems and unique 3D parts using adaptive molds.
Combined LSAM and five-axis CNC milling capabilities will optimize D-Composites’ production services, flexibility and cut time and cost for composite tooling manufacture.
Evaluation of CFRTP m-pipe through Element’s U.K. facility aims to qualify the system for new operating environments.
Innovative prepreg tooling is highly drapable, capable of forming complex carbon fiber tooling shapes, in addition to reducing through thickness porosity and only requiring one debulk during layup.
JEC World 2024: The Alliance for European Flax-Linen & Hemp is hosting an extended Natural Fibre Village, in addition to its latest work with the ecoinvent materials database and a conference session.
As the marine market corrects after the COVID-19 upswing, the emphasis is on decarbonization and sustainability, automation and new forms of mobility offering opportunity for composites.
Novel material to combine Ohoskin’s leather alternative made from orange and cactus byproducts with ReCarbon’s recycled carbon fiber.
Kordsa concludes significant investment aimed at further enhancing its expertise in composites technologies, including development and distribution of more sustainable fiber options to customers.
ST Engineering MRAS discusses the importance of addressing human factors to reduce separator inclusion in bonded structures.
Twenty U.S. teams from 15 states were selected for Phase 1 of funded efforts to develop, mature and commercialize recycling technologies for FRPs and rare earth elements used in wind turbines.
JEC World 2024: Zünd is highlighting digital excellence via its ZCC Cut Center, heat sealing module (HSM), G3 Cutter and ZPC software.
JEC World 2024: Endless Industries offers 3D printing customers integration of its proprietary printhead, software and fiber filaments to achieve the benefits of lightweight composite parts.
This compact cell brings together 3D printing, AFP and milling aided by a comprehensive software program, further simplifying the manufacture of complex thermoplastic composite aerostructures in the future.
In 2006, guest columnist Bob Hartunian related the story of his efforts two decades prior, while at McDonnell Douglas, to develop a thermoplastic composite crytank for hydrogen storage. He learned a lot of lessons.
Multifunctional four-axis winding system offering fiber flexibility will underpin the NCC’s work in testing and manufacturing pressure vessels leading to commercial production.
Named the NASA Government Invention of the Year, the 3D orthogonally woven materials supports structural and thermal performance needs for Orion mission and more.
CW explores key composite developments that have shaped how we see and think about the industry today.
Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.
As battery electric and fuel cell electric vehicles continue to supplant internal combustion engine vehicles, composite materials are quickly finding adoption to offset a variety of challenges, particularly for battery enclosure and fuel cell development.
Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.
Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.
The composite pressure vessel market is fast-growing and now dominated by demand for hydrogen storage.
The burgeoning advanced air mobility (AAM) market promises to introduce a new mode of transport for urban and intercity travelers — particularly those who wish to bypass the traffic congestion endemic to the world’s largest cities. The electric vertical take-off and landing (eVTOL) aircraft serving this market, because they depend on battery-powered propulsion, also depend on high-strength, high-performance composite structures produced at volumes heretofore unseen in the aerospace composites industry. This CW Tech Days will feature subject matter experts exploring the materials, tooling and manufacturing challenges of ramping up composites fabrication operations to efficiently meet the demands of a challenging and promising new marketplace.
Manufacturers often struggle with production anomalies that can be traced back to material deviations. These can cause fluctuations in material flow, cooling, and cure according to environmental influences and/or batch-to-batch variations. Today’s competitive environment demands cost-efficient, error-free production using automated production and stable processes. As industries advance new bio-based, faster reacting and increased recycled content materials and faster processes, how can manufacturers quickly establish and maintain quality control? In-mold dielectric sensors paired with data analytics technology enable manufacturers to: Determine glass transition temperature in real time Monitor material deviations such as resin mix ratio, aging, and batch-to-batch variations throughout the process Predict the influence of deviations or material defects during the process See the progression of curing and demold the part when the desired degree of cure, Tg or crystallinity is achieved Document resin mix ratios using snap-cure resins for qualification and certification of RTM parts Successful case histories with real parts illustrate how sensXPERT sensors, machine learning, and material models monitor, predict, and optimize production to compensate for deviations. This Digital Mold technology has enabled manufacturers to reduce scrap by up to 50% and generated energy savings of up to 23%. Agenda: Dealing with the challenge of material deviations and production anomalies How dielectric sensors work with different composite resins, fibers and processes What is required for installation Case histories of in-mold dielectric sensors and data analytics used to monitor resin mixing ratios and predict potential material deviations How this Digital Mold technology has enabled manufacturers to optimize production, and improve quality and reliability
SolvaLite is a family of new fast cure epoxy systems that — combined with Solvay's proprietary Double Diaphragm Forming technology — allows short cycle times and reproducibility. Agenda: Application Development Center and capabilities Solutions for high-rate manufacturing for automotive Application examples: battery enclosures and body panels
OEMs around the world are looking for smarter materials to forward-think their products by combining high mechanical performance with lightweight design and long-lasting durability. In this webinar, composite experts from Exel Composites explain the benefits of a unique continuous manufacturing process for composites profiles and tubes called pull-winding. Pull-winding makes it possible to manufacture strong, lightweight and extremely thin-walled composite tubes and profiles that meet both demanding mechanical specifications and aesthetic needs. The possibilities for customizing the profile’s features are almost limitless — and because pull-winding is a continuous process, it is well suited for high volume production with consistent quality. Join the webinar to learn why you should consider pull-wound composites for your product. Agenda: Introducing pull-winding, and how it compares to other composite manufacturing technologies like filament winding or pultrusion What are the benefits of pull-winding and how can it achieve thin-walled profiles? Practical examples of product challenges solved by pull-winding
Composite systems consist of two sub-constituents: woven fibers as the reinforcement element and resin as the matrix. The most commonly used fibers are glass and carbon, which can be processed in plane or satin structures to form woven fabrics. Carbon fibers, in particular, are known for their high strength/weight properties. Thermoset resins, such as epoxies and polyurethanes, are used in more demanding applications due to their high physical-mechanical properties. However, composites manufacturers still face the challenge of designing the right cure cycles and repairing out-of-shelf-life parts. To address these issues, Alpha Technologies proposes using the encapsulated sample rheometer (premier ESR) to determine the viscoelastic properties of thermosets. Premier ESR generates repeatable and reproducible analytical data and can measure a broad range of viscosity values, making it ideal for resins such as low viscous uncured prepreg or neat resins as well as highly viscous cured prepregs. During testing, before cure, cure and after cure properties can be detected without removing the material from the test chamber. Moreover, ESR can run a broad range of tests, from isothermal and non-isothermal cures to advanced techniques such as large amplitude oscillatory shear tests. During this webinar, Alpha Technologies will be presenting some of the selected studies that were completed on epoxy prepreg systems utilizing ESR and how it solves many issues in a fast and effective way. It will highlight the advantages of this technique that were proven with the work of several researchers. Moreover, Alpha Technologies will display part of these interesting findings using the correlations between the viscoelastic properties such as G’ and mechanical properties such as short beam shear strength (SBS).
Surface preparation is a critical step in composite structure bonding and plays a major role in determining the final bonding performance. Solvay has developed FusePly, a breakthrough technology that offers the potential to build reliable and robust bonded composite parts through the creation of covalently-bonded structures at bondline interface. FusePly technology meets the manufacturing challenges faced by aircraft builders and industrial bonding users looking for improved performance, buildrates and lightweighting. In this webinar, you will discover FusePly's key benefits as well as processing and data. Agenda: Surface preparation challenges for composite bonding FusePly technology overview Properties and performance data
The 48th International Conference & Exposition on Advanced Ceramics & Composites (ICACC 2024) will be held from Jan. 28–Feb. 2, 2024, in Daytona Beach, Fla. It is a great honor to chair this conference, which has a strong history of being one of the best international meetings on advanced structural and functional ceramics, composites, and other emerging ceramic materials and technologies.
Venue ONLY ON-SITE @AZL Hub in Aachen Building Part 3B, 4th Floor Campus Boulevard 30 52074 Aachen Time: January 31st, 2024 | 11:00-16:00h (CET) This first constitutive session will shape the future of the workgroup. ✓ Insights into solutions for e.g. circularity, recycling, sustainability, end of life etc. ✓ Interactive exchange along the value chain to tackle these challenges: Share your input in the “World Café” workshop session! ✓ Are you a solution provider? Take your chance and present your solution approach in a short 5-minute pitch. Get in touch with Alexander.
The Transformative Vertical Flight (TVF) 2024 meeting will take place Feb. 6–8, 2024 in Santa Clara, California, in the heart of Silicon Valley and will feature more than 100 speakers on important progress on vertical takeoff and landing (VTOL) aircraft and technology.
The EPTA – European Pultrusion Technology Association in cooperation with the American Composites Manufacturers Association (ACMA) invites you to the 17th World Pultrusion Conference which takes place on 29 February – 1 March 2024 in Hamburg, Germany. Visit the most important event in Europe in the market for pultruded fiber reinforced materials This conference takes place every two years and is the meeting point of the European and worldwide Pultrusion Industry. More than 25 international speakers from Finland, Belgium, Germany, France, Spain, The Netherlands, Turkey, UK, USA, Canada and others will present practical presentations about innovative applications, technologies and processes. Equally current market trends and developments are on the agenda. This World Pultrusion Conference takes place again in the week before the JEC World Composites Show (5-7 March 2024, Paris). The presentation language will be English. Please finde here the full program and booking opportunities. We appreciate very much welcoming you in Hamburg! Inquiries should be requested by email: info@pultruders.com
The Program of this Summit consists of a range of 12 high-level lectures by 14 invited speakers only. Topics are composite related innovations in Automotive & Transport, Space & Aerospace, Advanced Materials, and Process Engineering, as well as Challenging Applications in other markets like Architecture, Construction, Sports, Energy, Marine & more.
JEC World in Paris is the only trade show that unites the global composite industry: an indication of the industry’s commitment to an international platform where users can find a full spectrum of processes, new materials, and composite solutions.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.
Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.
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Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.
The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.
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.
Novel material to combine Ohoskin’s leather alternative made from orange and cactus byproducts with ReCarbon’s recycled carbon fiber.
The three-year strategic collaboration will help boost the company’s growth, reinforce its commitments to become carbon neutral by 2040 and innovate more circular chemicals and materials.
Oak Ridge National Laboratory's Sustainable Manufacturing Technologies Group helps industrial partners tackle the sustainability challenges presented by fiber-reinforced composite materials.
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JEC World 2024: Flax fiber producer Groupe Depestele and sustainable composites company Greenboats demonstrate flax fiber materials, demonstrators and product offer Circular Structures.
Acrylonitrile to be used in Tenax uses waste and residue from biomass-derived products or recycled raw materials that are ISCC Plus certified, maintaining same performance properties as conventional-based products.
Closed mold processes offer many advantages over open molding. This knowledge center details the basics of closed mold methods and the products and tools essential to producing a part correctly.
In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.
This CW Tech Days event will explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
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.
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.
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.
During CW Tech Days: Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
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.
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 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.
Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
Explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.
This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.
This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.
This collection features recent CW stories that detail a range of tooling technologies, processes and materials.
A 25% weight reduction vs. legacy steel yields economics that justify upfront cost of carbon fiber.
RIBA Composites’ Carbon Fiber Arm for Concrete Pumping. Illustration: Karl Reque
Carbon fiber booms co-developed by Italian construction equipment manufacturer Centro Italiano Forniture Alberghiere Srl (CIFA, Lomazzo) and composites fabricator RIBA Composites Srl (Faenza) replace steel in the final sections of the mechanical arms mounted on trucks like the one in the next photo in this series, to help place pumped concrete in hard-to-reach locations. Source: RIBA Composites
Carbon fiber booms replace steel in the final sections of the mechanical arms mounted on trucks like the one and also on trailers. Source: RIBA Composites
At 101m, this is the world’s longest concrete pumping arm (a certified Guinness Book of World Records awardee). The final 50m of the arm (colored gray) is assembled from three composite booms molded by RIBA Composites. The longest boom, at 14m, weighed ~1000 kg, including 650 kg of carbon fiber, and was cured in a single autoclave cycle. Source: RIBA Composites
Three types of carbon fiber prepreg are layed up in female molds, two tools (lower, pictured here, and a matched upper tool) per boom section. Source: RIBA Composites
Here an assembled mold and completed layup are shown bagged internally and externally and ready for cure in an autoclave. Source: RIBA Composites
As the use of composites has expanded over the past 70 years, one of their many benefits has consistently driven innovation: Composites enable manufacturers to design and build parts with the strength and stiffness of conventional materials but at significantly reduced weight. Such efforts have captured the “low-hanging fruit,” to much applause, in huge markets — aerospace, boatbuilding and wind energy come to mind. No less important, however, are efforts by pioneers in niche applications that demonstrate, with little fanfare, the unlimited potential of the technology.
Prime examples are Italian construction equipment manufacturer Centro Italiano Forniture Alberghiere Srl (CIFA, Lomazzo) and composites fabricator RIBA Composites Srl (Faenza). To- gether they have developed carbon fiber composite booms for concrete-pumping machines. In full commercial production since 2011, the booms can be made in a variety of lengths.
Mounted on trucks or trailers, concrete-pumping systems typically are fitted with articulating arms made of steel, which support the steel tubing through which concrete is pumped. Depending on site accessibility and the height of the concrete pour, the arm’s end might extend hundreds of feet from the pump location. The greater the distance, the greater the moment of downward force that acts on the arm and must be counter-balanced at the truck or trailer.
RIBA’s carbon fiber booms replace the outermost segments of the arm where that force is greatest (see photo, at left) and realize section weight savings on the order of 25%. This opens the way to other benefits that justify the nominally higher cost of the carbon fiber. “The reduced weight means a smaller counterweight is needed,” says Andrea Bedeschi, RIBA’s general manager. In turn, the arm can be operated with smaller hydraulic cylinders and the entire system can be carried by a smaller, lighter truck or trailer, reducing initial investment and improving fuel economy. Additionally, a carbon boom extends the work length of the arm by as much as 20%. Finally, because scrutiny of and restrictions on truck weight are increasing, operators with oversized loads can face expensive surcharge levies or, in some countries, find themselves banned from roads. The lure of these potential benefits was the motivation for tackling the challenge of designing, making and selling a completely new part for an entirely new application.
The chances for a commercially successful outcome to this essentially blank-slate project were bolstered by RIBA’s experience in designing and building carbon fiber spars and masts for sailboats. “We are experts in building long tube sections,” Bedeschi says. “The way we design and manufacture these booms is basically by applying the same principles for carbon fiber masts.”
To prove project feasibility, RIBA conducted FEA modeling studies, using MSC Software’s (Newport Beach, Calif.) MSC Nastran. According to Bedeschi, the effort entailed three key technical challenges, one related to design, another related to manufacturing and a third with an impact on long-term operation. A fourth challenge, market acceptance of a new paradigm in the construction industry, was mitigated, in part, by partner CIFA’s buy-in to the project once feasibility studies were completed and costs, including ROIs, were evaluated.
The key to project feasibility was designing a laminate structure with stiffness similar to the steel benchmark, a daunting challenge given that the latter has a Young’s modulus of about 207 GPa, vs. roughly 120 GPa for a PAN-based carbon/epoxy unidirectional laminate layer of the same thickness. In crude terms, this 40% stiffness deficit could be overcome by building up laminate thickness, but that would also build cost. FEA simulation enabled engineers to simultaneously assess laminate structures that would meet the stiffness criteria and explore the most cost-effective means to construct those laminates.
Each boom is subject to two primary loads: Static loads from the weight of the boom, the attached steel tubing and the concrete pumped through it; and dynamic loads generated in boom joints as the arm is moved. Simulation of both revealed that optimum boom strength-to-weight would be achieved by a hollow, rectangular geometry and a ply schedule comprising unidirectional 24K carbon fiber tape (with fibers oriented along the isostatic lines or stress trajectories), ±45° biaxial 24K carbon fiber prepreg, and ±90° woven 24K carbon fiber prepreg built up to a nominal wall thickness ranging from 10 mm up to 30 mm in high-load areas. All materials are impregnated with a toughened epoxy supplied by Saati (Legnano, Italy). The UD tapes, which account for ~50% of the laminate thickness, play a role in optimizing the structure’s bending stiffness. The ±45° biaxial prepreg and ±90° woven prepreg each comprise ~25% of the total thickness, enhancing the structure’s resistance to torque and damage respectively. RIBA sources its fabric, prepreg and fibers variously from Saati, G. Angeloni Srl (Venice, Italy), Toray Carbon Fibers Europe (Paris, France), Toho Tenax Europe GmbH (Wuppertal, Germany) and Mitsubishi Rayon Co. Ltd. (Tokyo, Japan).
The FEA study also focused on joint construction, which would require some type of pinned connection. “There was an engineering concern about this feature of the boom design because of the reduced load-bearing capacity of composites compared to metal and the potential to damage the epoxy matrix in the joint area,” Bedeschi recalls. Analysis suggested that 50-60-mm metal bushings would work if a way could be found to properly and reliably bond the metal components to the carbon/epoxy composite. Engineers devised a two-fold solution. First, to bond bushings to carbon/epoxy laminates, RIBA used Hysol epoxy adhesive, supplied by Henkel (Düsseldorf, Germany), in which the adhesive layer’s bondline is controlled by glass microspheres, the diameter of which ensures an optimum, repeatable adhesive thickness, maximizing polymerization and shear strength at the bond. Second, the laminate at the joint interface is constructed of ±45° fabric, which reportedly reduces stress in the laminate at the joint surface. Extensive testing of laminate specimens was conducted in parallel with FEA to ensure that actual mechanical properties (in particular, stiffness) correlated with the simulations.
After testing validated the computer models, RIBA received approval from CIFA to build the first commercial boom sections for a concrete-pumping machine. They replaced the final two articulating sections — roughly half the total length of a 45m mechanical arm. Each section is about 11m in length. They do not replace the initial steel sections of the arm with composites because the cost vs. benefit tradeoff favors metals. Building the entire arm with composites would be cost-prohibitive.
Boom sections are molded in female molds. During layup, overlaps of 25.4 mm to 38 mm are created between adjacent plies of prepreg, per aerospace practice. The molds are joined at the laminate overlaps, creating a hollow tube. After layup, the molds are bagged internally and externally, and the bag materials are joined at the mold’s open ends to form a single bag (see photos, at left). During autoclave cure (at 6 bar), the vacuum pulled on the bag combined with the external pressure applied by the autoclave ensures optimal consolidation and strength-to-weight ratio in the laminate, yet avoids pressure-related deformation or alteration of the mold shape. “The pressure is acting on all the surface of the bag, internally and externally,” says Deschi. “In this way we squeeze the plies without affecting the mold.”
A final challenge was curing parts with walls as thick as 30 mm. Epoxy undergoes a robust exothermic reaction — the thicker the laminate, the higher the temperature. The risk is uneven heating of the mold and laminate layers, resulting in material degradation at the center of the laminate’s through-thickness. Using a theoretical autocatalytic model, engineers predicted cure behavior as a function of temperature and devised a cure cycle with a cure temperature of 130°C and dwell steps that avoided exothermic peaks and resulted in homogeneous heating of the mold and laminate. Cycle duration, including cool down, is ~18 hours.
After cure, the demolded boom is CNC-machined on a 5-axis system, bushings are bonded into place and each section is inspected using a phased-array ultrasonic NDT system.
Since making its first 22m boom section set, RIBA’s line of booms for concrete-pumping equipment has steadily expanded. The company now makes 10 different carbon booms for concrete-pumpers with arms ranging from 25m to 101m. Widths of booms can vary from 15 to 45 cm.
Last year, RIBA produced booms for 110 arms— about 250 individual booms, and Bedeschi expects a 10% increase in sales during 2015. That the booms have quickly made inroads into an inherently conservative industry is a testament to their highly functional design and benefits.
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