Composites World October 2022

Multifunctional
interiors:
COMPOSITES
ENABLE MODERN
ARCHITECTURE
OCTOBER 2022
Thermoplastic composites
welding advances for
sustainable airframes / 50
Plant tour: AvCarb, Lowell,
Mass., U.S. / 62
3D knitted hybrid
thermoplastic structures / 76
A property of Gardner Business Media VOL 8 No 10
KNOWLEDGE IS POWER
AND WE HAVE THE DEMOS THAT CAN HELP YOU ATTAIN IT.
LIVE at Booth L23 during CAMX 2022 – It’s the Composites One
and Closed Mold Alliance Demo Zone.
At LIVE demos in a single enclosed space on the CAMX Show floor, you’ll learn
innovative processes to kickstart your business. Talk to dependable experts
adept at the latest technologies. And gain tips and techniques
that can help you attain the results you need.
Get the power of knowledge from Composites One - LIVE - at Booth L23
during CAMX 2022 in Anaheim, CA, October 17-20.
Because knowledge is power. Only from Composites One and the Closed Mold Alliance.
Innovative. Dependable. Results.
Composites One • Aerovac • MVP • RTM North Technologies
Presented LIVE by Composites One, the Closed Mold Alliance and our industry partners.
CompositesManufacturing
The Official Magazine of the American Composites Manufacturers Association
TABLE OF CONTENTS
OCTOBER 2022 / Vol: 8 No

–: 10
COLUMNS FEATURES
4 From the Editor 16 CAMX 2022 preview
The largest composites industry trade show in
6 Troubleshooter North America takes place Oct. 17-20 in
Louis Dorworth of Abaris Training 16 Anaheim, Calif., U.S. CW previews many of the
Resources outlines key considerations to exhibits and technologies that will be on
make when fabricating quality composite display.
molds to minimize risk of leakage under By Grace Nehls, Chris Pasion,
pressure or vacuum.
Katie Leesemann and Hannah Mason
10 Gardner Business Index
The GBI: Composites Fabricating ended 42 Composites enable epic
August with all component indices
continuing to show slowed rates of growth. interior for Museum of the
Future
For this one-of-a-kind lobby, AFI pioneered
42 digital, reconfigurable molds to achieve
organic-shaped, multifunctional panels and
stairwell cladding.
» DEPARTMENTS By Ginger Gardiner
12 Trends
72 Applications 50 Thermoplastic composite
74 Marketplace
welding advances for more
74 Showcase
sustainable airfames
Multiple demonstrators help various welding
80 Post Cure technologies approach TRL 6 in the quest for
50 lighter weight, lower cost.
By Ginger Gardiner
62 Plant Tour: AvCarb, Lowell,

Mass., U.S.
At AvCarb, specialty fuel cell products have
driven innovation in carbon fiber chemistry.
By Jeff Sloan
62
» ON THE COVER FOCUS ON DESIGN

Advanced Fiberglass Industries (AFI)
supplied 7,700 square meters of complex-
76 One-shot manufacture
curved, glass fiber/epoxy panels for the of 3D knitted hybrid
wall, ceiling and spiral staircase cladding thermoplastic composite
in the Museum of the Future's lobby
(pictured). Key architectural elements were
structures
made possible thanks to digital, reconfigu- MAPICC 3D project replaces steel seat
rable molds and AFI's long history taking support with a 3D knitted composite made
on challenging composite parts. See p. 50. from thermoplastic hybrid yarns.
By Stewart Mitchell
Source | Advanced Fiberglass Industries
CompositesWorld (ISSN 2376-5232) is published Valley Ave., Cincinnati, OH 45244-3029. accurate. In applying recommendations, however, you should exercise care and normal MEMBERSHIPS:
monthly and copyright © 2022 by Gardner Business If undeliverable, send Form 3579. precautions to prevent personal injury and damage to facilities or products. In no case
Media Inc. 6915 Valley Ave., Cincinnati, OH 45244- CANADA POST: Canada Returns to be can the authors or the publisher accept responsibility for personal injury or damages
3029. Telephone: (513) 527-8800. Printed in U.S.A. sent to IMEX Global Solutions, PO Box which may occur in working with methods and/or materials presented herein, nor can
Periodicals postage paid at Cincinnati, OH and 25542, London, ON N6C 6B2 Canada. the publisher assume responsibility for the validity of claims or performance of items
additional mailing offices. All rights reserved. Publications Mail Agreement #40612608. appearing in editorial presentations or advertisements in this publication. Contact
POSTMASTER: Send address changes The information presented in this edition information is provided to enable interested parties to conduct further inquiry into
to CompositesWorld Magazine, 6915 of CompositesWorld is believed to be specific products or services.
CompositesWorld.com 1
@CompositesWrld
V.P. ADVANCED MATERIALS MEDIA GROUP Rick Brandt

rbrandt@gardnerweb.com
EDITOR-IN-CHIEF Jeff Sloan
jeff @compositesworld.com
SENIOR TECHNICAL EDITOR Ginger Gardiner
ggardiner@compositesworld.com
TECHNICAL EDITOR Hannah Mason
hmason@compositesworld.com
MANAGING EDITOR Grace Nehls
gnehls@gardnerweb.com
DIGITAL ASSISTANT EDITOR Cara Decknadel
cdecknadel@gardnerweb.com
SENIOR COPY EDITOR Jann Bond
jannb@gardnerweb.com
DIRECTOR, STRATEGIC INITIATIVES Scott Stephenson
AND EVENTS sstephenson@compositesworld.com
ADVERTISING PRODUCTION MANAGER Becky Taggert
btaggert@gardnerweb.com
GRAPHIC DESIGNER Susan Kraus
skraus@gardnerweb.com
MARKETING MANAGER Chris Saulnier
csaulnier@gardnerweb.com
CW CONTRIBUTING WRITERS
Dan Adams adams@eng.utah.edu

Dale Brosius dale@compositesworld.com
Louis Dorworth lou@abaris.com
Peggy Malnati peggy@compositesworld.com
Karen Mason karen@masonwriting.com
Stewart Mitchell smitchell@compositesworld.com
CW SALES GROUP
MIDWESTERN US Jack Kline / REGIONAL MANAGER

Jack.Kline@gardnerweb.com
EASTERN US SALES OFFICE Barbara Businger / REGIONAL MANAGER
barb@compositesworld.com
MOUNTAIN, WEST, INTERNATIONAL Michael Schwartz / REGIONAL MANAGER
mschwartz@gardnerweb.com
EUROPEAN SALES OFFICE Simone Mas / EUROPEAN SALES MANAGER
smas@gardnerweb.com
COMPOSITESWORLD IS A PROPERTY OF
HEADQUARTERS
6915 Valley Ave., Cincinnati, OH 45244-3029
Phone 513-527-8800 Fax 513-527-8801
gardnerweb.com
subscribe@compositesworld.com
CHAIRMAN Richard G. Kline

PRESIDENT Richard G. Kline, Jr.
CHIEF MARKETING OFFICER Melissa Kline Skavlem
CHIEF FINANCIAL OFFICER Ernest Brubaker
AUDIENCE DEVELOPMENT DIRECTOR Mary Leiphart
EXECUTIVE V.P. CUSTOM CONTENT Tom Beard
ADVERTISING AND PRODUCTION DIRECTOR Bill Caldwell
EXECUTIVE V.P. CONTENT Kate Hand
CHIEF EVENTS OFFICER Allison Miller
EXECUTIVE V.P. NEW PRODUCT DEVELOPMENT Dave Necessary
EXECUTIVE V.P. SALES Ryan Delahanty
EXECUTIVE V.P. MARKETING & CREATIVE Jeff Norgord
DIRECTOR OF MARKET RESEARCH Jan Schafer
GARDNER BUSINESS MEDIA ALSO PUBLISHES
Modern Machine Shop MoldMaking Technology
Plastics Technology Production Machining
Products Finishing PF Mexico Additive Manufacturing
2 OCTOBER 2022 CompositesWorld

Smarter
composites
release systems.
TECHNOLOGY SOLUTIONS + IDEAS
From the highly complex to the everyday, we provide custom solutions that provide
consistency, dependability, and value, from aerospace applications to automotive,
construction, marine, sporting goods, wind energy, and more. And we do so in a safe,
sustainable fashion with a broad range of advanced water-based products. Whether
it’s a cleaner, primer, sealer, release agent, or an entire system, we can deliver a
solution fit for your specific application.
© Copyright 2022 Chem-Trend L.P.

VISIT CHEMTREND.COM/COMPOSITES All Rights Reserved.
FROM THE EDITOR
» You have probably heard by now that CAMX 2022 is coming technologies they will feature in their booths. We heard from 
up this month, Oct. 17-20 in Anaheim, Calif., U.S. CAMX is North exhibitors this year — a record. Looking through these “previews,”
America’s largest conference and a trade show targeted toward the it’s clear there are many new products and technologies being intro-
composites manufacturing industry. It can be difficult sometimes duced at the show. You can find some of the previews in this issue of
to justify to yourself, and those to whom you report, that attending CW, starting on p. . Others can be found in the September issue.
a trade event has value sufficient to offset the time and capital All can be found online at www.compositesworld.com/hashtag/
commitment. If you’re camx. But it’s best if you just go to the show and see for yourself.
struggling to do that for • Education. If you’re new — or relatively new — to the compos-
I hereby offer 10 CAMX , I hereby offer ites industry, CAMX offers myriad opportunities to get to know it
compelling reasons to these  compelling reasons better. I already mentioned the conference programming, and you
attend CAMX 2022. to attend the show. can add to that Composites One’s Demo Zone. The Demo Zone is
• In-person connections. If a large, glass-enclosed space on the show floor (booth L) where
COVID taught us anything, it’s Composites One and the Closed Mold Alliance demonstrate manu-
the importance of in-person interactions. There is real value in the facture of composite parts using a variety of materials, tools and
composites industry gathering in one place to learn, share ideas, processes, including infusion, resin transfer molding, silicone bag
collaborate, network and just plain socialize. If that’s not enough... molding and prepreg and autoclave processing. Expert tip: The
• Conference. CAMX is a trade show and conference. The demos attract large crowds and are great for socializing.
conference is multi-faceted, offering a variety of topics in a variety • Meet a CW editor. CW’s entire editorial staff will be at CAMX.
of environments. Your options include technical papers focused We are pretty decent folks who are always happy to talk composites.
on original research and education sessions focused on case histo- Stop by CW’s booth (D), say hello and take a selfie with us.
ries. You’ll also find speaker panels and featured sessions that • CAMX Show Daily. CW publishes the CAMX Show Daily, a good
emphasize many of the topics that are shaping the industry. You old-fashioned daily newspaper that will keep you up to speed on
might also check out “Good Day, CAMX,” on Wednesday morning, show happenings. You will likely have a Show Daily thrust into your
which features a panel on next-gen thermoplastic composite aero- hands as you enter the show. This is a thrilling experience.
structures. And don’t forget the keynote speaker, Michael Steep. • CW, the magazine. If you love the feeling of receiving CW each
He’s talking Tuesday morning about supply chain challenges and month via mail or email, it’s even better in person. We’ll have the
opportunities. Expert tip: The conference offers great opportuni- September and October issues available at our booth. Stop by and
ties to meet and interact with subject matter experts, and you can’t pick one up.
have too many subject matter experts in your life. • Steps. If, like the rest of the world, you are now counting your
• Awards. CAMX offers two awards programs — the CAMX steps each day, CAMX offers a great opportunity to stay on target. You
Awards and the Awards in Composites Excellence (ACE). The should hit , steps with a full-day, robust tour of the exhibit hall.
CAMX Awards, given in two categories, will be announced at • Disneyland. CAMX is, literally, next door to Disneyland. Every
the General Session on Tuesday morning. The ACE winners, amusement park is chock full of composites. Consider it research.
presented in six categories, will be announced Tuesday afternoon Safe travels and we’ll see you in Anaheim.
on the show floor. Expert tip: The award winners tend to soak up a
lot of attention, but be sure to visit the exhibit areas for each award
program on the show floor. There are always interesting technolo-
gies and products among the non-winners.
• New products/technologies. Every year, CW asks CAMX
exhibitors to send us information about the products and JEFF SLOAN — Editor-In- Chief

FIELD-PROVEN ADHESIVES FOR
DEMANDING VACUUM MOLDING
INFUSION APPLICATIONS.
STICK WITH THE BEST

Specifically formulated for a stronger,
more flexible matrix.
NewStar 900 Line Adhesives are formulated to cross-link with resins to
create an integrated matrix and not interfere with polymer matrix integrity.
• Low shrinkage during cure • Low VOCs, No HAPS

• CA & OTC Compliant • Long open time
• Fast-tack, strong bonds • Available in Canisters and Aerosols
Comprehensive 3rd party testing confirms the N900 line delivers

superior performance in vacuum infusion applications when compared
to the other competitive infusion adhesives.
N E W STA R A D H E S I V E S U S A .C O M | 8 6 6 - 7 3 5 - 9 8 76
N AC O M P O S I T E S .C O M
THE TROUBLESHOOTER
Why does my
composite mold leak
under vacuum or
applied pressure?
» The biggest complaint I get about composite versus metal
molds is that they tend to leak over time. This is especially
true when making low-temperature cure, high-temperature
service laminated tooling. Sometimes they leak immediately
when tested for first article compliance, causing the fabricator
to desperately try to seal the leaks and (temporarily) fix the
problem to save their own investment, or worse, deliver it on
time to an unsuspecting customer. Regardless, fixing leaks after
fabrication is undesirable, and over time scrapped parts and
repeated repairs can prove costly.
What can be done up front to ensure that molded composite
tools do not leak in service? To answer this question, we need to
understand what factors contribute to leaking tools in the first
place. The following are some important points to consider.
Tool design
Adding flanges with large radii around the periphery of the
tool can minimize the potential for edge impact damage
during fabrication, demolding and in service. The bonus to FIG. 1 CFRP mold
this approach is increased stiffness in the tool laminate itself, Both the permanent pattern and the layup mold in these images have flanges with
allowing for minimal support structure (Fig. 1). Consideration generous radii outside of the part area, providing increased stiffness to the laminate
and protection from edge impact. Source | Ascent Aerospace
for flanges and other molded features occur at the model or
pattern design, enabling layup of these features along with the
tool laminate.
Material selection and process methodology

Prepreg materials and processes are desirable for best results.
It is far more difficult to build wet layup (or infused) tools with
reasonable control of the resin content and the ability to provide
intermittent compaction steps (debulks) to avoid bridging in the
corners during layup. It can be done, but at higher risk for leaks
in production.
While often deployed as a time saver, the use of bulk fabrics
in the laminate construction can be detrimental over time, as
they often require extra resin to fill the intersections between
yarns and adjacent layers. They are also more prone to bridging
in corners or at overlaps, where resin will try to fill the low-pres-
sure area created by the open space. The excess resin is prob- FIG. 2 Edge protection
lematic and will eventually microcrack, creating a leak path
This mold has an extruded rubber bulb bonded to the tool laminate to provide extra
within the tool laminate. It is recommended that twill and/or protection to the tool and the operator. Note the molded flanges and index features
harness satin (HS) fabrics with an areal weight of ≤ gsm for used in the mold design. Source | Abaris

Composite tooling
Upper part of mold

Molded index feature
Vacuum bag
Sealant tape on
primary mold
flange
Lower part of mold with integral

Part
sealing flange and molded index
feature for locating mating tool
flange
FIG. 3 Molded index features vs. tooling pins FIG. 4 Multi-piece tooling concept
Molded index concept for locating the molded part to subsequent trim and/or drilling This illustration demonstrates the idea of placing multiple pieces of a tool into a par-
jigs or fixtures. Molded indexes can also be used for locating and secondary bonding ent mold so that vacuum/pressure integrity can be maintained. Source | Abaris
mating parts. Source | Abaris
carbon fiber or < gsm for glass fiber be used to minimize the Microfracture of the matrix resin
problem. Note: HS fabrics require more scrutiny of warp face If the matrix resin is damaged, it’s most likely to occur during
orientation to acquire true symmetry (Reference August  the demolding process when wedges are used to remove the tool
article, “Doing the twist: A look at dimensional issues in high- from the model or pattern. This is especially true with the exposed
temperature cured laminates”). edge (pancake) tool design, where the laminate is in-plane with
Multiple debulks are recommended for best results. The first the wedging surface. The force from the local impact and flex of
ply should always be compacted so that it is tight to the model the laminate during the demolding process causes severe micro-
or pattern prior to the layup of subsequent plies. The number cracking in a fan-like pattern at each wedge location. Thermal
of plies between debulks depends on the mold configuration. cycling (expansion and contraction) exacerbates the condition as
The more complex the mold, the more debulks are required. the microfracture network continues to grow in resin-rich areas
A final overnight debulk is recommended prior to cure if time within the laminate, ultimately causing loss of vacuum/pressure
(and materials) allow, to draw off moisture, volatiles and provide integrity. Thus, having a flange with a generous radius at the
laminate compaction prior to cure. wedge line will stiffen the structure and minimize the chance
for fracture.
Initial low-temperature cure
Highly reactive, low-temperature curing resins allow for good Cutting or machining edges
dimensional control between a model (or pattern) and the tool It is highly recommended not to use a reciprocating saw (jig saw
laminate by minimizing the thermal expan- or Sawzall) or high-speed abrasive
sion factor during cure. Many prepreg tooling cutting wheel to trim the sharp edges
systems initially cure at ~65°C for a number Remember the motto of a tool laminate. A reciprocating saw
of hours. Depending on the system, where will microfracture the edges and the
“prework instead of rework”
the temperature is measured and the heat cutting wheel can overheat the matrix
when fabricating
transfer coefficient of the model, this resin, making it more prone to fracture.
may not be enough time or temperature composite tooling. It is suggested that the edge be laid up
to push the resin to maturity. It may as close to net shape as possible, followed
appear to be cured, but it is not fully by hand or belt sanding running parallel to
crosslinked. The vitrified resin at this stage is highly susceptible the edge, rather than trimming. Afterward, cover the edge with
to fracture when impacted or flexed. Increasing the soak time at a rubber edge protector to safeguard edges from damage and
the initial process temperature or raising the temperature (after employees from injury (Fig. 2).
the initial cure) to ~80°C for a couple of hours can help push the
crosslinks further towards maturity prior to demolding. After- Holes, pins, bushings and penetrations in a
wards, a full post-cure above the intended service temperature is tool laminate
recommended before proceeding. Ask any toolmaker who does tool maintenance and they will
THE TROUBLESHOOTER
tell you that over time, tooling holes, pins, bushings and other Multi-piece tools
penetrations into or through the tool laminate will begin to leak. Instead of splitting a tool into separate pieces with a split-line to
When used cycle after cycle, stresses on pin locations, bushings accommodate negative draft configurations, consider designing
and metal vacuum plumbing/hardware locations all develop the mold with pieces that are inserted into a “parent” tool for
microcracking in the adjacent matrix resin that will eventually maintaining vacuum/pressure integrity across the split-line
link up with the microfracture (leak) network. It may be best to (Fig. 4, p. 7).
use molded features in the mold to provide indexing of the part
for subsequent tools used in trimming and drilling operations From hindsight to foresight
(Fig. 3, p. 7). There are many more good ideas for reducing or eliminating leaks
in a composite mold. For example, in the
1980s, I was part of a team that used a
Viton interleaf layer1 in the tool laminate
design to mitigate leaks in prepreg auto-
clave-cured tools. The Viton layer works
well at eliminating leaks but requires
extra consideration in the laminate design
to reduce thermal expansion effects. The
point is that with a little knowledge and
COMPOSITE CURING OVENS

some foresight, tool designers and fabri-
cators can take extra care ahead of time
100 standard models • Gas or Electric Heat to produce quality, leak-free composite
molds. Remember the motto “prework
instead of rework” when fabricating
Premium Quality & Performance composite tooling.
• Heavy Duty Construction
with quality components REFERENCES
1
Reference patent number 4,671,837, "Process for Forming
• Temperatures to 500° F Composite Molds to be Used in the Manufacture of
Composite Parts." Robert B. Stewart, patents.google.com/
• Built to Last! Backed by our patent/US4671837
Exclusive and Unprecedented
5-Year WOW™ Warranty
• Certified for +/- 5° or +/- 10° F

temperature uniformity
• Factory tested PRIOR to Read this article online |

shipment to reduce installation short.compositesworld.com/moldleaks
and start-up times
Available with DataSense™

Technologies IoT Based
Performance Monitoring System
Options available:
• Wisconsin Oven Premium • Vacuum pump & ports • Pressure transducers
control system • Thermocouple jack panels • Motorized controlled
• DataSense™ Technologies • Digital programmable controller dampers
Industrial IoT System for • Process timer • Insulated floor
predictive maintenance to • Disconnect switch • Many other options
reduce unplanned downtime • Chart recorders/data acquisition available upon request
Louis Dorworth is the direct
services manager at Abaris
Training Resources Inc. (Reno,
Wisconsin Oven Corporation Nev., U.S.). Lou has been involved
WISOVEN.COM 2675 Main Street • PO Box 873 • East Troy, WI 53120 in the composites industry since
1978 and has experience in material and process
sales@wisoven.com Wisconsin Oven is a brand of (M&P) engineering, research and development
Thermal Product Solutions, LLC
262-642-3938 (R&D), tooling, manufacturing engineering, teaching
and troubleshooting. Lou is a coauthor of the
textbook titled “Essentials of Advanced Composite
Fabrication and Damage Repair,” second edition.
2022 WOC CCO Ad 4.375x6.875 v2.indd 1 8/29/22 3:32 PM

Significant Cost Savings
on Additive Tool
Partnership between Thermwood and General Atomics
• Cost Reduction: 2-3 times
• Faster Development: 3-4 times
• Production Capable Tool
• Vacuum Integrity
• Suitable for Large, Deep 3D Geometries,
Backup Structures & Vacuum Piping
Cost Savings of around

$50,000 vs traditional methods
• Thermwood LSAM 1020
• Printed with ABS
(20% Carbon Fiber Filled)
• Printed in 16 hours
• Machined in 32 hours
• Final part weighed 1,190 lbs
Total lead time for the part decreased from

MADE IN USA 6-8 weeks to less than 2 weeks by utilizing the
powerful LSAM system.
See us at Booth W2
www.thermwood.com
800-533-6901
GARDNER BUSINESS INDEX: COMPOSITES FABRICATING
Composites industry GBI holds

its own in August
August—52.1 ABOUT THE AUTHOR
Jan Schafer, MBA, is

the director of market
» The Gardner Business Index (GBI): Composites Fabricating closed August at 52.1, about
research for Gardner
Intelligence, a division of
the same as July’s reading of 51.8. The month represents a reprieve in slowing growth that Gardner Business Media
started in April, barely remaining within the expansion zone. (Cincinnati, Ohio, U.S.). She has been an
essential part of Gardner Intelligence for over
All component indices showed slowed rates of growth again in August, with new orders
five years, and has led research and
holding its position as the lowest component reading. Backlog, production and employment analysis in various industries for over
growth decelerated again, landing at indices practically on top of each other for another 30 years. jschafer@gardnerweb.com
month. Supplier deliveries lengthened at a continually slowing rate while exports continued
to contract at an accelerating rate.
GBI: Composites Fabricating Toeing the line

GBI: Composites Fabricating ended August
with slowed expansion but managed to
stay above water (a.k.a. the line dividing
business expansion and contraction).
Source (all images) | Gardner Business Intelligence
GBI: Composites Fabricating — New Orders and Backlog Slowed expansion

(three-month moving average) continues
New orders expansion slowed again in
New Orders (3-MMA) August, barely dodging a “flat” (or “lower”)
Backlog (3-MMA) reading. Backlog followed suit, ending the
month with a little more wiggle room than
new orders relative to being flat or entering
contraction.
PRESENTED BY
Stay ahead of the curve with Gardner Intelligence.

Visit the blog at gardnerintelligence.com or email jschafer@gardnerweb.com

TOUGHENED
PREPREG SYSTEM
• Demonstrated impact and

fatigue resistance
• Available with public

allowable design databases
For decades, our highly toughened prepreg system has • In stock and ready to ship
been the material of choice for aerospace companies
seeking to manufacture lighter and stronger structures. • Flexible cure profiles for
efficient production systems
These prepreg materials are designed to meet primary
structure performance requirements, withstand • Uniform resin content and
demanding operating conditions, and enable no-bleed resin system
consistent part production. The robust performance of
our materials, coupled with publicly available design
data and digital design tools, helps customers achieve
streamlined development, cost advantages, and
optimum structural performance.
Material solutions for today and tomorrow.
800.208.6729
www.toraycma.com
TRENDS
Denmark-based Isodan Engineering presents a mobile, dust-free mechanical processing
solution for on-site composites recycling, and Ontario-based CpK Interior Products
enters the composites battery enclosure market with a relatively fast, low-cost solution.
ENERGY
Dustless, mobile solution for

on-site wind turbine blade repurposing
Wind blade operators, OEMs and others in the composite

wind blade supply chain are increasingly seeking and
ramping up solutions for recycling and repurposing wind
blades at their end of life (EOL). One challenge for effective
and widespread wind blade recycling is that transportation
Source | Isodan
of these large structures to the limited number of existing
recycling facilities can be prohibitively expensive.
Isodan Engineering ApS (Holeby, Denmark) is one insulation materials — which remains the company’s key
company presenting a potential solution, with its mobile, business. In the 1980s, aiming to make its materials and
containerized recycling plants designed to travel between process more sustainability focused, the company began
wind farms and break wind blades down on site into reus- using recycled newsprint and other paper for its insulation.
able shreds or pieces. However, Isodan serves customers globally, and though paper
Isodan got its start in 1974, selling paper-based building is inexpensive, moving large volumes of shredded paper to
and from the company’s Denmark facil-
ity for shredding turned out to be costly.
Ultimately, Isodan developed a mobile,
shipping container-based paper recy-
cling system that could be transported
to the site where insulation would be
installed. In this small, localized recy-
cling plant, newsprint is placed in one
end, and shredded material is deposited
into bags on the other end.
The company has now been using
and demonstrating this technology for
paper and insulation for 30 years. More
recently, Isodan has leveraged its mobile
Form composites efficiently and effectively with recycling technology into a similar solu-
a custom compression molding press. Gain a tion for on-site mechanical recycling of
competitive edge with features like multi-zone composite wind turbine blades.
temperature control, precise pressure ramping, “With insulation materials, the big
comprehensive data acquisition, and automated issue is that paper is a cheap material
part inspection. but takes up a lot of physical space,
which can make the transport costs
Lead the way in your industry with a high,” explains Morten Nielsen, owner
world-class compression molding system. of Isodan Engineering ApS. “Now, you
have basically the same battle with the
wind industry and fiberglass recycling.
You have the wind turbine blades, which
are enormous and cost a lot to trans-
port, so the solution would be to break
them down into a transportable size on
location.”
The system is designed as a two-step

Mobile composites recycling
process, run by one operator. Large wind blade pieces are or used as a mobile plant with a separate power generator.
inserted into one end, where they enter a “pre-shredder” The first machine was developed for recycling company
station and are shredded into finer particles. They travel Global Fiberglass Solutions (Bothell, Wash., U.S.). According
by conveyor to a secondary “refiner” station for further to Christensen, Global Fiberglass Solutions was well-
processing to the specified size and length requirements. versed in crushing and granulating fiberglass wind turbine
Nielsen notes that this second step can be customized blades to produce reusable materials such as its “ecopoly”
as needed, and may be one simple grinding or shredding compounded pellets and panels for construction applica-
stage, or a multi-step process to produce the required tions, “however, that process was very dusty and therefore
material. The entire system operates under negative pres- hazardous.” Isodan was chosen for its self-contained, dust-
sure to eliminate the airborne dust that is a typical safety free technology, and delivered its first customer unit to
concern for fiberglass shredding or recycling. At the end Global Fiberglass Solutions in July 2018.
of the process, bags of shredded material can be collected Christensen notes that interest in Isodan’s systems has
straight from the system to be repurposed into new grown over the past year or so as more companies look for
applications. sustainability solutions — not just for EOL wind blades, but
According to Nielsen, the output depends on the size for fiberglass boat hulls in the marine industry. In addition,
of the unit and how refined the final product needs to be, he notes, fabricators are looking to repurpose fiberglass
though a 20-foot unit can process between 500 and 1,500 manufacturing scrap as well.
kilograms of material per hour. “It’s a rapidly growing part of our business,” Nielsen says.
“We offer a front-end solution for repurposing and However, one of the biggest challenges that still exists
granulating these composite materials into lengths that can within the industry, he adds, is that solutions still need to
then be repurposed into other useful products,” says Finn be matured for the reused material. “In early years, nobody
Christensen, export manager at Isodan Engineering ApS. wanted to talk much about the recycling process, but that
The systems are each custom-designed, built directly has changed a lot,” Nielsen observes. “I think we’d probably
into 20- or 40-foot shipping containers so that they can call ourselves an early bird in this market in terms of coming
be easily transported via truck, rail or boat. They can be up with a commercial solution, and we’re continuing to see
installed as stationary machines within a recycling facility a lot of interest.”
Efficiency beyond the cut.

• Reliable, customizable cutting & kitting
workflow automation with semi- to fully
automated/robotic picking/sorting/placing
• Introducing the Heat Sealing Module - HSM
for clean processing of thermoplastic
composites
#LetsTalkWorkflow at CAMX 2022

Oct 17-20, Anaheim, CA - Booth G42 www.zund.com infous@zund.com 414 433 0700
TRENDS
UniFORM: High-quality, high-complex EV battery

enclosures at low cycle times, low tooling costs
CpK Interior Products Inc. (Corbyville, Ontario, Canada) is a division of automaker
Stellantis (Hoofddorp, Netherlands) specializing in materials for and manufacture
of interior automotive components like instrument panels. The company recently
added composite battery enclosures to its product list, after developing a process for
building high-quality, high-complexity boxes and trays with a low cycle time and low
tooling costs.
The company operates four facilities within the Windsor, Ontario, Canada/Detroit,
Source | CpK Interior Mich., U.S, region, each serving one step in the process of building plastic or compos-
Products Inc.
ite automotive components. The resin
compounding facility in Belleville, Ontario,
produces a variety of thermoplastic
materials and serves as a research and
FIND OUT MORE
development (R&D) center, including
CAMX work on new product areas and new
17-20 OCT materials, such as natural fiber compos-
BOOTH J10 ites and graphene-reinforced composites.
Materials from Belleville are shipped
to Port Hope, Ontario, where they are
manufactured into plastic components
ADVANCED NONWOVENS FOR or combined with fiber reinforcement
to build composite components using
AEROSPACE
the company’s processing capabilities:
injection molding, resin transfer mold-
ing (RTM), thermoforming and more.
Parts are finished and assembled at the
Guelph, Ontario, facility prior to OEM
EMI SHIELDING delivery. And a fourth facility in Auburn
SURFACE FINISH Hills, Mich., serves as the design head-
quarters and includes product engineers
and program managers.
Now, the company is entering the
world of composite battery enclosures.
According to Dr. Gregory Farrar, head of
R&D at CpK Interior Products, “The elec-
tric vehicle [EV] battery supply chain
is growing in Ontario, with a need for
lightweight enclosures. We want to seize
this opportunity and become part of the
supply chain.”
In 2019, the CpK Interior Products
ADHESIVE FIRE PROTECTION team began by comparing the cycle
CARRIERS times, part quality, possible part
complexity and tooling cost for various
processing methods: wet compression
GALVANIC CORROSION BARRIER molding (WCM), high-pressure resin
transfer molding (HP-RTM) and prepreg
with autoclave cure.
HP-RTM and autoclave process-
HOW WILL OUR MATERIALS HELP YOU? ing produced high-quality and highly
complex parts, but at relatively high
cycle times and high tooling costs,
whereas WCM enabled production of
www.tfpglobal.com parts quickly with low tooling costs, but
with lower quality and complexity.
enquiries@tfpglobal.com • 1 518 280 8500 CpK Interior Products, therefore,
set out to develop a method for

Battery enclosures
NEWS
manufacturing battery enclosures with the quality and continued running internal tests — on electromagnetic
complexity of autoclave or HP-RTM processing, but at the interference (EMI) shielding and other properties — to
shorter cycle time and lower tooling costs of WCM. produce a full data set on its capabilities.
The project, a collaboration with several industry partners, The ultimate goal, says Farrar, is to leverage each of CpK
involved materials development and process design. The Interior’s capabilities — R&D, design engineering, materials
resulting process, called UniFORM, “combines WCM with a development, fabrication and assembly — to fill the need
proprietary tool design, where we use a vacuum in the tool- for lightweight, high-quality composite
ing to enable us to produce high-quality parts with very low battery enclosures at a realistic price point
cycle time,” says Dr. Murali Reddy, lead for R&D and sustain- and cycle time for the automotive market.
ability at CpK Interior Products. Read the full article online at
He explains, “The way it works is we lay down the fabrics short.compositesworld.com/CkPInteriorP
into the tool, apply the liquid resin, close the tool. The tool
is held to the cure temperature of the
resin, and we pull the vacuum, and
the part is formed.” The process ends
up being a hybrid between vacuum-
assisted HP-RTM and WCM, with the
three key elements being vacuum-
assisted tooling, high-temperature cure
and snap-cure resins. Depending on
the complexity of the part design, the
process was demonstrated with or with-
out preforming needed.
Reddy notes that a variety of carbon
fiber types were tested and confirmed
for feasibility so far, and that cycles
time of less than a minute were
achieved for several materials. Recycled
and twill materials were tested as well,
resulting in longer cycle times of up to
3.5 minutes.
To put its new technology to the
test, in 2021 the company approached
a North American OEM focused on
battery enclosure design. The enclosure,
per the required specifications, featured
a carbon fiber/epoxy top and bottom
tray, and included metal and injection
molded plastic inner frame components.
On the composite trays, finite
element analysis (FEA) modeling was
used first to analyze properties such
as impact resistance, crush resistance
and structural stiffness versus steel or
aluminum. The CpK Interior Products
model passed each OEM requirement,
and a prototype was built and tested.
“We tested the possibility of produc-
ing the battery box without any
preforms, just raw materials,” says
Reddy. Each tray was produced in a
two-minute cycle time, with 50% fiber
volume. The resulting weight was 44
pounds per tray — an 86.4% weight
reduction versus the 324-pound steel
version and a 60% weight reduction
versus the 110-pound aluminum version.
And overall part thickness measured to
3 millimeters, sized 2,061 millimeters x
1,361 millimeters. CpK Interior Products
SHOW PREVIEW
CAMX 2022 What:
preview
2022 Composites and
Advanced Materials
Expo (CAMX)
Who:
American Composites
Manufacturers Assn.
(ACMA, Arlington,
Va., U.S.); Society for
the Advancement of
Material and Process
Engineering (SAMPE,
Diamond Bar, Calif.,
U.S.)
When:
Oct. 17-20, 2022
Where:
Anaheim Convention
Center, Anaheim, Calif.,
U.S.
Source | CW
By Hannah Mason / Technical Editor, Grace Nehls / Managing Editor,

Chris Pasion / Managing Editor and Katie Leesemann / Editorial Assistant
» CAMX 2022 is fast approaching, taking place Oct. 17-20 at Featured panelists include Miles Arnone, CEO of Re:Build Manu-
the Anaheim Convention Center in Anaheim, Calif., U.S. This facturing; Jay Wakenshaw, chief operation officer at Elroy Air; and
year’s show promises to provide an opportunity to make new Jonathan Sourkes, head of sales of Aero SBU, Victrex. Moderating
connections, learn about the composites industry and explore the panel is Marcy Offner from Composites One (Schaumburg, Ill.,
new technologies on display from more than 400 exhibitors. The U.S.). Attend the event to learn more.
event features more than 100 conference sessions, a variety of live
demonstrations and a general session keynote presentation about Exhibit previews
supply chain disruptions and new opportunities, presented by CAMX has always provided a platform for the introduction of innova-
author and business leader Michael Steep. CAMX also will cele- tive technologies and products. CW solicited all CAMX exhibitors for
brate new technologies and innovations through the presentation information about the software, materials, equipment and services to
of its CAMX Awards and Awards for Composites Excellence (ACE). be featured in their booths. We heard back from many of them — in
One new event this year is “Good Day, CAMX,” a panel discussion fact, CW received a record number of  previews this year!
taking place at  a.m. on Oct. . The discussion explores a collabora- To accommodate as many previews as possible, CW has split
tion led by Re:Build Manufacturing (Framington, Mass., U.S.), along them into two batches. The first report was published in the
with Elroy Air (South San Francisco, Calif., U.S.) and Victrex (Bristol, September  issue of CW; what follows is the second report.
R.I., U.S.) to produce next-generation aerospace-certified structures Please visit compositesworld.com for the full list and to follow our
and lead the adoption of thermoplastic materials. coverage of CAMX during and after the show.

CAMX 2022
AFP, postprocessing
robotic solutions
Addcomposites (Espoo, Finland)
and IND Group (Sherbrooke,
Quebec, Canada) have teamed up
Source | Accudyne Systems
again this year to showcase upcoming
and existing products. As operating
Ultrasonic composite preform trimming partners providing the North American market
equipment with turnkey, off-the-shelf automated fiber place- Source | Addcomposites
Accudyne Systems (Newark, Del., U.S.) has developed ultrasonic trimming ment (AFP) and postprocessing robotic solutions, both companies are
solutions for a variety of thermoset composite preforms. co-exhibiting to show customers a more complete visual of the value
An ultrasonic generator uses high-frequency AC current to drive a proposition they offer.
piezoelectric crystal at the knife’s resonant frequency. The amplitude Specifically at the show, Addcomposites supplies the fiber placement
of this vibration is on the order of a few thousandths of an inch, but the head to IND Group, which is integrated into the Group’s cobot solution
sawing motion and energy added at the cutting point improve the ability platform known as Cobii. The Cobii family of products are temporarily
to cut individual fibers and resist the accumulation of resin. Trimming is available for training purposes, short-term repair jobs or for university
performed against a urethane cutting surface. Custom holding fixtures can instruction. The Cobii products include AFP, trimming, sanding, buffing
be molded, even in single quantities, through the use of 3D-printed molds. and other capabilities.
Both gantry and robotic solutions are controlled through a Siemens Also highlighted is the AFP-XS system, Addcomposites’ standard
(Munich, Germany) Sinumerik CNC controller using standard G-code. toolhead designed for various industrial robots, and AddPath, the
Accudyne has provided complimentary simulation and part-programming accompanying layup planning software.
solutions, importing machining paths from Catia V5 and automatically IND Group focuses on lean robotics to supply portable and flexible
generating collision-free robot programs. units that can be deployed and integrated in record time. A collaborative
Accudyne has also integrated ultrasonic cutting into pick-and-place, sanding unit is displayed at CAMX, giving the opportunity for attendees
lamination and AFP technologies. Accudyne Systems Inc., Booth S65, to experience easy programming functions while in teaching mode.
accudyne.com Addcomposites, Booth S55, addcomposites.com
Larger Compression
Molding Presses?
At Greenerd, we’re always up to your hydraulic
pressing challenges, especially the bigger,
complicated compression molding/ composites
projects. Our design, engineering, manufacturing,
automation and integration expertise has produced
huge successes in all major industry segments.
And we’re ready to bring you our 140 years of
experience today.
• Complete design, engineering, build and system

integration
• State-of-the-art automation capabilities
• Unlimited size and tonnage
AMERICAN MADE
2500 Ton Hydraulic

BRING THEM ON
Compression Molding Press
greenerd.com • 800-877-9110
G.21.10.2.compressionmolding-HP-Composite-Molding.indd 1 8/30/22 3:17 PM

SHOW PREVIEW
Recycled PET structural, Sustainable thermosets,

insulation foam core thermoplastics
Armacell (Brampton, Ontario, Canada) Avient Corp. (Avon Lake, Ohio, U.S.)
offers a wide range of innovative, eco- highlights its breadth of composite solu-
friendly PET foam solutions for structural tions, including new recycled material
and insulation applications based on formulations to further support a circular
100% recycled PET (rPET). Specifically, the economy and reduce carbon emissions.
company points to its ArmaPET family, featuring a A new formulation of Polystrand contin-
small ecological footprint. uous fiber-reinforced thermoplastic compos-
Source | Armacell Source | Avient Corp.
ArmaPET Struct is a versatile and durable solution for ites made with a resin matrix of more than 95%
structural sandwich applications, with an environmentally responsible post-consumer rPET is featured. Available in unidirectional (UD) tapes
approach. It features minimal fluctuation in product properties and is and multiaxial laminates, the solution offers low weight, high strength
said to increase process stability. and impact resistance. Polystrand’s performance is said to be comparable
ArmaPET Eco combines insulation and structural integrity, ensuring to conventional composites made with a virgin PET resin matrix.
energy and emission efficiency for decades of use. With secured lifetime Avient also highlights other composite materials and engineered
insulation performance, the 100% recycled material product is said to fiber solutions. In its thermoplastic composites section are Hammerhead
prevent degradation by moisture, rodents and insects. Marine Composite Panels and Polystrand structural sandwich panels. In
ArmaPET Curve is designed for recyclable thermoformable micro the thermoset composites category, Avient provides Gordon Composites
sandwich solutions produced in continuous manufacturing processes. continuous glass and carbon fiber barstock, laminates and composite
ArmaPET Curve optimizes micro sandwich strength-to-weigh ratios, has springs. Gordon Glass archery bow limbs and Glasforms pultruded rods,
improved 3D thermoformability and is highly temperature-resistant. tubes and custom profiles are also offered.
According to Armacell, ArmaPET Shape particle foam offers maximum Available engineered fiber solutions include Fiber-Line high-
design flexibility to produce lightweight, rigid 3D foam parts using performance fibers (coated, twisted and custom-wound aramid, glass,
innovative fusion technology. It offers zero-waste production, with carbon, HMPE and LCP fibers) and the Fiber-Line lineup (pultruded rods
foaming directly inside the mold. Armacell Benelux S.C.S., Booth D42, and custom extrusion-coated rods and fibers). Avient Corp., Booth U32,
armacell-core-foams.com avient.com/composites
Jumbo Vacuum Visit us at CAMX booth P24

Vulcanizing
Machine
Compression
Molding
Machine
Complete
with Crane
System
Teﬂon Molding
Machine
Large Compression
Molding Machine
2-Sided Operation
panstone.com • polymermachineryco. com • Call 330-633-5734 for more information

Visit us at CAMX in Hall C, Booth T62.
FLY LIGHTER,
WITH LESS FUEL
Aircraft structures made with thermoplastic

composites can reduce operating costs and
make flight more sustainable
INNOVATING ADVANCED
We’re advancing innovative materials and breakthrough technologies to STRUCTURES
create lighter weight, more sustainable components – from the smallest
brackets to even larger, complex fan cowls – to reduce the overall weight of an AEROSPACE REDEFINED
aircraft. And lighter means more fuel-efficient. With automated manufacturing

and integrated thermoplastic composite structures, we can help you fly lighter –
and shape a more sustainable future along the way.
collinsaerospace.com/thermoplastics
© 2022 Collins Aerospace

SHOW PREVIEW
High-precision surface Heaters, tempera-

quality assessment ture controllers and
Brighton Science (formerly BTG Labs, vacuum curing/
Cincinnati, Ohio, U.S.) designs high-precision debulking
instruments to bring visibility to a variety of BriskHeat Corp. (Columbus, Ohio,
Source | BriskHeat Corp.
surfaces. Brighton aims to bring surface intel- U.S.) manufactures a full line of
ligence to R&D efforts and mission-critical heaters and temperature controllers designed to solve a wide variety of
decisions for manufacturers, equipping composite curing and repair applications.
Source | Brighton Science them with insight to reduce scrap, recalls BriskHeat’s ACR3 Hot Bonder is used in applications like curing wet
and rework caused by adhesion failure. Along with 20 years of scientific layups and prepregs, resin infusion and adhesive bonding. Each heating
and engineering experience in bonding and adhesion, Brighton offers a zone is capable of using up to 10 thermocouples to record temperatures
versatile suite of handheld diagnostic tools to help provide manufacturers in multiple locations of the cure. The screen enables real-time graphing of
with convenience, consistency and confidence. all temperatures for the specified zone, and each zone features a separate
Among Brighton’s lineup is the Surface Analyst. Unlike conventional built-in vacuum pump and printer for convenience.
methods like dyne ink or water break tests, Brighton says the Surface The BriskHeat Vacuum Curing and Debulking table is reported to easily
Analyst is a different type of tool that can bring lab precision surface heat and debulk composite parts in a single-step setup. The sturdy silicone
quality inspection to the factory floor. Through the push of a button rubber vacuum membrane is capable of up to 800% elongation to fit
or automated command, the Surface Analyst reportedly takes precise, smoothly across parts. The ramp/soak temperature controller follows the
repeatable and objective inspections, giving manufacturers complete heating cycle programmed by the operator and can be stored for future
control of their adhesion process, according to the company. use. Programs can include up to 12 steps for multiple ramps, soaks and
Whether troubleshooting on the production line or designing a break- cooldowns. In addition, the two-stage built-in vacuum pump can draw
through product in R&D, specifying new materials or trying to identify almost 29" of mercury, BriskHeat notes.
the root cause of an adhesion or bonding failure, or other challenges, BriskHeat also highlights its durable SR silicone rubber composite
Brighton Science says it can be a partner to improve performance across heating blankets. Capable of conforming to a bend radius as small as
a wide range of adhesion and cleaning applications. Brighton Science, 0.25", the blanket can be bent repeatedly without fear of wires breaking.
Booth U52, brighton-science.com BriskHeat Corp., Booth R11, briskheat.com

CAMX 2022
Advanced thermoplastic, ther-

moset composite capabilities
Collins Aerospace (Charlotte, N.C., U.S.) specializes
in technologically advanced, intelligent solutions
that seek to redefine the aerospace and defense
industry.
Thermoplastic and thermoset composite tech-
Source | Collins Aerospace
nologies are one way in which Collins Aerospace
is creating solutions for complex, lightweight
structures that are safe, efficient, sustainable and relatively low in cost to manufacture.
Moreover, the company is identifying how thermoplastics can improve products used in space
exploration and defense applications.
On display at this year’s show is an integrated curved stiffener as well as upper and
lower longerons, all commonly positioned on a large fan cowl of an aircraft nacelle. Collins’
thermoplastic portfolio ranges from wing and fuselage clips and brackets to large nacelle
thermoplastic structural assemblies — wing and fuselage detail parts, nacelle structures, doors
and flight control surfaces.
Using a combination of materials, manufacturing processes and expertise, integrated ther-
moplastic composites are said to be lighter in weight and more affordable due to their distinc-
tive welding capabilities, which minimizes or eliminates the need for fasteners. Thermoplastics
also provide high-temperature properties and durability, compared to thermosets.
When it comes to manufacturing more complex products, customers can benefit by as
much as an 80% reduction in manufacturing cycle time and a 50% reduction in part weight
SMOOTH YOUR
compared to similar products produced using metallics, according to the company. EXTERIOR
Collins Aerospace, Booth T62, collinsaerospace.com
WITH EASE
High-temperature CMC structure, assembly services SIKA ADVANCED

Established in 1978, Composites Horizons LLC (CHI, Covina, Calif., U.S.), a PCC Company, is a
supplier of high-temperature composite structures and assemblies for the aerospace, defense
RESINS FILLING
and industrial industries. Supplying customers such as GE Aviation, Honeywell, Raytheon/ & FAIRING
Pratt & Whitney and Rolls Royce, the company offers composites manufacturing services
using high-temperature polymer matrix (polyimides) and oxide-based (ox-ox) ceramic matrix COMPOUNDS
composite (CMC) materials. PROVIDE AN
CHI currently manufactures engine, duct, heat shield and exhaust structures using bisma-
leimide (BMI) prepreg systems as well as PMR-15, AFRPE-4 and RM1100 polyimide materials. EXCELLENT
With more than 25 years of experience in the processing of polyimide materials, CHI has
developed specialized tooling, layup and cure techniques that have made the company a key
FINISH
polyimide composites processor in the aerospace industry.
CHI has been manufacturing ox-ox CMC at its 45,000-square-foot facility since 2014 and
has delivered multiple ox-ox-based exhaust components for commercial aircraft engine TOOLING & COMPOSITE
applications. In addition, it continues to support the commercialization and adoption of these SOLUTIONS FROM
ox-ox structures via the development, characterization and demonstration of low-cost ox-ox DESIGN TO PRODUCTION
CMC product forms (such as lower cost fabric-based prepregs) and manufacturing techniques,
including the demonstration and development of producing ox-ox tape materials via auto-
WWW.SIKAINDUSTRY.COM
mated tape laying (ATL). These developments offer the potential to reduce the cost of ox-ox 800-688-7452
CMC structures by up to 50% versus structures designed using traditional fabric-based ox-ox
prepregs, CHI contends.
The company’s Covina facility consists of 160,000 square feet of manufacturing space and
includes high-temperature/pressure autoclaves, material-specific cleanrooms, high-temper-
ature presses and ovens, ceramic sintering furnaces, material-specific dedicated cleanrooms,
five-axis machining, coordinate measuring machine (CMM) equipment, nondestructive inspec-
tion (NDI) and assembly areas. Composites Horizons LLC, Booth X75, chi-covina.com
Untitled-2.25 x 9.125 CW Specs.indd 4 9/7/2021 9:35:08 AM
SHOW PREVIEW
Live demos showcase closed molding processes

and innovations
In the demo zone, distributor Composites One (Arlington Heights, Ill., U.S.), the Closed Mold Alliance
and industry partners are presenting nine live demonstrations showcasing the latest technologies
in vacuum infusion, light resin transfer molding (LRTM), silicone bag molding, and prepreg and
autoclave processing.
The demos are broken up by market segment, featuring applications in aerospace, marine, wind
and automotive parts manufacture. Nine dedicated technical team members from Composites One
are spearheading the demos along with support from supplier partners. Aerovac Composites One will
Source | Composites One
also be a large part of the vacuum infusion and prepreg processing demonstrations.
All demos are performed live in the Closed
Mold Alliance’s glass-enclosed staging area,
with demonstrations scheduled for almost
WICKERT Anzeige USA - Thema: Composite Presses,: 111 x 175 mm / Satzspiegelanzeige, 4c, DU: 00.00.2021, ET: 00.00.2021
every hour that the show floor is open. Cameras

are also set up so that attendees can see
close-up footage of the processes as they are
happening.
COMPOSITE PRESSES This year’s featured demonstrations include
a lifelong bond a side-by-side comparison of an infusion layup
using precut kits compared to cutting fabrics
by hand. “The demonstration is really fun
and shows how kitting can provide efficiency
in composites manufacturing,” notes Marcy
Offner, director, marketing communications at
Composites One.
Another demonstration shows a marine
• Compression
hardtop fabricated from a variety of materials
and manufactured using three different
• Thermoforming processes: LRTM, vacuum infusion and silicone
• Injection
bag molding. “You can see how the same part
• Press
can be made completely differently, depending
on what your needs are and how many parts
Automation
•
you want to produce each day,” says Offner.
Specialized “You’ll get a feel for all the different possibilities
Solutions of closed molding.”
In addition, along with partner Magnum
Venus Products (MVP, Knoxville, Tenn., U.S.),
Composites One is demonstrating a fast-flow,
LRTM process to show how processes can
be sped up to enable higher rate or higher
efficiency manufacture.
On the final day of CAMX, Thursday, Oct. 20,
the demo organizers will hold an open house in
the booth, offering attendees a chance to talk to
the technical team, ask questions about demos
seen during the week and see the demonstra-
tion parts up close. “This will be the first time
bringing the open house component back to
our CAMX demos since 2019,” says Offner.
“We’re excited to bring back more opportuni-
COMPOSITE PRESSES AND PRESS SYSTEMS
ties for in-person and hands-on learning.”
Composites One, Booth L23, compositesone.com
www.wickert-usa.com

CAMX 2022
Heavy-duty cutting tool

head
The Heavy-Duty Toolhead from
Eastman Machine Co. (Buffalo, N.Y.,
Source | Eastman Machine Co. U.S.) is said to be ideal for increasing
production flexibility and minimizing
downtime while changing tool configurations. Powered by its own brushless motor and inde-
pendently controlled air supply, the Heavy-Duty Toolhead incorporates two cutting spindles,
including the use of a marking pen. Eastman’s catalog of precision tools includes round blades,
a notching tool, drag knives and a punching tool. With the wide selection of tools and the
incorporation of two spindles, an uninterrupted cut file can be run using any tool combination.
Eastman says the Heavy-Duty Toolhead is reliable and can be used for years with only
minimal maintenance. The toolhead has thicker spindles to reduce flex when cutting, ideally
resulting in a more accurate cut in denser materials and less deflection when cutting rigid
materials. The Heavy-Duty Toolhead is designed to provide more clearance for thicker materials
and is compatible with a static table and conveyor system configurations of any size.
Eastman says its 10-sided Blade is a popular tool in the industry, ideal for cutting composites.
Available with a variety of exclusive depth-limiting discs, the Eastman 10-sided Blade is
engineered to cut through advanced textiles such as stitched fiberglass and chopped strand
mats. The tools are engineered to offer versatility and adaptability while adhering to stringent
industry requirements for accuracy, speed and repeated quality. The increased cutting pressure
makes cutting advanced textiles relatively easy while extending the life of the blade, according
to the company. Eastman Machine Co., Booth S32, eastmancuts.com
ASSEMBLE
WITH
STRENGTH
Environmentally
conscious epoxy
resins SIKA
Entropy Resins (Gardena, Calif.,
U.S.) is a specialist in creating
STRUCTRUAL
epoxy resins and hardeners to SEALANTS &
lower the company’s impact
on the environment without Source | Entropy Resins
ADHESIVES
compromising performance. PROVIDE
Through green chemistry, sustainable raw materials and efficient manufacturing, Entropy says
it conserves energy, minimizes harmful byproducts and reduces greenhouse gas emissions. STRONGER
Demonstrations using life cycle assessment (LCA) showcase how Entropy’s epoxies reduce
the environmental impact of end products. The company also performs third-party, bio-based
BONDS AND
content testing certified by the U.S. Department of Agriculture (USDA) to show that no “green” SEALS
claim goes unsubstantiated. Any claim is supported by data, the company says.
Entropy likes to ensure its resins are made both responsibly and better. The company devel- TOOLING & COMPOSITE
oped Super Sap technology to reduce the impact of Entropy Resins on the environment without SOLUTIONS FROM
compromising performance. This is achieved through green chemistry, bio-based and rapidly DESIGN TO PRODUCTION
renewable raw materials and efficient manufacturing under ISO 9001:2015.
A major part of sustainability is transparency, the company believes. This belief drives WWW.SIKAINDUSTRY.COM
Entropy’s use of third-party laboratories to measure the bio-based content of its products. Every 800-688-7452
Super Sap resin product is certified under the USDA Certified Biobased Product label program,
the company reports. Moreover, LCAs help Entropy Resins quantify how Super Sap technology
reduces the environmental impact of products that ultimately reduce the carbon footprint of
customers’ products.
Entropy Resin products include clear laminating epoxy; optically brightened laminating
epoxy; high bio-based laminating epoxy; compression molding epoxy; and clear casting resin
epoxy. Entropy Resins, Booth G12, entropyresins.com
SHOW PREVIEW
Graphene products
and applications,
networking resources
The Graphene Council (New Bern,
Source | Fives Machining Systems Inc.
N.C., U.S.) is a global community
of more than 30,000 materials
Automated tape laying, fiber placement professionals that produce and
machines use graphene to create the next
Source | Graphene Council
Fives Machining Systems Inc. (Hebron, Ky., U.S.) Composites & Automated generation of products and appli-
Solutions business line provides end-to-end composites manufacturing cations, including composites and
solutions from lamination to demolding and everything in between. plastics. Founded in 2013, it represents the interests of graphene experts
Fives supports customizable lamination, forming, inspection and curing and organizations, producers, researchers, application developers and
solutions for its customers. Above all, the company says it specializes in end users.
developing highly automated, end-to-end solutions that seek to increase Graphene Council seeks to help companies understand how to
productivity across the complete line. leverage 2D advanced materials, such as graphene, to improve products
This automation specialization led Fives to develop a range of across a range of characteristics. The material imparts multiple benefits
distinctive and customized automation solutions. Fives offers tape laying not only to composite parts, but is also being used to make tools
and fiber placement machines. Featured products include the Cincinnati perform better and to last longer, according to Graphene Council.
Robotic Viper, Cincinnati Supercharger and Fives In-Process Inspection. Graphene is a unique form of carbon that has distinctive properties at
Cincinnati Robotic Viper is an AFP machine designed for OEM or Tier the atomic scale. It is said to be the thinnest known material, — so thin it
1 capabilities and quality standards. The next-generation edition seeks is considered 2D — exhibits high strength and is highly conductive (heat
to automate hand-laid parts and includes machine configurations able and electricity). When in a single layer of carbon, graphene is almost
to accommodate many shape and size applications, including concave transparent.
and convex. It also possesses a dockable head for flexibility and an Some initiatives important to the Graphene Council include
in-process inspection capability. Development of International Standards, material characterization and
The Cincinnati SuperCharger is an automated tape lamination testing services and Verified Graphene Producers inspection programs.
machine. The Cincinnati SuperCharger features the choice of vertical Companies are able to join The Graphene Council to gain access to
travel, X-axis rails in incremental sections for flexibility in part length, the network and valuable resources. Member benefits include:
up to 25° counters and up to 60 m/min layup rate. It is also available as • The Graphene Report, an up-to-date and comprehensive global
a 9- or 10-axis machine. Machine height can be configured for specific resource on commercial graphene developments.
applications, with high-speed axis motion for high productivity and • Two free registrations to Graphene Council Member conferences.
choice of crossrail width. • Weekly graphene intelligence briefings including information from
Fives In-process Inspection (IPI) provides integrated measurement science journals, commercial news, applications and patents, and
technology for automated composite layup. A quality monitoring announcements of webinars, conferences and events.
solution, the Fives IPI features a custom design to seamlessly integrate Membership in the Graphene Council helps support the development
into an AFP machine. Optical coherence tomography (OCT) imaging of standards and the commercial adoption of this material.
technology creates 3D maps of composite surfaces. Real-time defect The Graphene Council, Booth Z42, thegraphenecouncil.org
measurement, and real-time tow placement measurement and control
are possible. Fives Machining Systems, Booth N54, fivesgroup.com
Fully Servo Drive Pultrusion Process For Optimal

Control - Kent Pultrusion ServoPul Machines
INNOVATIVE. COMPOSITE. SOLUTIONS

A SUBSIDIARY OF MNM MFG INC
Kent’s ServoPul Machines

Introduce Servo Motor & Drive
Technology to control Pulling &
Clamping Forces and Register Interactive Touchscreen Servo Controlled In line Cut-Off Saw Systems
monitored feedback to the PLC Controls the machine Clamping & Pulling travels and cuts product at
operating system. operation line speed

CAMX 2022
Broadband, infrared
heat technologies
Heraeus Noblelight (Cambridge,
U.K. and Gaithersburg, Md., U.S.) is
highlighting its broadband flashlamp
Source | Heraeus Noblelight heat source, the humm3, along
with infrared heat technologies for
increasing production rates and quality in composites processing and fabricating applications.
Humm3 technology is a high-power, safe, highly controllable broadband heat source for
AFP, automated tape laying (ATL), filament winding and other composites applications.
Heraeus Noblelight’s Humm3 technology delivers homogeneous, highly controllable heat to
the process area over a wide range of temperatures at rapid process rates. Its instantaneous
temperature ramp-up and cooldown is said to be ideally suited to process complex parts using
dry fiber and thermoplastic composite materials.
Humm3 reportedly delivers power previously only available from a laser, but without
cumbersome safety protocols and costs associated with a laser safety enclosure. The system
also offers scalable heated widths from 12.5-300 mm and beyond, with wider widths offering
the possibility to greatly improve material deposition and thus production rates.
Heraeus Noblelight’s infrared emitters, modules and systems cure thermosetting plastics
and heat thermoplastics prior to welding, molding or forming. Precise control and placement
of infrared radiation ensures a more efficient composite fabrication process. Example applica-
tions include prepreg layup, de-bulking prepreg carbon fiber tape layups, softening of multiply
prepreg material prior to molding and more. Heraeus Noblelight America LLC, Booth F54, DESIGN TO
heraeus.com
PRODUCTION
Corrosion-resistant resins
When it comes to corrosion-resistant fiber-
reinforced plastic (FRP) tanks, pipes, ducting, SIKA IS A
pultruded profiles and custom components,
Derakane resins by INEOS (Dublin, Ohio, U.S.)
PROVIDER AND
aim to bring trusted polymer performance. DEVELOPER OF
Derakane’s track record, INEOS says, is proven
through hundreds of cases that provide decades
HIGH QUALITY
of proof of chemical containment and transport
Source | INEOS PERFORMING
in a variety of applications, including chemical
processing, coatings and linings, power genera- RESIN SYSTEMS
tion, mineral processing, pulp and paper and wastewater treatment.
Embracing the best features of INEOS’ legacy resins, Derakane Signia is meant to deliver
& ADHESIVE
elevated results — less environmental impact, better quality and better efficiency — all SOLUTIONS
contained within an identifiable resin system. With high resistance to oxidizing acids, solvents
and caustic materials, Derakane offers reliability, low maintenance and extended service life.
FOR TOOLING AND
In the job shop, INEOS reports several benefits to Derakane Signia. Prepared with a distinc- COMPOSITES
tive styrene suppressant system to reduce emissions, extend permits and provide a low-odor
environment, Signia has low styrene emissions. Signia is also designed to assist with improved
shop efficiency through easy surface preparation, increased secondary bonding and reduced WWW.SIKAINDUSTRY.COM
gassing for faster consolidation and less process time. The resin also offers long shelf life to 800-688-7452
maintain its processing characteristics.
INEOS also reports benefits of using Derakane Signia in the field. It possesses a consistent
polymer backbone meant to deliver the same chemical resistance and mechanical properties
as its predecessors — all with better processing, according to the company. Signia also has
verifiable identification through a proprietary detection system to verify the integrity of a
customer’s design wherever corrosion-resistant FRP pipes and tanks are present. INEOS
Composites, Booth J42, ineos.com/composites
SHOW PREVIEW
Computer-
controlled filament
winding machine
Since 1961, McClean Anderson
(Schofield, Wis., U.S.) has
developed filament winding
Source | Magnum Venus Products
equipment. Since its first Source | McClean Anderson
Inflatable vacuum bagging seal computer-controlled filament

Magnum Venus Products (MVP, Knoxville, Tenn., U.S.) launches an winding machine pioneered in 1976, the N101, the company says it has
inflatable seal for closed molding applications. The reusable two-part seal, released increasingly efficient equipment for improved winding accuracy
called the Secure Vacuum Bag Seal (SVB Seal), replaces single-use sealant and production speeds. Ocelot is McClean Anderson’s latest machine
tapes and is designed to reduce consumable cost and waste, decrease control, demonstrated at CAMX alongside Simwind, its next-generation
time and labor requirements, and improve part quality and consistency. fiber pattern development software to design and model complex
The SVB Seal is said to eliminate pleating and creates an airtight seal filament-wound structures.
with every part. In addition to reducing consumable waste, one SVB Seal Ocelot includes all features provided within the Flexwind control
can be used to build hundreds of parts before replacement. while providing additional advantages. It features a high-performance,
It is designed to fit into a groove built into the perimeter of the mold ultra-compact control cabinet industrial PC with Windows 10 OS – green
and its setup is the same as a typical vacuum bagging process. Once the and sustainable IT, 17" high-definition touch display and etherCAT-based
luminant is prepared for infusion, the bag is applied to the top of the communication with unlimited input and output possibilities. It offers
mold. Instead of applying tacky tape to seal the bag to the perimeter Advanced Safety Logic technology and Rapid Custom Automation.
of the mold, the bag is secured into a groove in the mold flange under Ocelot is also able to execute Composite Designer/SimWind2 motion
the first half of the SVB Seal. Once the first half of the seal is in place, and auxiliary profiles (*.MMT, *.CHN, *.BUF, *.AUX, *.TEN files), has tools
the second half of the seal is added and vacuum is pulled on the mold. for troubleshooting and system diagnostics and features Open Platform
Charles Tur, MVP’s closed molding specialist, leads live demonstrations Communication and integration with external industrial hardware and
everyday with the SVB Seal in the MVP booth. Magnum Venus Products, software. McClean Anderson LLC, Booth T22, mccleananderson.com
Booth T11, mvpind.com
THERMOPLASTIC SYSTEMS
calitzler.com
Features
■ Creels
■ Tow Spreading
■ Waterborne Resin Application
■ Oven for Pre-Melting Resin
■ Resin Consolidation Die Application
C. A. Litzler Co., Inc.
■ Profile Thickness Systems
4800 W. 160th Street
Cleveland, OH 44135 USA ■ Compaction Rolls
216-267-8020 ■ Winders
sales@calitzler.com ■ Controls & Automation
Half Pg Thermoplastic Ad_8.18.indd 1 8/7/18 2:13 PM

Propelling the future of flight, energy
generation, transportation, and recreation.
Hexcel is a leading supplier of carbon fiber, honeycomb and other

composite materials providing lightweight strength for the commercial
aerospace and space & defense industries.
We also provide a wide range of composite products and

game-changing process technologies for the marine, wind
energy, automotive and sports & leisure industries.
Explore Hexcel products and lightweighting solutions at hexcel.com.

SHOW PREVIEW
Laminated composite design evaluation support tool

Metycalc is Metyx Composites’ application for the design of laminated composite
constructions. Accessed through www.metyx.com/metycalc, the program supports
composites engineers by helping to achieve estimated goals of stiffness, strength and
weight for a particular laminate design. Moreover, it is presented to the composites
industry as a value-added support tool that can facilitate the evaluation of a variety of
design solutions.
Engineering estimates that are generated by Metycalc are based on engineering
Source | Metyx Composites
principles and empirical data and can be useful for approximate size of composite
laminates and for comparing various composite
laminate designs, according to the company.
The application also reportedly has the ability
• Over 40 types of
W yoming
to review beam bending calculations using
fixtures in stock,
ready to be shipped. a variety of boundary conditions and load
configurations, including:
T est
• Expert consultation
with Drs. Dan and • SS Ends – Center Load
Don Adams • SS Ends – 4-Point Bend
F ixtures
• Email or call today to • SS Ends – Uniform Loading
discuss your fixture and
• Clamped Ends – Center Load
custom design needs.
INC. • Clamped Ends – Uniform Load
• Cantilevered – End (tip) Load
• Cantilevered – Uniform Loading
CERAMIC FLEXURAL TEST FIXTURES Any composite material application with
requirements for critical performance and
safety must be verified through a mainstream
CERAMIC FLEXURAL
engineering and development approach, such
STRENGTH
TEST FIXTURES as final laminate testing through ISO/ASTM
MODEL: WTF-CF test standards, which Metyx says should be
ASTM C1161 used to complement this design tool. This is
also the case for core materials for sandwich
laminate constructions, include facing details
CONFIGURATIONS A, B, C AND A CUSTOM SMALL-SCALE FIXTURE ARE SHOWN such as grooves and perforations, in which
resin absorption is taken into consideration to
provide a more accurate result with respect to
overall laminate weight.
Metycalc is also said to help speed produc-
tion and reduce labor by showing how different
material selections can change the process,
as well as revealing cost-effective solutions to
optimize the number of layers needed to meet
design goals.
Free to use and user friendly, Metycalc can
CERAMIC FLEXURAL STRENGTH CERAMIC EQUIBIAXIAL FLEXURAL be accessed across platforms including PC,
THREE-AND FOUR-POINT LOADING TEST FIXTURE MAC, Android and Apple. Metyx Composites,
MODEL: WTF-CF MODEL: WTF-CB
Booth S11, metyx.com
ASTM C1161 ASTM C1499
CUSTOM MADE TO YOUR SPECIMEN SIZE
Dr. Donald F. Adams, President Dr. Daniel O. Adams, Vice President

50+ years of Composite 40+ years of Composite
Testing Experience Testing Experience
2960 E. Millcreek Canyon Road

Salt Lake City, UT 84109 email: wtf@wyomingtestfixtures.com
Phone (801) 484-5055 www.wyomingtestfixtures.com

SHOW PREVIEW
Graphene-based Modified epoxy,

specialty additives cyanate ester
Mito Material Solutions prepreg
(Indianapolis, Ind., U.S.) reports that materials
it has unlocked the power of hybrid Prepreg composite materials
polymer materials with specialty manufacturer and supplier
additives to improve performance. NEXX Technologies (New
The Mito family of products includes York City, N.Y., U.S.), show- Source | NEXX Technologies
Source | Mito Material Solutions
a graphene additive, E-GO, and cases its range of modified
cornstarch-based SMITO. All of Mito’s products are said to be easily epoxy and cyanate ester prepreg materials, EndurEdge Max, aiming to
dispersible, safe-to-handle, scalable solutions. streamline the process of prepreg manufacture. The two currently available
For 2022, the company highlights a new application using its graphene thermoset chemistries are modified epoxy and cyanate ester.
additive. Commonly sold as a powder or masterbatch, E-GO is now avail- The company reports decreased manufacturing time when compared
able dispersed in a solvent-based liquid that is sprayed onto the fiber- to traditional composite prepregs. Out-of-autoclave (OOA) and vacuum
reinforced material during production. Mito has partnered with a sporting bag-only (VBO) processing are possible thanks to engineered air release
goods manufacturer it met at CAMX 2021 to integrate an E-GO blend via channels, with an extended out time of more than one year with no change
this spray method onto prepreg carbon fiber prior to the curing process. in rheology and processing conditions. These attributes accompany a host
The spray enables manufacturers to locate with pinpoint accuracy exactly of benefits for the end-user, the company notes. No freezing is required,
where on the part additional flex, strength and durability are needed, debulking or post-cure processes are eliminated and mechanical properties
according to the company. This new integration method is sought in order are optimized to meet or exceed legacy system performance. The materials
to open Mito’s markets into more complex composite components and are also snap-cure capable, feature relaxed fibers — the company’s
shapes, like cylinders. impregnation process makes prepreg material feel like dry fabric, enabling
Mito’s ultimate goal is to equip composite products with the advantage easier wrapping and reduced layup time — and they are available in a
of functional chemistry, offering sustainability and good product perfor- variety of materials. NEXX Technologies, an MGC company, Booth N48,
mance. Mito Material Solutions, Booth S26, mitomaterials.com enduredge.com

SHOW PREVIEW
Epoxy resin systems Tooling resin demonstration

As a fully integrated supplier Polynt (Carpentersville, Ill., U.S.) exhibits four resins — Polynt A 6125 IAH,
of epoxy systems, Olin Epoxy OptiPLUS 40-8091, OptiPLUS KRF100LC-25 and Armorclear 961XK192 — in
(Roberta, Ga., U.S.) provides a the Composites One (Schaumburg, Ill., U.S.) Demo Zone at CAMX.
broad portfolio of solutions for chal- Polynt A 6125 IAH is a low-profile light RTM resin that exhibits what is
lenging composites applications. said to be superior surface quality and dimensional stability even at room
Olin says its Litestone Epoxy temperature cure, in addition to rapid demolding. High surface quality is
Source | Olin Epoxy Systems offers a platform to meet achieved without the use of fillers. Dimensional stability is achieved due to a
industry conditions specific to proprietary shrinkage control system and low exotherm during cure.
design, fabrication and system integration requirements in a variety OptiPLUS 40-8091 LPA infusion tooling resin is part of Polynt’s OptiPLUS
of manufacturing methods such as filament winding, pultrusion, resin line and enables master mold replication even at 70% fiber content. Tools
transfer molding (RTM), infusion and hand layup. The company also made with this technology exhibit high strength and improved dimensional
spotlights Voraforce Epoxy Systems and notes it as a key enabling stability. A high glass transition temperature (Tg) also supports tools in a
technology for high-throughput production of lightweight automotive variety of demanding conditions.
composites for manufacturing processes such as high-pressure resin OptiPLUS KRF100LC-25 is a pre-promoted bisphenol A vinyl ester resin
transfer molding (HP-RTM). In addition, Olin’s Airstone Epoxy Systems specifically designed for low-color applications where transparency with
are said to contain solutions recognized by global wind blade manufac- glass and carbon fiber would be desirable. The resin offers the traditional
turers for performance and reliability. strength, corrosion resistance and temperature resistance of bisphenol A
Next-generation composites applications and product demonstrations vinyl esters.
are available at Olin’s CAMX booth. One featured demonstration focuses To illustrate this, the upper half of a mold will be in the Demo Zone to
on composite pressure vessels, involving the Litestone portfolio for showcase how the low-color cured system can be used to allow resin flow
filament winding. Olin also demonstrates composite rebar, additionally visibility when creating composite parts in a closed system tool. Also, the
highlighting Litestone, but for pultrusion. The last of the demonstra- upper mold will feature Polynt’s clear gel coat, Armorclear 961XK192, which
tions covers suspension systems, featuring the Litestone and Voraforce is said to offer clarity, improved toughness and ease of processing. Polynt,
portfolios for HP-RTM. Olin Corp., Booth W22, olinepoxy.com Booth R1, polynt.com
ASTM ASTM
D5379 D7078
WE HAVE OVER
ASTM 300 FIXTURES IN
C297
STOCK AND
READY TO SHIP
We have been providing fixtures for over 30

years
Call or email us for any custom modifications ASTM

or designs D2344
Consultation available with our expert

engineering service with over 45 years of
experience
Call us today for a complete line of testing fixtures:

ASTM D2990
By Standard: Type of Testing: Type of Material:
 Composites
 ASTM  Compression
 Wood
 ISO  Tensile
 Fabric
 BS  Shear  Metal
 EN  Impact  Rope and Wire

 Plastics
 PSTC  Flexure
Website: WWW.MTTUSA.NET Email: Sales@mttusa.net

420 Harvester Ct. Wheeling, IL 60090 Ph: 847-215-7448
ASTM C393
ASTM C273
BS 7260

CAMX 2022
Ablative, thermal protection systems

Park Aerospace Corp. (Newton, Kan., U.S.), founded in 1954, is an advanced
materials company that develops and manufactures high-technology
advanced composite materials, parts and assemblies for the aerospace
markets. Park’s core capabilities are in the areas of polymer chemistry
formulation and coating technology.
Park’s facility in Newton, Kan., U.S. was commissioned in 2009. The plant
is now an 180,000-square-foot facility and covers advanced aerospace
composite materials manufacturing, composite parts design, fabrication
and assembly for all aerospace customers. Among Park’s offerings are Source | Park Aerospace Corp.
thermal protection system (TPS) resin systems,

reinforcements for TPS, structural polymer
material systems for space applications, struc-
tural design and composite strut fabrication.
Park’s range of TPS resin systems includes
carbon and silica-filled phenolic resin matrices
(F-502, F-552, F-554, F-555, F-557 and F-562),
polyimide resin (V-303) and cyanate ester
resin (V-376).
These resin systems are offered with a
variety of reinforcements and in straight
broadgoods, chopped molding compounds
and biased product formats. Park is an exclu-
sive North American distributor of Raycarb
C2 B NG carbonized rayon. It also offers Enka
carbonized rayon and silicia fabric. Currently
under development is stretch-broken PAN.
Structural polymer material systems that
may find use in space applications are also
provided by Park Aerospace. Among these
Multi-material AFP heads for thermoset,
are 250° curing epoxy E-765; 350° toughened SHAPE thermoplastic, and dry-fiber layup
epoxies E-752, E-752 LT and E-752MTS; and
cyanate ester resin V-376. These resin systems YOUR Quick change IR and laser heating
Automated head exchange <2mins
are available with reinforcements as well,
including Raycarb C2 B NG carbonized rayon,
ADVANCED Robotic or gantry configuration
Enka carbonized rayon, silica fabric and COMPOSITES In-situ consolidation from closed loop feedback
standard and high-modulus (HM) fibers.
For launch vehicle and payload applica-
tions, Park Aerospace Corp. offers structural
design and composite strut fabrication. Park’s
proprietary strut technology includes Sigma
Struts for medium- to high-load designs and
Alpha Struts for modest- to mid-load designs.
NASA is said to have used Park’s Sigma Struts
among programs including Space Shuttle,
James Webb Space Telescope, NASA MLAS
Test Vehicle (Orion) and other classified
applications. Park Aerospace Corp., Booth
V42, parkaerospace.com John Melilli, Composite Automation - john@compositeautomation.com
2-year warranty | 24x7 support sales@mikrosam.com www.mikrosam.com
NOVEMBER 15–17, 2022
H YAT T R E G E N C Y | G R E E N V I L L E , S C
Join the carbon fiber experts for the

25th Annual Carbon Fiber Conference!
• Tour Clemson University’s International Center

Scan here to for Automotive Research
register now! • Choose to attend one or both of Carbon Fiber’s

expert led pre-conference sessions
• Take part in two days of conference
programming with the industry’s top minds
SPECIAL DISCOUNT • Celebrate 25 years of Carbon Fiber at the Grand Reception
FOR EARLY BIRDS! • Find talent at Carbon Fiber’s Student Showcase
Register by October 14 to • Network with exhibitors who can help your business thrive
save $100 on the advanced rate.
PRESENTED BY:
Spe c i a l E v e n t s
coming to
Carbon Fiber 2022!
PRE-CONFERENCE TOUR
Tuesday, November 15
Clemson University’s International Center
for Automotive Research
This tour will break attendees into groups as you’re
guided throughout the facility. You’ll see various
items and processes in the lab including materials
testing, machinery, cutting tables and more.
This event is free but space is limited!
PRE-CONFERENCE SEMINAR* PRE-CONFERENCE SEMINAR*

Tuesday, November 15 | 9:00 AM Tuesday, November 15 | 1:00 PM
Carbon Fiber Composites and the Hydrogen Carbon Fiber In Our Changing World
Economy: Opportunities and Challenges Presented by:
Moderated by: Anthony J. (Tony) Roberts / Carbon Fiber Sales
Ginger Gardiner / Senior Technical Editor / CompositesWorld and Marketing Consultant
Daniel Pichler / Partner | Joint Managing Director
This presentation will discuss the emerging market of CarbConsult GmbH
for carbon fiber in the hydrogen economy as well as
the technical, manufacturing, industrialization and Tony Roberts and Dan Pichler apply their 80
economic challenges it faces and solutions being years of combined industry experience to dive
explored by industry leaders. deep into the market and shed some light on
*Pre-conference sessions require separate fee what is happening in the world of carbon fiber.
Celebr a te w i th u s ! m
Register by October 14 to claim the early bird rate and a
limited-edition Carbon Fiber 25th Anniversary lapel pin!
Learn more at
CarbonFiberEvent.com
SHOW PREVIEW
Specialty chemical Large composite

packaging, applicator structures
systems assembly, thermo-
PPG’s (Pittsburgh, Pa., U.S.) Semco plastic technologies
Packaging & Application Systems manu- Qarbon Aerospace (Red Oak,
factures packaging materials that are Texas, U.S.) is a manufacturer
intended to store, mix, dispense, apply of composite components
and remove specialty chemicals used in and assemblies at all levels Source | Qarbon Aerospace
manufacturing and repair environments of complexity with products
Source | PPG for many industries. PPG Semco has more installed on commercial, military and space aircraft. Qarbon says it lever-
than 50 years of experience in handling ages its experience in composites manufacture, large structures assembly
the packaging and dispensing of a variety of materials. and thermoplastic technologies to partner with customers in design
The company’s range of products includes cartridges, nozzles, a optimization to produce defect free, on-time deliveries at optimum value.
sempen applicator, removal tools, dispensing and mixing tools, hybrid The company’s manufacturing capabilities include:
and UV-blocking syringes and cartridges. PPG Semco’s disposable plastic • Major assembly and systems integration: Includes wings, vertical and
cartridges are available in 1-, 2.5-, 6-, 8-, 12-, 20- and 32-fluid-ounce and horizontal stabilizers, tail sections, nacelles and fuselage sections for
1/10-gallon capacities. fixed- and rotary-wing aircraft.
Available in low- or high-density natural polyethylene, all sizes are fit • Automated layup: Qarbon’s climate-controlled areas (CCA) are
with 1/4" national pipe thread (NPT) female thread dispensing orifice. equipped with 3- and 5-axis ALT, an automated stringer machine,
Special colors are available, however, minimum order, lead time and same-qualified resin transfer molding (SQRTM) and fiber tow
pricing considerations apply. The cartridges are capable of handling a placement machines.
variety of chemical fluids for storage and application and can be easily • Hand layup: Qarbon says its CCAs meet stringent air quality require-
adapted to both pneumatic and manual dispensing systems. PPG Semco ments. All CCAs are fitted with the latest technologies in overhead
cartridges are commonly used in single components, plural components ply projection systems and debulk stations.
or pre-mixed and frozen applications with polysulfides, solder pastes, • High-temp composites capabilities: Service temperatures up to
adhesives, epoxies, urethanes, greases, acrylics and more. CP and 700°F are possible, with autoclaves up to 800°F, pressure up to 200
CWP cartridges are the standard Semco cartridge with either a P or psi and ovens up to 1,000°F available.
WP plunger inserted. This inserted plunger enables for filling from the • Core fabrication: In-house core machining and forming enables
dispensing end, which is said to reduce the potential for air entrapment Qarbon to control cost and lead time with multiple 5-axis core
and improve production rates. milling centers, Nomex and aluminum core forming, hot die forming
The PPG Semkit package is a complete, multicomponent plastic and pin routing.
cartridge assembly that stores, mixes and applies multiple component In addition to its manufacturing capabilities, Qarbon Aerospace also
adhesives, sealants, encapsulants and other materials. PPG says it has highlights its technologies in thermoplastic composites. Both technolo-
been industry tested for more than 50 years and still represents the gies are ready for launch platform applications. Qarbon’s induction
best blend of performance and safety available in the industry. Semkit welding of UD carbon fiber tape enables fabrication of dissimilar thick
packages are reportedly ideal for epoxies, polysulfides, polyurethanes joints, blind one-sided welding and high-curvature part performance.
and silicones used in the aerospace, electronics, automotive, construc- In addition, Helios Ice Protection is an electrothermal icing protec-
tion, marine and telecommunications industries. According to PPG, tion system offered by the company. Qarbon Aerospace, Booth V14,
the kit assures material performance, optimum quality and increased qarbonaerospace.com
productivity on the production line and in the field. PPG, Booth F61,
ppgindustrialcoatings.com
Adhesives, pastes, tooling systems, resins

Scott Bader North America (Stow, Ohio, U.S.) showcases its leading range of structural
adhesives and advanced composites.
At CAMX 2022, the Scott Bader North American team discusses the company’s latest
innovations, including Crestabond and Crestomer structural adhesives, Crestafix bonding
pastes, Crestapol urethane acrylate resins and Crestamould tooling systems.
The Crestapol range of high-performance urethane acrylate resins feature the fire-
retardant (FR) properties of filled Crestapol resins and Crystic FR gelcoats. Crestapol
resins can reportedly be processed using open molding, infusion, RTM and pultrusion,
even with heavily aluminum trihydrate (ATH) filler (up to 200 phr). Scott Bader Inc.,
Booth M42, scottbader.com Source | Scott Bader

CAMX 2022
High-performance Custom press and

prepregs, resins automation
and adhesives solutions
Renegade Materials Corp. (a Wickert Hydraulic Presses USA
wholly owned subsidiary of (Hebron, Ky., U.S.) is a division
Teijin Holdings USA, Miamisburg, of Wickert Maschinenbau
Ohio, U.S.), promotes its high- GmbH, a family-owned
performance prepreg, RTM resin company founded in 1901 and
Source | Wickert Hydraulic
and adhesive products for use in based in Landau, Germany. The Presses USA
demanding aerospace applica- company is active in the development
tions. Renegade Materials offers and manufacture of custom hydraulic presses and fully automated press
polyimide, BMI, epoxy, cyanate systems. All machines and systems have a modular footprint for optimal
ester and hybrid systems. space savings and feature pressing forces of 2-10,000 metric tons. The
Renegade Materials’ poly- provided systems are used to process composites, elastomers, plastics
imides are reported to be next- and powder materials.
generation, non-carcinogenic Hydraulic composite presses for forming fiber-reinforced composites
Source | Renegade Materials
(non-MDA) formulations for are one of Wickert’s core products. Composites presses from Wickert are
prepreg, adhesive and RTM processes. These polyimide technologies available for various process technologies such as compression molding,
are extensively deployed in high-temperature engine and aerostructure thermoforming or injection molding, and can be provided as turnkey,
applications. Renegade developed its trademark RM-1100 polyimide fully automated systems, the company says.
prepregs — exhibiting optimized hot-wet properties and thermal oxida- Wickert says its high level of specialization is evident in two case
tive stability — for use in commercial and defense applications. studies. The first is an instance where a German research institute was
The company’s AFR-PE-4, RM-1100 and MVK-14 polyimide prepregs developing a test series of engine block carriers for the Volkswagen Golf
all find use in high-rate production applications alongside Renegade’s e. The company processed glass mat-reinforced thermoplastics that
polyimide paste and film adhesive complements. REACH-compliant required a rapid buildup of force; the mats, which are heated to 446°F
versions of all polyimides are available. Renegade Materials also offers in a preheating station, have to be processed immediately in the press
RTM-1100 and MVK-10 polyimide RTM resins used for molding complex at a minimum of 374°F. Wickert’s automated turnkey line featuring the
geometric parts that experience service termperatures of more than company’s WKP 2500 S Press served as a suitable solution.
600°F. Renegade’s polyimide products are safe alternatives to PMR-15, The four-column composite press with fully hydraulic closing system
titanium and toxic-insulating systems in primary structures for engines and active parallelism control offers a maximum deviation of 0.05
and airframes. mm during the pressing process, Wickert reports. It has a 59" × 79"
Renegade Materials’ BMI product line includes prepreg systems clamping plate and is characterized by its dynamic opening and closing
(RM-3002 and RM-3004), RTM resins (RM-3000 and RM-3010) and speed of 300 mm/s, a press speed of 10 mm/s and an opening force of
adhesives (RM-3011, RM-3006 and RM-3007). The company’s RM-3004 37 tons. Wickert explains that the press is notable not only for its high
OOA BMI prepreg system offers high strength and toughness, according speed, but also because of its high precision. The integration of a robot,
to the company. Renegade BMI products are qualified in major high-rate which handles the material from the furnace into the die, promotes a
production aerospace programs. smooth run of the production process.
In addition, Renegade Materials offers low-dielectric epoxy and The second case study that Wickert says highlights its experience
cyanate ester prepreg systems for radomes and low dielectric loss appli- involves the aerospace industry, which uses composite components,
cations. RM-2014-LDk-TK low-dielectric epoxy prepregs exhibit dielec- including 3D-shaped, thermoformed carbon fiber-reinforced polymer
tric properties nearly equivalent to traditional cyanate ester prepregs at (CFRP) clips. Important conditions for this application were the produc-
a lower cost and with OOA processability. RM-2014-LDk-TK prepreg is tion of a small quantity but a high variance of different product shapes,
said to be specially tailored for the satcom and nose radome markets. a necessary homogeneous preheating up to 806°F, a transfer time from
RM-5003 is a high-purity cyanate ester prepreg system developed the preheating oven into the mold of less than six seconds and consis-
to support demanding low dielectric constant and loss requirements tent data acquisition of parameters.
for radome applications. RM-5001 caters to low coefficient of thermal Wickert says it developed a fully automated production cell. This
expansion (CTE), and low moisture requirements of satellite and space cell houses a press with a magnetic mold clamping system, automatic
markets. Renegade Materials Corp., Booth X2, renegadematerials.com release agent spraying the mold and a distinctive press design to
compensate for eccentric loads. Additionally, there is a robot with
gripping system for product manipulation, and an additional robot for
mold manipulation and mold change. Wickert Hydraulic Presses USA,
Booth G1, wickert-usa.com
SHOW PREVIEW
Thermoset, thermo-
plastic composite
materials
With its Tenax carbon fibers and
composites, Teijin Carbon America
(Rockwood, Tenn., U.S.) offers solu-
Source | Saint-Gobain Vetrotex tions to the aerospace, automotive,
infrastructure industries and more.
Technical glass fiber textiles Tenax high-strength continuous
Vetrotex (Tlaxcala, Mexico) is a fiberglass manufacturer for technical filament fibers include a range of Source |Teijin Carbon America
textiles. The company operates globally with sales offices in Australia, the standard, intermediate (IM) and
Czech Republic, India, Japan, Korea, the U.S., France, China and Malaysia, high-modulus (HM) products and are available in tow sizes from 1K to 48K
with production facilities in Europe and North America. and suited for processes like prepregging, pultrusion, weaving, filament
The company’s aim is to serve its customers anywhere in the world winding and braiding. Tenax filament yarn is surface treated to improve
with its global presence while focusing on local service. Vetrotex strives fiber-to-resin interfacial bond strength, and fiber sizing is applied to
to be a true business partner to its customers in all aspects. Vetrotex protect the fiber and improve handling and wetout. A variety of available
says innovation is a major part of its constantly developing mindset, sizings make it fully compatible with thermoset matrix systems. Teijin says
encouraged across the company for the satisfaction of customers. its tailored thermoplastic sizing is compatible with thermoplastic matrix
With more than 80 years of experience in fiberglass manufacturing, systems like PEEK, PEI and PPS.
Vetrotex works in partnership with its customers, continuously investing Tenax short fibers, either milled or chopped, are designed to improve
in research and development (R&D) for improved technologies and properties in thermoset and thermoplastic applications. They come in
product solutions. It strives to offer a complete range of service and easy-to-handle bundle sizes and modifications that enable use in high-
products tailored and focused on customer needs. The company says temperature thermoplastics, and are available in a variety of sizes.
its clients enable it to position itself as a reputable provider of building, Pyromex is an oxidized PAN fiber (OPF) with non-flammable and
industrial and a wide spectrum of other applications requiring technical non-melting characteristics. Pyromex OPF is ideal for critical aerospace
textiles. applications thanks to its chemical purity and aerospace-grade production
Vetrotex’s parent company, Saint-Gobain, is a glass producer with standards. As a result, Teijin reports Pyromex is widely used in welding
more than 350 years of experience. With a large presence in the habitat blankets, fleece insulation and carbon/carbon brake applications.
and construction markets, it designs, manufactures and distributes Tenax ThermoPlastics, when combined with rapid production processes,
building materials and other industrial products, providing solutions reportedly enable fast processing, low scrap rates, good mechanical
to meet the growing demand for energy efficiency and environmental performance, chemical resistance and recyclability. Teijin offers three
protection. Because of this prestige, Vetrotex is able to use Saint- types of products: ThermoPlastics UniDirectional (TPUD), ThermoPlastics
Gobain’s vast resources to develop and manufacture distinctive glass Consolidated Laminate (TPCL) and ThermoPlastic Woven Fabric (TPWF).
fiber products. Vetrotex, Booth X56, vetrotextextiles.com Teijin Carbon America Inc., Booth X2, teijincarbon.com
Automated heat-sealing behind. This enables fully unattended cutting

module automation, the company notes, and once the seal
Zünd America’s (Oak Creek, Wis., U.S.) focus at this and cut operations are completed, the processed
year’s CAMX is on #LetsTalkWorkflow — industry- parts benefit from complete stability and ease of
specific workflow solutions that help make digital handling. Zünd contends that the HSM tool facili-
cutting processes simpler, faster and more produc- tates and drastically improves clean cutting and
tive. This involves the display of a new and improved handling of dry fiber materials with thermoplastic
method for cutting thermoplastic composites, the content, thus overcoming major, industry-wide
Heat-Sealing Module (HSM). challenges and enabling more widespread use of
HSM, developed for Zünd digital cutting systems, these materials.
aims to solve the challenge of processing ther- The HSM tool will be shown in operation on
Source | Zund America Inc.
moplastic composites— particularly their fraying a Zünd G3 cutter configuration in conjunction
properties, which lead to weak and irregular edges. When mounted on a with the Robot PortaTable 130, another new Zünd automation solution
Zünd digital cutter, the module uses hot air to heat-seal the perimeter of a that consists of a roller table (for easy changeovers to other Zünd cutting
part prior to cutting. Driven by a fully digitally controlled process, the Zünd systems) equipped with a collaborative robot (cobot) for fully automated
software directs the module over the composite material, sealing the fibers parts kitting and sorting. This solution, too, is designed to make processing
around the part edges. In a next step, the high-performance power rotary composite materials quicker, easier and more productive.
tool (PRT) cuts the material in full, without leaving uncut or loose fibers Zund America Inc., Booth G42, zund.com

CAMX 2022
Autoclave, infusion spray fabricated Robotic filament

reusable, sealing bags winding technology
SWORL Reusable Vacuum Bags (Hutto, Texas, U.S.) introduces its lightest Roth Composite Machinery
weight spray fabricated reusable vacuum bag and sealing mechanisms. (Hesse, Germany) showcases
SWORL bags are currently being used to reduce bagging labor by as much a variety of machines for the
as 78%, according to the production of large composite
company. At the same pressure vessels for commercial
time, they also help vehicles as well as for the
Source | Roth Composite Machinery
eliminate part rework transportation of hydrogen.
or part rejects which The company’s range of products and services include machines for
might have been caused wet and towpreg winding and their integration into fully automated
by consumable bag production lines for large-scale production as well as robotic filament
pinholes, bridging or winding machines for laboratory and small-scale applications.
blown bags. The FWA 1 Duplex filament winding machine is one new machine type
Fabricated in hours that is said to set new standards in mechanical engineering for the manu-
Source | SWORL
and ready for next-day facture of products using filament winding. The new process technology
use, SWORL bags enables winding from both sides of a spindle and thus halves the winding
can be used in autoclave or infusion processes against such materials times compared to standard machines. According to the company, the
as epoxy prepregs, vinyl esters, polyesters, urethanes, polyurea and new machine concept achieves twice the productivity of its current leading
thermoformed plastics. SWORL’s tear and tensile strength enables standard. An innovative frame design tames the dynamics of the acceler-
SWORL bags to produce hundreds of part cycles. SWORL says its sealing ated production process with an increased fiber delivery volume with ease.
mechanisms are suitable for both legacy and new tooling. Due to the The FWA 1 Duplexis available with three, four or five spindles. It is said
IP nature for some of its sealing processes, SWORL does not publish to be suitable for production processes in wet, dry and towpreg winding
this information on its website. SWORL Reusable Vacuum Bags, Cauls, procedures by using all common fiber types, including carbon or glass
Bladders, Booth R42 , sworl.net fibers. Roth Composite Machinery GmbH, Booth G47, roth-composite-
machinery.com
DELIVERING HIGH VALUE

COMPLEX COMPOSITES
CONVENTIONAL METHODS THE HAWTHORN
WITH PRE-PREG ADVANTAGE
LABOR $$$$$ $ - $$
FACILITIES $$$ $
CONSUMABLES $ - $$$ $ - $$
TOTAL COST $500 - $1000/lb $200 - $400/lb
LEARN MORE
www.HawthornComposites.com/Advantage
SHOW PREVIEW
Customizable composite curing ovens

Wisconsin Oven Corp. showcases its high-performance
composite curing ovens used for manufacturing composite
parts in a range of industries. Within the aerospace industry
this includes components such as wing structures, tails and
fuselages. For the consumer industry, emerging technologies
Source | Thermwood Corp.
Source | Wisconsin Oven Corp. continue to use composites for customer needs such as light-
weight bike frames, automobile parts, fishing rods, baseball bats and underground storage tanks. Large-scale additive manu-
The company’s composite curing ovens are available as gas fired and indirect gas fired or electri- facturing demonstrations
cally heated. They are designed to meet customers’ specific process requirements. Options commonly Thermwood (Dale, Ind., U.S.) prints live
used for composite curing ovens include data acquisition systems equipment and vacuum systems. on an LSAM Additive Printer 510 at CAMX
Wisconsin Oven’s composite curing ovens are said to offer the following advantages: 2022. LSAM Research Laboratory at Purdue
• Quicker heating rates and recovery times: Each oven features a high-pressure recirculation ADDITIVE3D Software is on display as well, with
blower, with fully enclosed and pressurized supply ducts. The equipment is designed for combi- Purdue University representatives on site for
nation airflow arrangement which ensures fast and uniform heat distribution throughout the demonstrations.
work chamber, even with varying loads. Thermwood is printing Airtech (Huntington
• Consistent temperature certification: Composite curing ovens are typically guaranteed and Beach, Calif., U.S.) materials modified for use
certified for ±10° at 350°F temperature uniformity. Tighter tolerances and certification at other in composite tooling for large-format additive
temperatures are available. Equipment is completely tested prior to shipment and must pass an manufacturing (LFAM). It also has several
extensive quality inspection prior to shipment. customer-created, large-scale tools from General
• Reduced maintenance: Heavy-duty construction, brand-name components and quality workman- Atomics (San Diego, Calif., U.S.), Airtech and
ship, make this the workhorse for facilities, according to the company. Equipment is backed by Ascent Aerospace (Macomb Township, Mich.,
Wisconsin Oven’s three-year heat and recirculation warranty. U.S.) on display.
• IoT (Internet of Things) system availability: Data-Sense predictive maintenance technology LSAM Additive Printers systems are single-
remotely monitors the performance and health of equipment, preventing unexpected downtime gantry, moving table configurations with two
and increasing equipment performance. Wisconsin Oven Corp., Booth N35, wisoven.com available table sizes, 5' × 5' and 5' × 10'. The 5
x 10' table is available in two configurations, 5'
wide with 10' of front-to-back motion, and 10'
wide with 5' of front-to-back motion. Choice
of configuration depends on several factors
including fitting on existing factory floor space.
The highly rigid tab and slot, structural steel
gantry also incorporates a fume extraction
system that pulls print fumes through specially
designed activated charcoal filters to remove
them and “sweeten” the air, according to the
company.
Thermwood reports LSAM Additive Printers
use the same print head mechanism as all the
others, including the largest LSAM Systems, and,
therefore, produce the same notable print quality
that has distinguished LSAM in large-scale
additive printing. The printers also use the same
Ultra 6 control with patented print features and
capability.
The systems come standard with a single-
hopper polymer dryer for applications that don’t
change print material very often. For installa-
tions that print a wider variety of materials, a
dual-hopper dryer is available as an option. An
enclosure that surrounds the machine is also
available. A machine with the full enclosure can
also be built to meet European CE standards.
Thermwood Corp., Booth W2, thermwood.com

INSIDE MANUFACTURING
Curved
calligraphy
panels, double
helix stairs
AFI supplied 7,700 square
meters of complex-curved,
glass fiber/epoxy panels
for the wall, ceiling and
spiral staircase cladding in
the Museum of the Future’s
lobby.
Source (all images) | Advanced
Fiberglass Industries
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.
By Ginger Gardiner / Senior Technical Editor
»The Museum of the Future (MOTF, Dubai, United Arab which extends up to the seventh floor. All told, the museum’s interior
Emirates) is one of the most complex and challenging projects in consumes a total of , square meters of composites.
modern architecture. Opened in February 2022, it is described as AFI also supplied  oval light structures for the parking decks.
“the most beautiful building in the world” by His Highness Sheikh Like the exterior cladding, the interior panels feature Arabic callig-
Mohammed bin Rashid Al Maktoum, who conceived the museum raphy cutouts with inset LED lighting and also integrate sound
as an incubator for innovation and invention. dampening. They also are certified for fire resistance (FR) per ASTM
The museum features seven floors, each dedicated to a E- class A and EN  regulations — a challenge in itself.
different exhibition space, as well as ongoing research and devel- Key elements in overcoming these challenges include the use of
opment (R&D) — for example, in sustainability, data science, Sicomin (Châteauneuf-les-Martigues, France) FR epoxy, Adapa’s
health and well-being, bioengineering and other technologies (Aalborg, Denmark) reusable, adaptive mold system (Learn More)
that are not yet fully conceptualized. and AFI’s long history of developing innovative, cost-effective
CW wrote about the museum’s multifunctional exterior in composite solutions for demanding projects.
 (see Learn More), but its interior lobby is also iconic and
enabled by composites. DailyArt Magazine describes entering Innovation in GFRP
the spacious and impressive lobby as “an adventure.” This unique Specializing in design and construction of composite components,
experience is made possible by Dubai-based Advanced Fiber- AFI was established in Dubai in 1997 and has two production facili-
glass Industries (AFI), which was tasked with construction of ties of 55,000 and 15,000 square feet. “We can build to any specs
the complete lobby façade, including the calligraphy-embedded and design requirements,” says Majid Akram Chaudhry, general
ceiling and walls and cladding for its three spiral staircases, one of manager of AFI. The company’s facilities feature a climate-controlled

Museum of the Future lobby
NEWS
FIG. 1 Two surfaces, 228 unique panels

The panel thickness varies with height in the lobby, from 10 millimeters in
GFRP A
Zone 1 to 250 millimeters in Zone 4. AFI created this thickness using an A
surface
surface laminated onto the Adapa mold. This was followed with expanded
polystyrene (EPS) foam supports that were CNC-cut to the thickness
required as well as the shape, but undersized to provide a 110-millimeter-
wide “cove” for LED lights. The B surface was then laminated, providing LED light cove
the panel rear surface for attaching to the building’s structure. (110 mm wide)
EPS foam underneath

(10-250 mm thick)
Front side of
CAD model of MOTF GFRP B surface
lobby facade
cleanroom, curing oven, paint booth, a CNC three-axis router and almost no shrinkage, making construction and installation of these
a KUKA (Augsburg, Germany) CNC seven-axis milling robot. The complex panels easier. However, the budget for the project was
company primarily manufactures with hand layup and vacuum based on much cheaper resins.” The increased cost was indeed an
bagging, but also has developed these techniques for use with the issue, admits Chaudhry, “but the epoxy also would enable cutting
Adapa mold system, discussed below. the weight of the panels by half. We also had ideas about how to
AFI’s operations are segmented into three specialties: military, save costs during manufacturing [see “Adaptive molds” p. 44]. So,
automotive and architecture. Its innovation comes from decades we proposed this new epoxy-based design to Killa Design, and they
of devising solutions for a range of composite components. For approved the change.” Killa Design is the local architecture studio
example, it has manufactured more than , glass fiber-rein- in Dubai responsible for the MOTF design, including oversight of
forced polymer (GFRP) hoods for Dubai-based NIMR Automo- construction details.
tive. “This is a -square-meter bonnet, which is bigger than that AFI applied two Sicomin epoxy systems, both using intumescent
for a Hummer,” says Chaudhry. “We work with NIMR to design technology as well as FR additives, though not based on aluminum
products such as fenders, dashboards and consoles for military trihydroxide. “The technology that we used allows much higher FR
vehicles.” AFI has also designed and built body panels, doors, content and performance in order to meet the requirements of the
dashboards, fenders and bumpers for concept and small-series ASTM E- and EN regulations demanded by this project,”
production cars, trucks and recreational vehicles. explains Denjean. “The main fire resistance was achieved by using
In architecture, AFI has built the -meter-diameter sphere SGi  bio-based FR epoxy gel coat. The second tier of protection
atop the -story Ministry of Foreign Affairs building in Ashgabat, was SR  FR hand-laminating resin, which has a low viscosity of
Turkmenistan, and , square meters of panels for the  millipoise at °C — about half that of a conventional FR epoxy
-meter-high dome for the Center of Islamic Civilization in hand lamination resin.”
Tashkent, Uzbekistan. AFI has also constructed curved restau- AFI used this system with a laminating machine to wet out
rant interiors and spiral staircases, as well as unique structures -gsm glass fiber quadraxial fabric from Metyx Composites
such as the crushed granite gel-coated Evolutes sculpture by (Istanbul, Turkey) that was then applied to the Adapa molding
Karim Rashid, showcased in the Armani suite of the renowned system using a small team of laminators. For Sicomin, one chal-
Burj Khalifa hotel in Dubai (see p.  Post Cure column in CW’s lenge was to modify the epoxy hardener formulation to be slow-
February  issue). reacting for making such large panels.
“The laminators needed sufficient pot life before gelling, but then
Redesign with FR epoxy sometimes, the laminators needed to go faster for smaller panels,”
The original design for the MOTF interiors specified use of an FR notes Denjean. “So, we had to make a fast and a slow hardener for
vinyl ester resin, explains Chaudhry, “but that was too heavy.” the laminating resin and then also be able to mix these for an inter-
Marc Denjean, export manager for Sicomin, had met AFI during mediate gel time, in order to accommodate AFI’s production needs.
an architecture and construction show in Dubai. “We introduced We customized this for them, and it took some months to set up,
the idea of using an FR epoxy resin,” he says, “which also offers because we had to test these different systems, qualify them and
1 CNC-cut foam placeholders were laid onto the curved Adapa mold to 3 CNC-cut EPS foam supports were bonded onto the cured A surface
produce the panel’s A surface that visitors see. laminate and coated with a light GFRP laminate.
Silicone
beam
Custom
bracket
PVC connects
foam beams
edge
GFRP
Wood stapled to embedded
PVC provides extra into silicone
grip/stability beams
2 Close-up of the system used to mold flanges on all four panel edges. 4 The final B surface laminate was applied on day three and room-temp
cured, followed by a final heated post-cure.
fire-test them. After this was completed, however, production ran Affordability via adaptive molds
very quickly.” The project used roughly  metric tonnes of resin, Because the cost of the panels using epoxy was so much greater
which Sicomin delivered in six months. than the original budget, the team at AFI needed a very efficient
“It’s a minimum -millimeter-thick laminate all over the lobby method to fabricate the 228 interior wall panels. Each panel was
because that was the criteria for the Class A fire rating certifica- unique due to the complex curved surfaces of the lobby’s walls
tion,” explains Chaudhry. and ceiling. “We had seen the Adapa mold system being used to
Denjean notes that fire resistance testing is always a big chal- produce glass fiber-reinforced concrete [GRC] panels for the Kuwait
lenge because requirements such as ASTM E- and EN are International Airport project,” says Chaudhry. “We got in touch with
so difficult to meet. “At Sicomin, we make our own test panels for the founder of Adapa, Christian Raun, and he came to Dubai to
the materials testing in fire test labs,” he says. “But our customers discuss our idea to use his system for molding the GFRP panels for
must build test parts just as they would for the project and also in the museum lobby.”
the factory where the actual parts will be produced. They then must Adapa’s adaptive mold system is based on multipoint forming,
get passing results on three consecutive tests.” Sicomin and Metyx a technology that basically works like the plastic toy that forms the
provided assistance to AFI throughout fire testing. The panels that shape of your hand when you press into its myriad pins. Instead
AFI prepared were tested at Thomas Bell-Wright Construction of plastic pins, Adapa uses a bed of actuated metal cylinders, each
Testing Laboratory in Dubai and passed all FR requirements. topped with a powerful magnet and controlled digitally using

Museum of the Future lobby
NEWS
6 Finished panels were bolted to each other and to the steel brackets
attached to the building structure.
5 Completed panels — with finished A surface (top) and B surface (bottom)

— were demolded and shipped to the MOTF site for installation.
sophisticated D software. For composites, molding takes place

on a surface membrane that integrates a ferromagnetic layer as
well as a silicone membrane. This provides a smooth interpola-
tion between the cylinder points, and a vacuum-tight surface for
molding at temperatures up to °C. The Adapa software uses
the part’s CAD file to create the production files for how the pins
should be actuated to produce the mold surface of the part. Once
these production files are transferred to the mold system, the
operator pushes a button and the actuated pins are raised and
lowered to form the D curved surface in roughly three minutes.
Thus, reconfiguring the mold between panels is fast and rela-
tively easy. Once a panel is cured, the mold can be flattened to 7 Panel joints (clearly visible here) were filled with FR epoxy adhesive,
overlaminated and ground smooth before the final coat of paint was
help demold the panel.
applied and LED lights were installed.
For AFI, this was revolutionary. Instead of building 
separate molds — which would have required CNC machining a
foam plug and then laminating the mold from that plug for each
panel — AFI would use three D .- x .-meter reconfigu- The silicone barriers — which appear as white beams in Step 
rable Adapa molds. This approach not only enabled massive cost (p. ) — were held in place by eight to nine metallic L-brackets
savings, but also eliminated the need for large amounts of space via the magnets under the molding surface. For thicker panels
for mold storage and panel production. AFI was able to mold (in Zones  and , explained below), explains Pullur, “we used a
all of the panels in a production room of less than  square -millimeter-thick PVC foam core [green color] as an extension
meters. AFI was also the first company to use the Adapa system for because the silicone barrier height was insufficient to create the
molding GFRP panels in the Middle East (Learn More). flanges needed. Due to this PVC core’s taller height, we inserted
“We did make some customizations,” says Sooraj Pullur, AFI’s some rectangular pieces of GFRP into the silicone barriers to
head of engineering. “This included extra [actuator] rods so that serve as a guide.” The latter can be seen in Step  (p. ), behind
we could avoid some minor waves that were occurring with our thin pieces of wood stapled to the PVC core to provide extra grip/
GFRP panels versus how it was designed for GRC — basically stability for this connection.
smoothing out the gaps between actuators. And we added more
magnets under the molding surface to solve some issues that we Challenging calligraphy
had with the silicone membrane rising during vacuum molding.” The calligraphy on the MOTF’s interior lobby is an integral part of
Additional actuators for higher resolution and stronger magnets its design, declaring His Highness Sheikh Mohammed’s vision and
for vacuum forming/molding are now standard within Adapa’s posing a challenge to all people everywhere: “We might not live
product family for composites. “The team also had to devise a for hundreds of years, but the products of our creativity can leave a
release agent system that worked with both the epoxy resin and legacy long after we are gone. The future belongs to those who can
the silicone membrane molding surface,” adds Denjean, “but the imagine it, design it and execute it. The future does not wait. The
Adapa system was robust and easy to use.” It also allowed AFI to future can be designed and built today.”
use epoxy resin and still meet the project’s budget. For AFI, these words posed a key challenge during design and
“We also worked with Adapa to develop silicone barriers for construction of the interior’s composite panels. “These Arabic
making the flanges on all four edges of each panel,” explains letters had to be very precise, including the dots [called diacritical
Pullur. These flanges were used to attach the panels to each other marks] and nothing could be changed,” explains Chaudhry, “with a
and were key to maintaining joint accuracy during installation. maximum tolerance of  to  millimeters.”
Complete Ultrasonic Systems IntegraƟon

For Your High-performance Materials
• New construction and system upgrades

System Design, Fabrication, Installation, • Multi-axis immersion tanks and gantries
Start-up, Testing, Commissioning • C-scan and full waveform compatible
• Conventional and phased array inspection
Matec Instrument Companies, Inc. | Northborough, MA | 1-508-393-0155 | sales@matec.com | matec.com

BEYOND EXTREME
PUSHING THE LIMITS OF PERFORMANCE
Innovations That Take The Heat
As the global leader in high temperature composite materials, Renegade
Materials Corporation develops prepregs, adhesives, resins and hybrid
composite systems that enable production of high temperature
performance aerospace components.
Polyimides, Bismaleimides, Epoxies, Cyanate Esters, and Hybrids
Contact Renegade to advance your project to the next level.
RENEGADEMATERIALS.COM
Anaheim, CA | OCTOBER 17-20, 2022

Visit us at Booth X2
The depth of the letters also changed with the height of the of expanded polystyrene (EPS) foam were used as placeholders and
lobby, to remain legible to visitors, even as the walls and ceiling later removed.
extend further away. AFI divided this height and letter depth into After the A surface was laminated, a second set of CNC-cut EPS
four zones. Zone  is up to . meters high, where the depth of the foam was bonded to it, providing the structure between the callig-
calligraphy letters is only  millimeters. That depth increases to raphy cutouts and the required panel thickness for each zone. The B
 millimeters in Zone , to  millimeters in Zone  and to  surface was then laminated across these EPS foam supports, which
millimeters in Zone . “From Zone  onwards, LED lights would were undersized from the A surface laminate to create a -milli-
be installed into the curves of the letters,” notes Pullur. “So, there meter-wide “cove” in which to install the LED lights. After the panels
had to be a cavity to install these, and we also had to incorporate were demolded, acoustic insulation was then installed (by a different
acoustic insulation to prevent echoing in the lobby, but without contractor) in the recesses created for the calligraphy letters.
affecting the smooth, curved design.” Pullur describes the manufacturing steps: “We used our CNC
AFI’s concept was to use two surfaces. The A surface would face machines to cut the foam placeholders and panel supports as per
out toward the building’s visitors and form the curvature of the the CAD model. On the first day, we used Adapa’s software to shape
lobby, while the B surface would attach to the building’s internal the mold surface, laid the foam placeholders and applied the FR
structure. The A surface was formed by a gel-coated GRFP skin gel coat. The lamination was then made in three stages. On the first
laid onto the silicone surface of a curved Adapa mold, but was day, we laminated the A surface. On the second day, we bonded the
omitted in certain areas to form a kind of negative space to repre- CNC-cut foam supports onto the A surface layer and then applied
sent the “cutout” calligraphy letters. In these areas, CNC-cut pieces a light laminate on top. On the last day, we applied the B surface
SIDEBAR
Spiral staircase cladding
Thanks to its performance on the lobby’s interior

cladding, AFI was also awarded the job of
cladding three spiral staircases in the lobby. One
spanned the full seven levels of the building. The
other two were intertwined in a DNA-like shape,
one terminating at the second floor and the other
reaching to the third floor. All three staircases
use a load-carrying spine made from steel (white
structure in Step 7, p. 45) while the stair treads
and risers were finished with traditional flooring
materials. Composites provide cladding for the LED
steel structure and form the inner banister for the light
double-helix staircases, as well as a seat for the Glass
glass panel outer banister for all three stairways. panel
Although this cladding was similar to that for
the walls and ceiling — comprising multiple panels
and made with the same materials — it was not
made using the Adapa system.
“These panels were made with traditional molds,” says Chaudhry. “We CNC milled plugs using our seven-axis
KUKA robotic system and then laminated the molds. We then molded the panels and joined them on site at
the museum. We used two sets of molds in the two DNA spirals because each had a different pitch and radius. FIG. 2 Multiple parts per
mold set
Each set of molds produced five panels [Fig. 2]. We used 10 molds in total and made 56 cladding panels. We
altered the length as necessary to cover the steel and fit the path.” AFI minimized the molds required to clad the
For the seven-story stairs, AFI again used two sets of molds to achieve the A and B curvature (Fig. 2). The twin “DNA” stairs and the seven-story staircase
parts from each mold set complete the repeated spiral and totaled 300 panels. beside the lobby’s elevators. For the DNA
stairs (left), AFI used two sets of molds, each
AFI ensured all the cladding panels would cover the steel structure by using a scanned 3D model of the
producing five parts that provide cladding
steel spines. “We then modeled all of the panels,” says Pullur. “The steel forms the curvature of the stairs, and
for the steel spine and form the LED-lit inner
we redesigned the staircase model to enable the same curvature, so that we would not have to make more banister as well as a seat for the glass panel
molds.” outer banister. For the seven-story stairs
Chaudhry adds that this approach worked well, allowing AFI to again save money. “We did not want to (right), AFI used one set of molds each for the
make a separate mold for each panel because that would have added too much cost. We were able to design “A” and “B” curvatures to create 300 panels
the panels to repeat, with that slight modification on the model, so that we kept the molds to a minimum.” total.

Museum of the FutureNEWS
lobby
laminate.” The epoxy resin was room-temperature cured overnight after each lami-
nation, and then heaters were used to apply a final post-cure. AFI’s humidity- and
temperature-controlled laminating room was well-organized for this panel production,
which was completed in  months.
“There was some trial and error to find the right methodology for the least time and
cost,” says Chaudhry. “It was basically one month of R&D with a lot of brainstorming.
But it allowed us to meet the design and budget requirements and win the job after
competing with several other competitors from around the world.” All of the panels
were manufactured at AFI’s production
facility and then transported to the MOTF
site for installation.
Read this article online |
“Installation was also a challenge,” says
short.compositesworld.
com/MOTFinterior AFI installation manager, Patrik Gajdosik.
Read about this museum’s “We wanted each and every joint between
composite exterior facade| panels to be seamless, so we came up with
short.compositesworld.com/MOTF an idea to form a small V section so there
See CW’s video of the Adapa system and would be no hairline joints visible. First,
Adapa’s image gallery |
we installed steel brackets to the build-
short.compositesworld.com/Adapavid and
short.compositesworld.com/Adapaimages ing’s wall and ceiling structure, and then
attached the panels to each other and to the
bracket system. Next, we filled the V gaps
using fire-retardant epoxy adhesive and overlaminated them, followed by grinding the
panel surface smooth and final painting. The lobby panels had to have a white matte
finish and a tolerance of only a few millimeters over a ,-square-meter surface.” AFI
achieved this — a D scan of the completed interior lobby showed the surface main-
tained a tolerance of ± millimeters. “When you go into the lobby now,” notes Gajdosik,
“it looks like one continuous structure.”
Greatest challenge, future growth

The schedule for AFI’s work on the MOTF lobby was initially planned for 18 months,
says Chaudhry, “but it was extended due to COVID and ended up at almost three years.”
Although the whole project was challenging, there were definitely aspects that stood out
for AFI. “The calligraphy itself was something that many people said wouldn’t be done
out of GFRP but would instead be some other material,” he notes. “That indeed was a
challenge, and especially to achieve it with cost efficiency. But it has all passed Killa
Design’s inspection and satisfied all finish and quality requirements. The final result
is a testament to what composites can do. However, I would say it wouldn’t have been
possible without the Adapa molding system, because if it had to be done traditionally,
the cost would have been more than doubled.”
“To me, it was a great project because of how AFI managed it,” says Denjean.
He notes this was the first project for Sicomin’s low-viscosity FR laminating resin,
“but now we have sold it into other projects in Dubai and Saudi Arabia, including a
,-square-meter project in Mecca. “We see continued growth for composites in
architecture in this region,” he adds.
Chaudhry agrees. “We never say no to a challenge,” he says. “We turn problems into
feasible solutions.”
CW senior technical editor Ginger Gardiner has an engineering/

materials background and more than 20 years of experience in the composites
industry. ginger@compositesworld.com
Thermoplastic
composites welding
advances for more
sustainable airframes
Multiple demonstrators help
various welding technologies
approach TRL 6 in the quest for
lighter weight, lower cost.
By Ginger Gardiner / Senior Technical Editor
Welded stringers in
»Thermoplastic composites welding has lower half of MFFD
the potential to significantly improve the GKN Fokker conduction welds CF/
sustainability of commercial aircraft produc- LMPAEK stringers to the skin of the
tion. According to Tier 1 airframer Collins Multifunctional Fuselage Demonstrator
Aerospace (Charlotte, N.C., U.S.), more auto- (MFFD) lower half being assembled
mated, out-of-autoclave (OOA), weldable at SAM|XL as part of Clean Sky 2’s
STUNNING project. The 2.5-ton, induc-
thermoplastic structures have the potential tion heated, 1-meter-long conduction
to reduce manufacturing cycle time by up welding tool is housed within a rack and
to 80% and weight by up to 50% compared pinion-equipped hoisting fixture that
to previous metal and thermoset composite positions the welder over each stringer
assemblies. These previous assemblies use using the notches in the circumference
of the fuselage shell tool.
drilling and mechanical fasteners, requiring
Source | GKN Fokker, SAM|XL
up to nine manufacturing steps. “We believe
that for a new, A320-type single-aisle
aircraft in five to eight years, thermoplastic composites will be a were originally developed and produced by Fokker Aerostructures
game-changer, not only to enable higher production rates but also (Hoogeveen), now part of Tier  airframer GKN Aerospace. For
best cost and weight,” says Cedric Eloy, deputy chief CTO, Tier 1 these structures, GKN Fokker uses KVE Composites’ (The Hague,
airframer Daher Aerospace (Paris, France). Netherlands) patented induction welding process. Induction,
Thermoplastic composite structures have been certified conduction and resistance welding are all defined and discussed
and flying for decades. These include resistance-welded main in CW’s  feature article on thermoplastic composites welding
landing gear doors on the Fokker  in , j-nose leading edge (see Learn More).
wing structures on the Airbus A and A in  and , There have been numerous welding developments since 
respectively, and induction-welded carbon fiber (CF)/polyphen- (see “Composites welding developments” sidebar, right), including
ylene sulfide (PPS) elevators and rudder on the Gulfstream G a move toward low-melt polyaryletherketone (LMPAEK)-based
business jet in . “There are more than  G aircraft flying,” composites for potential lower temperature processing versus
notes Arnt Offringa, director of the GKN Aerospace (Solihull, U.K.) polyetherketoneketone (PEKK) and polyetheretherketone (PEEK),
Global Technology Centre Netherlands (GTC-NL, Hoogeveen). continued advancements in automation and simulation and an
“Gulfstream now has seven aircraft models using welded ther- increase in the size and complexity of demonstrators. Welding has
moplastic control surfaces, with production continuing, so it’s also become more common. Most Tier  airframers have significant
become an established manufacturing method.” Offringa was a key welding R&D or established capabilities, many with technology
champion in the induction-welded structures listed above, which readiness levels (TRL) approaching -. And even though welded

Thermoplastic composites NEWS
welding
Composite welding developments

2019 Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) 2021 Airbus Atlantic (includes Nantes,
program switches its baseline unidirectional (UD) carbon fiber tape Montoir de Bretagne and previous STELIA
material from Toray Advanced sites) demonstrates 6-square-meter
Composites (Nijverdal, Netherlands) thermoplastic composite fuselage section
Cetex TC1320 with PEKK to TC1225 with induction-welded stringers using IS Groupe’s Source |
with Victrex (Lancashire, U.K.) LM and Arkema’s patented ISW process in the CORAC-funded ECHOS project. IS Groupe
PAEK, which potentially offers a

lower melt temperature plus faster 2021 As part of the LuFoV-3 TB-Rumpf Source | DLR CC
BY-NC-ND 3.0
Source | Clean
processing and lower cost. Aviation project, the German Aerospace Center
(DLR) Institute of Structures and Design
2019 Clean Sky 2 STUNNING (Stuttgart) and Airbus demonstrate an
project led by GKN Fokker integrated fuselage intersection comprising an OOA
to fabricate the MFFD lower vacuum-consolidated skin/stringer curved panel with resistance-
fuselage half launches the welded frames and cleats, all made using CF/PAEK UD tape.
MECATESTERS subprogram
Source | KVE Composites
(30 months), in which KVE 2021 Qarbon Aerospace (Red Oak, Texas, U.S.)
Composites and Rescoll (Pessac, France) will basically qualify CF/ used a patented, susceptor-less induction welding
LMPAEK unitape. process for its wing box demonstrator, with SLS
strengths of 45-47 MPa — reportedly 30-40% Source |
Qarbon Aerospace
2019 Induction-welded higher than industry standard co-cured joints with
ruddervators supplied by GKN mechanical fasteners — and a weld speed of 0.75 meter/minute.
Aerospace are tested as V-tail
control surfaces on the Bell 2022 KVE Composites and Daher demonstrate a
V-280 Valor tiltrotor. Source | Bell 600- x 600-millimeter, curved torsion box with
tapered-ply skins featuring seven welds (red)
2019 Clean Sky 2 KEELBEMAN using KVE’s patented induction welding process. Source | KVE Composites, Daher
project concludes with a 0.25- x KVE has demonstrated 4-meter-long welds of up to 15-millimeter-thick
0.5- x 1-meter-long keel beam laminates, SLS strength of 30-48 MPa and a speed of 1 meter/minute for
section demonstrator including fabric CF/PPS and 0.20 meter/minute for UD CF/PAEK.
stringers for an A320-type
Source | Clean Aviation, CETMA aircraft, made by CETMA from 2022 DLR Institute of Structures and Design
CF/PEKK tape using its patented induction welding process. (Augsburg, Germany) completes a test shell for
the MFFD upper fuselage half, using continuous
2020 Clean Sky 2 launches DEWTE- ultrasonic welding to attach stringers and resistance
COMP project with Tier 1 airframer welding to join C-frames to the skin.
Aernnova Aerospace and CETMA
to develop an automated induction Source | DLR CC BY-NC-ND 3.0
welding system for an integrated door
surround structure (DSS) with gussets, 2022 Collins Aerospace announces it will demonstrate a full-scale
wedges and fittings using CF/LMPAEK thermoplastic composite engine fan cowl with curved frame welded to skin
for the lower half of the MFFD. by year end.
Source | Clean Aviation, CETMA
structures have been certified since , there is debate in the U.S. (UD) tapes — versus the previous parts made with fabric — certi-
that certification of future welded structures should follow what’s fied and flying by .
been established for bonded structures. This is likely because
welding in the U.S. is not as mature as it is in Europe and details of MFFD lower half
previous certifications are not widely known. In any case, a good The most significant thermoplastic composites welding project
thermoplastic composite weld should show homogeneous material in progress is the Airbus-led Multifunctional Fuselage Demon-
through the thickness with no identifiable interface. In this way, strator (MFFD) project, funded by Clean Aviation (formerly Clean
welded structures are not at all like bonded structures. Sky 2). At 4 meters in diameter and 8 meters long, this A320-type
In Europe, emphasis is on advancing process control and fuselage section will be the world’s largest thermoplastic compos-
nondestructive testing (NDT) already used during production ites structure, once the upper and lower halves are welded
of certified structures, on demonstrating multiple welding tech- together. This assembly will be completed by Fraunhofer IFAM
niques via fabrication and testing of ever larger demonstrators, (Stade, Germany) before the assembled barrel is delivered to
and on having the first welded structures made with unidirectional Airbus (Hamburg, Germany) in 2023. Production of the lower half
FEATURE
is led by GKN Fokker in the STUNNING project, while the upper time, with a slight overlap of - centimeters, and then completes
half is managed by the DLR Center for Lightweight Production the second side. Two L-stringers were also welded to receive the
Technology (ZLP), which is part of the DLR Institute of Structure cabin floor (Fig. , opposite).
and Design in Augsburg, Germany. Components for both halves “Next, clips will be placed over these stringers and joined to the
have been made using Toray Advanced Composites TC1225 CF/ stringers and skin using spot ultrasonic welding,” says Van Rijswijk.
LMPAEK unitape. The MFFD project began in 2014 and aims to Although the dedicated ultrasonic welder used for this opera-
enable production of 70-100 fuselage shipsets per month, reduce tion has the same type of sonotrode as the tack welder (Fig. , p.
fuselage weight by 10% (1,000 kilograms) and reduce fuselage ), it is configured differently for this high-strength weld versus
costs by 20% (€1 million). tack welding. Later on, frames will be connected into the fuselage
The lower half is being assembled at SAM|XL (Delft, Neth- through these clips using the same ultrasonic spot-welding tech-
erlands) with planned delivery to Airbus by October . The nique, says Bram Jongbloed, materials and process engineer at
SAM|XL facility has multiple robotic arms and one large gantry- SAM|XL. “To make joints perpendicular to the skin, we have a
based robot for welding. As described in Fig.  (p. ), the first step second welder turned at  degrees,” he adds. This welder will
was to conduction weld omega stringers onto the curved fuselage press and weld the flat web of the frames to the omega-shaped flat
skin (Learn More). “The gantry robot end effector is equipped plate of the clips (Fig. ).
with suction cups to precisely place the stringers onto the skin,” “We have about  clips to join with ultrasonic welding, and
says Kjelt van Rijswijk, CEO of SAM|XL. “It is also equipped with then the frames,” says Muijs. “After that, we will install the floor
an ultrasonic spot welder to tack the stringers in place.” grid, equipped with composite floor beams, metal seat rails and
GKN Fokker then welded the stringers with a -meter-long other systems. We will conduction weld where the floor beams
conduction welding tool. The metal tool is induction heated and meet the frames and also below, where the support struts meet the
this immediate, even heating is conducted through the stringer’s frames [Fig. ].”
foot laminate to melt the matrix at the stringer-skin weld inter- He notes lessons already learned with conduction welding in
face. “The tool includes a heat sink that controls temperature on STUNNING: “Welding the stringers took much longer than we
the stringer surface,” explains Leo Muijs, chief technologist at GKN expected and also resulted in some shape changes in the skin. This
Fokker. “It applies pressure and then completes the welding cycle.” is not something we have seen in previous conduction-welded
He notes that these omega stringers have a foot to be welded on demonstrators. So, we are studying that now. There are also some
both sides. The weld tool moves down one side, one meter at a joggles [changes in thickness] in the stringers that we cannot go

Thermoplastic composites welding
NEWS
over well. The flat welding tool can deal with a certain slope, for FIG. 1 Multiple welding technologies demonstrated
example a : ply dropoff [e.g., one .-millimeter-thick ply The welding steps for fabricating the upper and lower halves of the 4- x 8-meter-
dropped every  millimeters] causes no problems, but we cannot long MFFD fuselage are shown here, along with project leaders and partners.
weld a dropoff of :.” There is also an issue of length. “Our Lower half welds of floor grid to frames are shown as white hatched rectangles at
lower right. Completed halves will be shipped to Airbus Hamburg to be welded
smallest welding tool is roughly half a meter long, which is too
together in 2023.
long to weld a -centimeter stiffener, for example,” he says. Other
Source | Clean Aviation, DLR CC BY-NC-ND 3.0, GKN Aerospace, SAM|XL, compiled by CW
welding methods could be used for these short stringers, says
Muijs, “but they were not specified for this demonstrator, which is
our current task. So, now we document these issues and include welding, one of the major lessons we learned is to avoid ply
it in our final report to Airbus. When we make future designs, endings or runouts beneath the stringer feet,” says Fischer. “These
we can create guidelines for conduction welding that help, and ply drops within the skin affect the weld quality.”
we are already working on different end effectors to solve these Michael Kupke, vice director, Institute of Structures and Design
issues. The whole goal of this demonstrator is to find these chal- and head of department at ZLP, explains: “In continuous ultra-
lenges and advance the technology to address them.” sonic welding, heat is generated when there is damping of the
ultrasonic waves. Stiffer materials transmit the waves, while softer
MFFD upper half materials increase damping. A soft layer of unreinforced polymer
DLR expects to deliver the upper half of the MFFD in early 2023. — the same matrix as in the composite surfaces being welded
It, too, has amassed lessons learned, starting in July 2021 with — is placed at the weld interface to control the energy during
production of a 1-meter-long full-scale test shell to verify its tech- welding. This is called an energy director.” So, just as the amount
nology bricks, including continuous and spot ultrasonic welding of fiber changes stiffness and damping, which affects the weld,
and resistance welding (Learn More). “We used continuous ultra- so do changes in laminate thickness. “We have to understand the
sonic welding for the Z-stringers and resistance welding for the effect of such changes in the surfaces being welded and address
frames,” explains Frederic Fischer, technical lead for thermoplastic this in the process,” says Kupke.
composites production at the ZLP. “We had six frames for this “We will have different sets of parameters for thicker skins and
test shell. We welded the first three and then went into a lessons- thinner skins,” adds Fischer. “And this is the case also for joggles
learned session and did a bit of rebuilding and redesign of the in stringers to match buildups and dropoffs in the fuselage skin.
welding bridge. And then we finished the last three. This test shell We’re adapting the welding process parameters to the layup and
allowed us to test the process parameters and setup of the welding geometry of the parts being welded. We verified that we can weld
elements, study the results and finalize what we are using for the stringers to shallow ramps with a : ratio.”
final 8-meter upper shell, which we started last April.” Another lesson was learned during resistance welding of the
What had to be changed? “With the continuous ultrasonic frames. “We saw that the in-situ consolidated tape skin had a
FEATURE
FIG. 2 Welded stringers and clips in STUNNING

The gantry robot at SAM|XL uses an end effector with suction cups and a sonotrode
(dashed red circle, left) to precisely place omega stringers and tack weld them to
the skin. After the stringers are conduction welded onto the fuselage skin, a second
ultrasonic welding tool is used to join the clips to it (above). Source | SAM|XL
comparatively high electrical conductivity. To rule out leakage DLR’s resistance welding bridge can be seen in Fig.  (p. ),
[of ] currents through the fuselage skin during welding — which anchored to the test fuselage shell tool. The bridge grips a curved
becomes more likely if the weld faces have similar fiber orienta- fuselage frame and presses it down onto the skin. “Every foot along
tion — we added an insulating layer to the carbon fiber-based the frame has its own welding module with a pneumatic cylinder
welding elements.” to apply a pressure of about  bar,” says Fischer. “Electric current is
COMPOSITES
CALL FOR
LMT ONSRUD
Visit www.onsrud.com
Honeycomb and composites materials have for more information
become the standards within the aerospace, 800-234-1560
medical, and transportation industries.
LMT Onsrud premium cutting tools increase
machining efficiencies, eliminate delamination,
and enhance part finishes. LMT Onsrud LP
1081 S. Northpoint Blvd
Trust LMT Onsrud to provide tools that meet Waukegan, IL 60085
your exacting standards! Phone 800 234 1560

THERMOPLASTIC
COMPOSITES
WITHOUT Industrial
BARRIERS Sports
LIVE DEMOS @
Medical
BOOTH Q11
Aerospace
Transportation
TRY OUR FREE ONLINE QUOTING TOOL

Allowing our customers to get part price estimates Military
in real time. oribicomposites.com/calculator

FEATURE
FIG. 3 Resistance-welded frames in upper MFFD

DLR’s curved welding bridge (top) is used to resistance weld fuselage frames, which were produced by Premium
Aerotech in Augsburg, Germany (top left) to the test fuselage skin. The bridge has a welding module for each frame
foot, applying 6 bar of pressure with a pneumatic cylinder and electrical current from the red to black wire (bottom
left) which heats the matrix to its melt temperature. Source | DLR CC BY-NC-ND 3.0
then run through the welding module [from the red to black wire in Premium Aerotec in Augsburg, Germany.) To support this, Clean
Fig.  through the welding element positioned between the frame Sky 2 awarded the DEWTECOMP project to R&D lab CETMA
foot and the fuselage skin.” This welding element generates heat in (Brindisi, Italy), aiming to weld structural frames with reinforce-
the weldline, analogous to the energy director used in ultrasonic ment parts such as gussets, wedges and fittings to produce a DSS
welding. with at least 15% weight savings and up to 75% energy savings
In the past, it was a stainless steel mesh, “but we now use the versus a standard autoclave-cured thermoset structure.
same carbon fiber composite as in the skin and frames,” says Kupke. “Our strategy was to divide the entire structure into different
“Though metal has better electrical conductivity, we have elimi- subassemblies that can be welded with a very simple tool and
nated any foreign material in the weldline — it is a single homoge- linear weld path,” says Giuseppe Buccoliero, advance materials
neous material throughout.” and process development engineer at CETMA. “These welded
“During resistance welding, we run current until the matrix subassemblies are then joined to manufacture the door frame
reaches the required process temperature, which is above the structure. We first developed the induction welding process
crystalline melting temperature,” continues Fischer. “We then for the CF/LMPAEK unitape, and then we followed a building
reduce the voltage in two steps, while pressure is applied, until block approach — testing coupons, components and finally to
the weldline cools. Welding takes about two minutes.” After the the demonstrator level. We also developed a fully automated
frames, DLR again uses resistance welding to integrate cleats as induction welding cell where the robotic arm movement and the
shear ties between the Z-stringers and curved fuselage frames. welding head are fully integrated and controlled by a single PLC
“DLR developed a cobot-on-robot-based welding system for [programmable logic controller].”
this process because it requires perfect positioning of each cleat CETMA also developed simulation that can predict not only
between stringer and frame and must also allow for tolerance thermal behavior in the weld, but also mechanical behavior, such
compensation.” as microcracking. “This helped us to optimize the welding process
for each DSS component, taking into account the laminate design
MFFD door structure and part geometry,” says Buccoliero. CETMA verifed weld perfor-
Another part of the MFFD project is the door surround struc- mance through lap shear, compression and double cantilever
ture (DSS) for the lower fuselage half, to be fabricated by Tier 1 beam testing, the latter for fracture toughness and comparing test
airframer Aernnova Aerospace (Miñano, Spain) using induction data with simulation results. It then scaled up to weld the frame
welding. (Note, the DSS for the upper MFFD half was produced by subassemblies, completing the project in June .

Thermoplastic composites welding
NEWS
FIG. 4 Welding development at NIAR

ATLAS has added automated cells for resistance welding (left), spot ultrasonic welding (center) and
induction welding (right) which will be used to produce a 30-foot-long demonstrator. Source | NIAR
CETMA is now working with its equipment partner SINERGO program will move quickly from coupons to the stiffened-skin
(Valdobbiadene, Italy) and Advantech Advisory (Lloret de Mar, panel element level, says Seneviratne. “We’ll do a comparison
Spain) to commercialize its patented induction welding tech- of bonded, bolted and welded joints in both in-plane and out-
nology, including gantry and robotic systems. of-plane loading for static strength, durability and damage toler-
ance. We’re doing this because we need to address the issues with
NIAR scaling these technologies. Fatigue testing is also key to under-
Wichita State University’s National Institute for Aviation Research stand long-term behavior. We have coupon-level fatigue data
(NIAR, Wichita, Kan., U.S.) is also developing resistance, ultra- showing our resistance welds can perform  times better than
sonic and induction welding process specifications. In March 2021, bonded joints. But then we changed the quasi-isotropic ply at the
it announced the addition of robotic
induction welding equipment as part of
its Modeling for Affordable Sustainable
Composites (MASC) research program,
sponsored by the U.S. Air Force Research
Laboratory (AFRL, Dayton, Ohio). Its
resistance welding and ultrasonic welding
cells were added shortly after (Fig. 4),
and are quasi-static, meaning they aren’t
robot-based or continuous, but instead
produce piece-wise welds. NIAR’s resis- Composite Parts,
Assemblies
tance welding uses carbon fiber resistance
elements in the weld interface.
AND Tooling
“Under this AFRL research, we’ll pursue
process development and then building
block certification protocols for all three
welding technologies through a -foot-
long manufacturing demonstrator called
► Rapid Design and Build
Frankenstein (FS-),” says Waruna Sene-
virate, director of the Advanced Technolo- ► One-Off or High Volume
gies Lab for Aerospace Systems (ATLAS) at
► Large, Complex Shapes
NIAR. “This demonstrator will allow us to
validate the in-house developed welding ► High-Precision Machining
processes and certification protocols in ► Non-Destructive Testing (NDI)
scale and to work with different manu-
facturers to produce welded thermo-
plastic composite parts and make sure the www.janicki.com | 360.856.5143
processes are robust.”
The building block testing in this
FEATURE
is helping mature its patented KVE Induct technology for UD-based

composites to TRL 4. The companies expect to reach TRL 5-6 with
completion of the TRAMPOLINE full-scale horizontal tailplane
(HTP) demonstrator in 2024 and aim to qualify that process with
Boeing and Airbus, targeting a flying application by 2026.
The Daher-led TRAMPOLINE project, funded by CORAC
(French Civil Aviation Research Council), targets a % weight
reduction and significantly reduced subassembly cycle time versus
thermoset composites. Its .-meter-long HTP demonstrator is
derived from Daher’s TBM single-engine turboprop business/light
utility aircraft and features curved surfaces and LMPAEK unitape
FIG. 5 Induction welding torsion box laminates ranging in thickness from . to  millimeters. Daher’s
KVE Composites and Daher have demonstrated a sub-scale torsion box demon- knowledge of the part and loads will reportedly enable the project
strator which will be followed by a full-scale business jet horizontal tail plane to mimic a full certification process.
(HTP) torsion box in 2023. Source | KVE Composites, Daher
In May , Daher announced a three-year agreement with
Luxembourg Institute of Science and Technology (LIST, Esch-Sur-
interface from  degrees to  degrees, and just that small change Alzette) to develop infrared (IR) welding technology suitable for
quadrupled the fatigue performance. Yet in the static test data it thick parts with large dimensions in high-volume manufacturing.
showed no difference. Further, as we scale up in size, can we still “Daher invested in KVE because we could see the importance of its
hold this performance? This is important as you start to evaluate technology,” says Michael Hugon, intellectual property manager at
welding process parameters and different materials.” Daher, “but from the beginning, we knew this is not the only way to
NIAR’s welding development testing is using Toray TC weld. We are working with KVE to investigate the limits of induc-
PAEK and Solvay Composite Materials (Alpharetta, Ga., U.S.) APC tion welding, and KVE agrees that we need to also invest in alter-
PEEK. Materials and welding techniques to be used for each part native technologies that could be complementary.”
of the manufacturing demonstrator were finalized by September In IR welding, he explains, IR heaters preheat the weld faces
. Lower level process development for all three welding tech- directly, which are then pressed together. During induction
nologies is to be completed this year. “We will then start moving welding, heat is induced in the carbon fiber laminate using an elec-
on to our element-level testing and scaling from there,” says Sene- tromagnetic field. “Thus, energy must go through the thickness of
viratne. “By summer , we should be assembling parts in the one part to heat the interface and melt the thermoplastic matrix,”
demonstrator, with the goal to have it completed by .” adds Hugon, “whereas IR welding is a simpler process. In our
stamping process, we use IR heating to soften plies in a composite
KVE, Daher advance induction and IR welding blank before shaping it into a D part. We have done this with
KVE Composites not only has more experience with welding (15 fuselage clips for  years now, but also in R&D of larger parts.”
years) than almost any other company, but also boasts the only Daher has developed CF/LMPAEK ribs up to  meters long and up
induction welding technology on flying aircraft, including the to  millimeters thick for Airbus’ Wing of Tomorrow program. “IR
Airbus A220, Gulfstream G650 and Dassault F6X, which all use welding uses the same heat mechanism as our stamping process,
fabric-based laminates. KVE was acquired by Daher in 2019, which but only heats the outer surfaces, after which we press two parts
FIG. 6 Mobile susceptor induction welding

Using a metal susceptor that moves with the induction welding head (top) allows
the ISW process to focus heat only at the weld interface. Used to produce the
ECHOS fuselage demonstrator (p. 51), the second-generation system shown here
will soon have integrated inline NDT. Source | IS Groupe

Thermoplastic composites NEWS
welding
together,” continues Hugon. “Induc- It aims to reach TRL  in  when it

tion welding works well for closed box completes integration of this inline NDT
structures, such as the torsion box we into its welding platforms.
have demonstrated in the TRAMPOLINE
project. But we are studying what the Welding development at
advantage is for each technology. We are Raytheon Technologies
using synergy between KVE and LIST, Raytheon Technologies Research Center
involving welding experts and materials (RTRC, East Hartford, Conn., U.S.) has
experts, to define specific component conducted induction welding trials on
demonstrators for this comparison.” large, curved panels (0.825-meter nominal
“A first target for IR welding is to FIG. 7 Induction welding at Raytheon inner diameter, 0.876-meter-long outer
imagine new concepts for large and thick Technologies arc, 1 meter long) comprising 16-24-ply
wing ribs,” says Dominique Bailly, Daher Induction welding trials on curved panels using a robotic laminates of CF/PAEK unitape, repre-
VP of R&D. “We have used induction system. Source | Raytheon Technologies Research Center senting a sub-scale stiffened-skin aircraft
welding for joining .-millimeter-thick structure. Dr. Wenping Zhao presented
UD laminates, but we don’t yet know its limits, and its performance this work at SAMPE 2022, which included development of in-situ
depends on whether fabric or UD laminates are used. We want to process control using a nonlinear model predictive control approach
optimize both induction and IR welding in parallel and provide and offline simulation that optimized the induction coil speed along
scientific data for certification.” the curved weldline to meet the temperature requirements for a
“We’ll also work to extrapolate design guidelines for business high-quality weld. The optimization relied on a numerical model
jet-scale structures in -, by scaling from the TBM-based HTP describing the spatial-temporal heat evolution in the weldline,
to a vertical tail plane,” adds Eloy. Bailly agrees: “The small torsion verified by physical experiments.
box demonstrator we showed this year is a good step, but next year Peak temperature variation and average weld speed across the
we’ll be assembling a : scale HTP.” To facilitate such develop- .-meter weld path was ±°C and . millimeters/second for
ments in the market, KVE has commercialized a compact welding uniform skin thickness and ±°C and . millimeters/second for
cell, used for welding of standardized SLS and L-profile pull-off non-uniform thickness panels. Process parameter development
coupons, and a larger, more versatile robotic cell for demonstrators
and serial production.
Mobile susceptor induction welding

Induction welding is also being advanced by the Institut de Soudure
(IS Groupe, Villepinte, France) and Arkema (Colombes, France) via
the patented ISW process. IS Groupe induction welded stringers in TechDays
T
Tech
echD
echDays
the Arches TP fuselage demonstrator with Tier 1 supplier STELIA
Aerospace (reorganized as Airbus Atlantic in January 2022). It subse-
quently reworked its dynamic, robot-based process to use a mobile CONSTRUCTION AND INFRASTRUCTURE
susceptor that is linked to the welding head. Heated by an induction Emerging Materials and Technologies
coil in the weld head, the metal susceptor focuses that heat precisely for Infrastructure and Construction
at the weld interface (Fig. 6, opposite). The mobile susceptor is used STREAMING LIVE ONLINE
in combination with a pure thermoplastic or low-fiber-volume inter- DECEMBER 1, 2022 | 11 AM – 3 PM (ET)
face ply to augment resin flow. COST TO ATTEND: $150
Interface plies have been tested using unreinforced PEI and

Arkema PEKK film as well as UD tape with -% carbon fiber by With the infrastructure bill passed, the United States
volume. Welds without an interface ply have also been conducted will see a decade of sustained investment and activity
in infrastructure, construction and rehabilitation. During
on skin/stringer plates made using UD CF/PEKK tape in quasi-
this online CW Tech Days event, experts will review
isotropic layups of - plies ranging in thickness from . to  and evaluate the composite materials, processes and
millimeters. Tests on welded flat and curved panels show SLS applications that should and will be considered for use
strengths that are % and %, respectively, of autoclave-consol- in the infrastructure and construction markets.
idated reference panels, and welds on panels with copper mesh
PRESENTED BY
lightning strike protection have been successful with no issues. In Scan here to
, IS Groupe worked with Airbus Atlantic in the CORAC-funded view speakers
ECHOS program to demonstrate a -square-meter curved fuselage and register!
panel with  -meter-long stringers welded using the ISW process.
IS Groupe has commercialized first- and second-generation ISW CompositesWorld.com
welding heads and developed inline NDT using ultrasonic testing.
FEATURE
began with flat panel testing on the KVE welding test setup at the University of South
Mix,
Carolina, which also helped to develop thermoplastic-coated optical fibers embedded
into the composite laminate and interrogated using Luna’s (Roanoke, Va., U.S.)
Meter, and
ODiSi eight-channel interrogator system.
RTRC also used force/torque sensors in its robotic induction welding head, an IR
camera and thermocouples to monitor pressure and temperature during welding.
Dispense Zhao acknowledged support provided by the Advanced Robotics for Manufac-
turing (ARM) Institute (Pittsburgh, Pa., U.S.), the GrayMatter Robotics team led
Materials by Dr. Ariyan Kakir and the University of South Carolina team, led by Dr. Wout De
Backer and by Dr. Michael van Tooren (technical fellow structures at Collins Aero-
with space, previously at Univ. of S.C.) regarding induction welding. “We have a follow-
on program to further improve welding quality by applying machine learning,”
Precision says Zhao. “As the technology matures, our aim is to transition to a large part
demonstration.”
Process control, NDT, certification, crack See numerous linked resources

arresters and more images in this article
online | short.compositesworld.
What parameters must be monitored and/or com/welding
controlled to ensure a good weld? “With compos-
Part 2 article | short.
ites, we must always know that the part saw the compositesworld.com/welding2
right temperature, pressure and time,” says Kupke Read CW’s 2018 feature | short.
at DLR. “We monitor and log these for every weld.” compositesworld.com/WeldTPCs
How this is done varies per welding technique,
from tracking power and current to the weld head
along with it speed and integrated force sensors, to
infrared (IR) cameras monitoring the part surface
temperature to optical fibers embedded in the
weldline. Most technologies rely on optimizing
process parameters during months of testing, and
then monitoring and logging that welding conforms to this specification on actual
parts. Ultrasound NDT is also being used, both post-weld and integrated into the
welding system for inline inspection, and noncontact methods are being researched
for larger areas and higher part volumes. Research is also pursuing AI to certify and
link process parameters to weld quality but also to fully automate robotic welding.
Seneviratne at NIAR notes crack arrest features (e.g., chicken rivets) are used today
Increase your in bonded primary structures, metal and composites, as well as the welded thermo-
plastic composite rudders and elevators that are flying, due to the failsafe require-
production ments of current certification protocols. “Eventually, I think we’ll have enough confi-
dence for welded composite primary structures without crack arrest features,” he says,
efficiency and but conditions this on first building years of history and data, “like we have done for
improve your bonded joints.”

This is a brief summary of the full “Part ” of this article, available online: “Thermo-
bottom line. plastic composites welding: Process control, certification, crack arresters and surface
prep” (Learn More). That discussion ends with Bach at KVE noting increased requests
for welding systems, as well as increased investment into welding technology overall
and demand for the next step in sustainability that it brings. His assessment: “We will
Be sure to stop see more welded thermoplastic composites flying within a decade.”
by and visit
our closed
mold demos at
CW senior technical editor Ginger Gardiner has an engineering/materials background
Booth #T11 and more than 20 years of experience in the composites industry.
ginger@compositesworld.com

breton hawx e1
THE GAME CHANGER
Breton Hawx is designed to overcome the limits.
Extremely rigid and stable, it’s the perfect solution for
high-speed milling and trimming on composite materials,
resin and light alloy parts. It can be easily integrated into
any workshop as it requires no foundation and has quick
installation times.
Engineered As one of the most renowned Founded in 1963, today Breton

on your manufacturers of high-speed is a global leader in the design
needs machining centres with gantry and manufacture of state-of-the-
architecture, Breton offers a art machines and large-scale
complete range of solutions additive manufacturing.
devoted to high-precision Breton USA is present with
machining for the aerospace, offices service points in North
automotive and mould & die America.
industries.
breton.it
Plant tour: AvCarb, Lowell, Mass., U.S.
Composites are often selected for their structural properties,

but at AvCarb, innovation in carbon fiber-based products
has driven fuel cell technology advances for decades.
By Jeff Sloan / Editor-in-Chief
» For the vast majority of applications of carbon fiber-reinforced Carbon fibers for fuel cells
polymers (CFRP), performance metrics revolve around light- AvCarb traces its history back to the 1960s, when it was best known as AVCO,
weighting and structural properties, such as strength, stiffness, which developed AVCOAT, a well-known ablative material used in the thermal
durability, toughness, crack resistance, corrosion resistance, protection system for NASA’s Apollo space program. Since then, the company
evolved to develop carbon fiber/phenolic friction products and, now, specializes in
weatherability and more. These have been and always will be the
the complex manufacture of carbon fiber fabrics and papers for electrode applica-
hallmarks of CFRP performance. tions in fuel cells and battery systems. Source (all images) | CW
There is one application, however, where carbon fiber’s proper-
ties are deployed in a different, non-structural, but just as impor-
tant way — in which high-quality carbon fiber-based products help Fuel cells 101
maximize the power-generating capability, and material forms To understand AvCarb, its manufacturing processes and its
manage the reactants of an electrochemical fuel cell reaction. That products, one first has to have a basic understanding of a fuel cell
application is the hydrogen fuel cell, and the carbon fiber product — its components and operation. Fuel cells come in a variety of
it uses is the gas diffusion layer (GDL), a thin, highly-engineered sizes and types, providing electrical power in drivetrains in myriad
carbon fiber paper composite, and a critical component in the fast- vehicles, including passenger cars and trucks, buses, long-haul
growing and rapidly evolving effort to leverage hydrogen as a tool trucks, trains and ships. They also can be used to provide stationary
to decarbonize the world’s energy supply. As important as GDLs power to residential structures and commercial buildings.
are to fuel cells, there are only a few companies in the world that Regardless of the application, all fuel cells operate in the same
have the experience and chemical and manufacturing expertise fundamental way, consuming hydrogen and using an electrochem-
required to produce them at sufficient quality and quantity. One of ical reaction to separate electrons from protons in each hydrogen
those companies is AvCarb, located in Lowell, Mass., U.S., and the atom. Following this separation, electrons are routed through an
focus of this plant tour. external circuit to produce electricity, before being moved to the

AvCarb plant
NEWStour
end of the process and the cell, where they unite with the hydrogen was acquired by Textron and the AVCO name lived on, as did the
protons and oxygen to produce water. AvCarb brand.
It’s important to understand the specific components of a fuel Masse says AvCarb’s next big application came in  when it was
cell to appreciate the role AvCarb’s products play. It might be easiest approached by General Motors, which was experiencing inconsis-
to think of a fuel cell as two nearly identical back-to-back halves, tent slippage fleetwide on its transmission torque converters. This
each of which uses the same materials to perform different func- slippage, by itself, was not necessarily a problem. What GM needed
tions (Fig. ). On one side — left side, in Fig.  — is a flow field was a material that could provide the same, repeatable slippage over
plate through which hydrogen is channeled. After it exits the flow the life of the transmission, thus allowing the engine to operate most
field plate, the hydrogen passes through the carbon fiber GDL efficiently. Masse says AvCarb’s solution was a carbon fiber/phenolic
(which includes a microporous layer — MPL), a thin graphitic layer friction material that, eventually, demonstrated consistent % torque
that acts as a moisture control barrier as well as an electrode that converter slippage for more than , miles. This friction material
diffuses the hydrogen before it passes through the anode layer. The was so successful that GM specified it on all of its - and -speed
anode layer is coated with a catalyst, typically platinum, that sepa-
rates hydrogen electrons from hydrogen ions (protons). The protons
are allowed to pass through the electrolyte at the center of the fuel
cell and into the cathode. The electrons are channeled through an
external circuit, where they generate an electric current.
Meanwhile, on the right side of the cell is another flow field plate
through which air is channeled before it passes through its own
GDL/MPL and then a cathode. Inside the cathode, the disparate
particles and atoms meet — hydrogen protons from the electrolyte,
hydrogen electrons from the external circuit and oxygen from the
air — to produce water molecules, which are then expelled from the
fuel cell as waste.
The efficiency of a fuel cell depends on its ability to convert as
many hydrogen atoms to electricity as possible, and the GDL is a
big part of this effort. The GDL must consistently and effectively FIG. 1 Fuel cell structure
diffuse the hydrogen across its surface to maximize the effect of the
Fuel cells come in a variety of sizes and designs, but all follow the same basic prin-
titanium catalyst on the anode. And that’s where AvCarb comes in. ciple. Hydrogen enters the cell from the left via a flow field plate, passes through
the GDL/microporous layer (MPL), enters the cathode and reacts with a catalyst
From friction to fuel cells (usually titanium). The catalyst separates the hydrogen into electrons (e-) and
CW’s tour of AvCarb starts in the company’s conference room, where and ions (H+). Electrons travel through a circuit that creates electricity. Ions travel
through the central electrolyte membrane and enter the cathode, on the right.
we are met by Guy Ebbrell, president, and Roger Masse, CEO. If
Electrons, after creating electricity, enter the cathode with oxygen from external air
there is institutional memory at AvCarb, then it exists almost entirely delivered via another flow field plate on the right. The ions, electrons and oxygen
in the form of Masse, who has worked for the company for 47 years, come together in the cathode to form water, which is emitted from the fuel cell as
starting third shift doing basic production work and then gradually waste. AvCarb’s specialty is the manufacture of the carbon fiber GDL.
moving up the ladder to the leadership position he holds today. Source | Jasna Jankovic, Ph.D., Materials Science and Engineering Dept., University of Connecticut
Masse relates the company’s history, which goes back to the early
s, when AvCarb started life in Lowell as Aviation Corp., or AVCO.
AVCO is best known for having developed AVCOAT, an ablative
material used in the thermal protection system for NASA’s Apollo
space program. AVCOAT -G consisted of an epoxy-novalac
resin system reinforced with quartz fibers and phenolic microbal-
loons. It was injected into a glass fiber honeycomb core that was
bonded to the entire outer shell of an Apollo crew module. That
entire system — honeycomb core infused with AVCOAT — provided
critical thermal protection for astronauts in the crew module.
Eventually, AVCO spun off its boron fibers business with the
creation of Specialty Materials (Lowell), which still operates today
and produces boron and silicon carbide fiber products. AvCarb,
meanwhile, was developed as a brand within AVCO, consisting of
FIG. 2 Stretch-breaking fibers
carbon fiber composite structures fabricated for space, defense,
Bundles of oxidized carbon fibers are shown here being drawn out of red barrels
friction, textile and other applications, that benefited from the
and into one of two stretch-breaking machines that AvCarb operates. Each fiber
carbonization technology on which the company was founded. is pulled through a stretch-breaking machine twice in preparation for the yarn-
AVCO continued to market its heat shield material. In , AVCO spinning process.
PLANT TOUR
FIG. 3 Spinning FIG. 4 Yarn winding

Following the stretch-breaking process, oxidized carbon Oxidized carbon fibers are unwound from spools and onto the “beamer” mandrel. These fibers will
fibers are spun as yarn onto these yellow bobbins. These become warp fibers in the weaving process, which follows.
fibers will eventually be woven to create fabrics for fuel cell
applications.
transmissions for the next  years and eventually licensed it to Ford to be really conductive and let that current go around the external
Motor Co. circuit. And then, here you are generating all this water. The GDL
“That drove a -% fuel efficiency gain on  million vehicles needs to be able to dispel that water without drying the membrane
produced,” Ebbrell says. “So that’s a significant innovation. And out because the membrane must stay wet — but not too wet. In all,
that’s the beginning of how we started to have a really positive it is a very complicated high-performance composite structure that
environmental impact.” AvCarb remains a global leader in friction is fully graphitized and unique in the industry.”
products today. As AVCO entered the fuel cell market with its graphitic carbon
Also in the s, AVCO started to look at carbon fiber’s poten- fiber fabrics and papers for GDL applications, Textron decided
tial in electrode technologies. “Although all the friction business to focus solely on defense work and sold the company to Ballard
kept going strong, we really started putting all our R&D efforts into Power Systems (Burnaby, B.C., Canada) in . The AVCO name
fuel cells,” Masse says. “It was certainly a new market, but it was a went away as the company became Ballard Material Products, but
fledgling market. It was very small. But it gave us an opportunity to the AvCarb brand survived. Ballard challenged AvCarb to deliver
start looking at different properties and technologies. It was gas flow a world-class gas diffusion system for Ballard’s fuel cell systems,
versus liquid. We were used to dealing with transmission fluids, a which AvCarb did.
much more viscous fluid. Now we’re dealing with water and gas and In , however, Ballard went through a divestment phase of
we needed to design porosity of a different type. So we were adding its own and sold the AvCarb brand and technology to the current
particles in. We were dealing with all different types of graphitic management team, backed by private investors. The AvCarb brand
materials. It was fun. I mean, it was a whole new type of composite thus became AvCarb the company, and for many years it focused
for us — really a lot more complicated. Everybody had a different on diversification of products and markets and expanding its GDL
fuel cell design.” expertise for the hydrogen markets. Then, in late , private
This led to work in crystal formations and carbon/carbon by equity firm Arsenal Capital Partners (ACP, New York, N.Y., U.S.),
certain types of heat treatment, porosity development for GDLs, recognizing the growing importance of fuel cells in general as
fabrics manufacture and more. “Our expertise was in managing part of its sustainability push in its growth fund, and recognizing
material thickness, porosity, crystal formation and heat treatment,” AvCarb’s unique capabilities in particular, acquired AvCarb with
Ebbrell says. “That was and is our sweet spot and fuel cells needed the promise of significant capital investment. Since ACP’s invest-
these properties. They were right up our alley.” ment in late , AvCarb has invested significantly in capacity,
That alley, however, was thick with onerous material require- R&D and customer service to support the anticipated rapid growth
ments. “We learned pretty quickly that the GDL is absolutely critical,” of AvCarb’s fuel cell and other energy material forms. By early ,
Masse says. “It has to be chemically inert. It has to compress the AvCarb will have installed and commissioned the world’s largest
right amount and not too much. It cannot physically degrade. It has asset base for servicing the GDL needs of a growing global customer

AvCarb plant tour
NEWS
base, with even more investment planned. targeted toward vehicle transmission applications.
Today, AvCarb’s fuel cell products represent a large majority of The feedstock for most of AvCarb’s products takes two forms:
the company’s revenues and clearly are a significant demand driver oxidized polyacrylonitrile (PAN) yarn or nonwoven carbon fiber
for the future. Masse notes that fuel cell technology is evolving paper. The use of these raw materials is central to AvCarb’s manu-
quickly, with a variety of increasingly complex designs entering the facturing expertise as it gives the company complete control over
market — different shapes, sizes, principles of operation — that the heat treatment process, which is critical to the development of
demand different GDL features and performance attributes. the material properties demanded by fuel cell and similar energy
It’s become incumbent on AvCarb to meet those needs. Masse systems. The use of oxidized PAN and nonwoven carbon fiber paper,
points to AvCarb’s unique mix of electrochemists, material scien- combined with the nature of the end products, also means that
tists and design engineers who help the company stand out and AvCarb’s manufacturing floor looks very different than a typical
drive the innovation needed to keep it ahead of the fuel cell tech- composites fabrication operation.
nology curve. “Our goal is to be the number
one provider of engineered carbon-based
products in growth areas that are impactful
to the planet’s future,” Masse says. “To do
that, we have to stay ahead of the market
technically, with sufficient capacity, and be
ready to address our customers’ needs as
they seek higher performance and global
supply chains.”
The AvCarb product line

AvCarb’s products fall into one of four broad
categories: fabrics, papers, gas diffusion
systems, molded graphite laminates, felts
and friction materials. All of these products
are manufactured using AvCarb’s propri-
etary carbon fiber graphitization process
and each is targeted at a specific application,
with many of those in the fuel cell/energy
generation market.
Fabrics are manufactured in roll format
and are targeted toward gas transport,
motion control and high-temperature appli-
cations. Carbon fiber papers, also manu-
factured in roll format, are nonwovens that
feature a porous carbon matrix and are
targeted toward specialty batteries, fuel cells
and electrolyzers. Gas diffusion systems are
carbon fiber papers in laminate format with
polytetrafluoroethylene (PTFE) and other
coatings, targeted specifically toward GDL
applications in proton exchange membrane
(PEM) fuel cell systems. Molded graphite
laminates comprise thicker and stronger
carbon fiber papers and are targeted
toward electrode-backing applications in
demanding environments. Felts, offered in
roll format, are targeted toward electrode
applications in flow battery systems, an
emerging and maturing electrolytic energy
production system. Finally, friction mate-
rials, offered in sheet format, comprise the
same carbon fiber/phenolic combination
that won over GM. These materials are still
PLANT TOUR
FIG. 5 Fabric production FIG. 6 Paper coating

AvCarb operates three Sulzer weavers, including this one, producing woven Nonwoven carbon fiber paper is the highest volume product at AvCarb and is
oxidized carbon fiber fabrics. Next stop for these fabrics is carbonization. targeted toward GDL applications. The paper starts as a PAN nonwoven to which
AvCarb adds a proprietary matrix. This is then oxidized and carbonized in a high-
temperature quasi-carbon/carbon process to create the paper. Here, a roll of paper
is visible in AvCarb’s coating line, where the company adds graphitic, carbon and
“There are very few companies in the world with the combina-
chemical coatings.
tion of capabilities and expertise that we have, and now with the
resources and vision of ACP, we are doubling our capacity in  machines, each about  meter wide, consuming the yarn that had
in Lowell, and actively planning for further expansion globally. In been spun and wound in the Textile Room (Fig. ). The result is the
addition, we are accelerating R&D to stay ahead of the needs of continuous roll fabric that will become the fabric products in which
future generations of fuel cell stacks under development,” Ebbrell AvCarb specializes.
says. “AvCarb’s value proposition and customer focus is diffi- Leaving the Weaving Room, we follow the woven PAN into the
cult to match. We are absolutely committed to the success of the Carbonization Room, where AvCarb applies its proprietary tech-
hydrogen and alternative energy economies..” nology to turn the oxidized carbon fibers into pure carbon fibers.
For this, the company employs a two-step system. The first step is
Stretch-breaking, weaving, coating a custom-made furnace about  meters long, through which the
Our tour of the 155,000-square-foot facility begins in the noisy woven fabric is passed in a continuous process. As the fabric comes
Textile Room where, as the name implies, fibers are received and out of the furnace and is wound onto mandrels, Ebbrell says, it’s
begin their journey toward becoming fabric. Here, oxidized PAN about % carbonized.
is drawn in thick, black, continuous bundles from red, cylindrical In the second step, the rolls of fabric are mounted on graphite
containers and into the first of two stretch-breaking machines (Fig. racks and placed in large, custom-made, high-temperature, graphi-
2, p. 63). These machines pull the fibers over a series of rollers to tization furnaces, which complete the carbonization process,
bring them into tension sufficient to break each one. The result is rendering a material that is .% pure carbon fiber.
a thick bundle of broken fibers called a sliver (pronounced “sly- From the Carbonization Room, the woven fabric will be assigned
ver”). After the sliver exits the first stretch-breaking machine, it’s to either a friction or an electrochemical customer application.
passed through another, which breaks the fibers a second time. Friction fabrics are typically phenolic-coated, then a final friction
“What happens is the fiber enters the machine and the down- component will be fabricated using precision molding and cutting
stream rollers go faster than the other three rollers,” Ebbrell says. equipment. Electrochemical products will either be supplied as is,
“They are literally snapping the fibers so that it’s more like a or have functional coatings applied such as PTFE.
natural fiber or like a cotton fiber. It’s a bunch of different lengths After coating, the electrochemical fabric travels to the Sintering
of material, which makes it kind of hairy, but also gives us great Room, where it’s rendered hydrophobic via the sintering of PTFE
electric, electrochemical and frictional performance.” on the fibers. Ebbrell explains that making the fabric hydrophobic is
After this, the slivers are twisted into smaller diameter tows or critical to fuel cell function as it helps keep moisture out of the cell,
yarns, which are drawn and stretched further as they are spun which improves energy production.
onto bobbins (Fig. , p. ). After that, these stretch-broken As important and promising as the fabric is, the material format
oxidized carbon fiber yarns can go to one of two processes in prep- most produced by AvCarb, and the material targeted most specifi-
aration for weaving. In the first, the yarns are spun onto -inch- cally toward GDLs, is the company’s line of carbon fiber papers. As
wide spools for use as weft material in weaving. In the second, noted, the carbon fiber paper is delivered as a nonwoven substrate
they are drawn and wound onto a “beamer,” a blue mandrel about with binder, in which the binder has not been oxidized or carbon-
. meters in diameter that prepares the fibers for use as warp ized. This is important, Ebbrell says, because much of AvCarb’s
material in weaving (Fig. , p. ). processing expertise, and its competitive advantage, revolves
Next, we leave the Textile Room and enter the Weaving Room, around the company’s strong heat treatment technology.
where AvCarb employs three Sulzer (Pego, Spain) weaving “Small changes in process can have a big influence on diffusivity

FILAMENT WINDING
& COMPOSITE SOLUTIONS
VISIT US AT CAMX 2022!
BOOTH F8
Leading manufacturer & service provider

Over 900 winding systems installed worldwide
Celebrating 60 years of trusted service
HIG H- PER FO R MA N C E I N N OVAT I V E EQ U I P M E N T

PLANT TOUR
follows akin to a carbon/carbon, “although it’s really quite different

from traditional carbon/carbon processing,” Ebbrell says.
After the binder/matrix is applied, the composite (carbon paper
with binder) is first oxidized via a continuous heat treatment process.
Following this, it, like the fabric, passes through a two-stage carbon-
ization process, eventually producing a carbon fiber nonwoven of
.% purity. Adjacent to the nonwoven’s carbonization line is the
heart of AvCarb’s innovation and where much of its chemical exper-
tise is applied. The coating line (Fig. , p. ) is a -meter-long, blue
and white, two-story, custom-made machine through which the
nonwovens travel for application of a variety of coatings to add func-
AvCarb leadership tionality to the carbon fibers.
Guy Ebbrell (left), president, and Roger Masse, CEO, in front of AvCarb’s long and Ebbrell says AvCarb passes a given roll of nonwoven through the
complex paper-coating line. AvCarb was acquired by Arsenal Capital Partners in system multiple times, depending on the coating recipe and the
2021 and has plans to expand its manufacturing capacity in Lowell, Mass., U.S. The customer, which is dictated by how the nonwoven will be used in the
company also has plans to add facilities in Asia and Europe. fuel cell. Most coatings are proprietary to AvCarb, but might include
PTFE, for the same reason it is applied to the fabrics.
of the final GDL,” Ebbrell says. “It is very important that we control “This is the last step in making a fuel cell GDL,” Ebbrell says. “Once
all of the steps in heat treatment — not just carbonizing the fibers, we’ve made the carbon paper, it’s coated with Teflon [PTFE] and
but the binders as well. Everything has to be carbonized together the Teflon needs to be sintered to give it the right property — hydro-
to achieve the high purity, high thermal conductivity and electrical phobic. So, if I were to get a water bottle and spray this stuff, at this
conductivity required.” end, where it’s being rewound, the water would just bead up and roll
The first step in this manufacturing process is the wet-coating off. And that property is critical to fuel cell performance.”
application of what Ebbrell calls a binder, but is really a carbon-
based matrix system — “our secret sauce,” he notes. The use of this Where AvCarb goes from here
matrix makes the high-temperature heat-treatment process that Back in the conference room we are rejoined by Masse, who

THE PLACE FOR SPACE!
MIX COMUNICAZIONE - MI
Ingersoll Machine Tools, Inc.

is your premier Automated Fiber Placement
and Composites solutions provider.
The Mongoose family of products is the perfect complement to the complex
and large geometries that the innovators in Space Exploration and Propulsion demand.
Mongoose solutions are designed, built, and tested at Ingersoll Machine Tools,
in Rockford, IL, the U.S. Headquarters of Camozzi Machine Tools.
Ingersoll Machine Tools Inc.

More info? Tel. +1 815 987 6000
Scan the QR code info@ingersoll.com
www.ingersoll.com
PLANT TOUR
simultaneously looks back with pride on almost 50 years of plans to add capacity there as well if and when it is needed.”
technology evolution, and ahead with hope that the fast-growing Says Ebbrell: “Aspirationally, we want to be the number one
hydrogen economy will drive the company’s growth for the next 50 supplier of these engineered carbon solutions for alternative energy
years. Until AvCarb was acquired in late 2021 by ACP, Masse says markets as we uphold our long-standing history in ICE engines. We
the company had been struggling to find the capital required to talked about fuel cell electrolyzers, flow batteries and other technolo-
expand capacity. The company’s unique capabilities, combined gies that are developing in the new energy markets, and how our 
with its relatively small size, made it somewhat vulnerable. years of experience in material science positions us for success. We
“I think that’s what puts us at this exciting point right now,” always start with a customer problem. We dig into that with them
Masse notes. “We have all the pieces we and we try to get an understanding of how a material behaves in the
need to support this growing market, all system, what makes it work, and how we can improve that perfor-
Read this article of these decarbonization applications for mance. And that is the story behind all of our successes.”
online | short. products that fuel cells need. I think the Of course, “doing it this way” has evolved over half a century —
compositesworld.com/
AvCarbpt only piece we were missing was having the much of it guided by Masse’s long and personal experience with
resources.” AvCarb. Still, he admits he’s close to retirement and might soon let
ACP, says Masse, had been eyeing the next generation take over. But for the man who started on third
AvCarb for some time as it sought a shift and then spent the next  years working nearly every job AVCO
position in the hydrogen market. The had to offer, leaving is bittersweet. I asked Masse what he would have
decision by ACP to secure that position said if,  years ago, someone told him that he’d one day be CEO. He
has given AvCarb the resources to expand pauses to think: “I would have laughed,” he says. “That would have
capacity to meet increase in demand for its made no sense whatsoever. Impossible to imagine.”
fuel cell, battery and friction products. This makes Masse particu-
larly excited that AvCarb is fully capable of helping meet the needs
of the global decarbonization marketplace on a large scale. Meeting
those needs will include expansion of AvCarb’s global footprint.
Jeff Sloan is editor-in-chief of CompositesWorld, and has been
“We want to locate near the customer,” Masse says, “and we see a engaged in plastics- and composites-industry journalism for
lot of growth coming out of Europe, so we expect to expand there. 26 years. jeff@compositesworld.com
We also see growth coming out of Asia, so we have well developed
Improve Your Skills

In Just 5 Days
20
A N NIVE
RS
AR
Y
HPC
Charter
Advertiser
Specialized Composite Courses such as

• Mold Fabrication for Production and Repairs
• Resin Infusion Technologies
Contact us today for more information

or for assistance enrolling
+1.775.827.6568
training@abaris.com
www.abaris.com

NORTH CAROLINA
IS #1 FOR BUSINESS
Explore all that North Carolina public power communities have to offer
Q: Why was North Carolina Attendin

g
CAMX?
recently ranked the #1 state Visit us a
t
for business by CNBC? Booth J6
8!
A: N.C. boasts the perfect formula
of talent, low cost of business,
shovel-ready greenfield sites and
ready buildings in public power
communities stretching from
the mountains to the ocean.
Let our experienced economic development team show you

how North Carolina can work for your organization and why
North Carolina public power communities are great places to do business!
To learn more about site selection in

North Carolina, visit ElectriCities.com/EconDev.
APPLICATIONS
Prefabricated ›Celeste is an under-construction, 12-meter power catamaran

composite panels,
designed by Roger Hill and built by boatbuilder Grant Symmans
at G&T Marine (Auckland, New Zealand). The privately owned,
joining system ease

custom-built, displacement hull power cat is said to be on track for
a May 2023 delivery, thanks in part to the ease of assembly with ATL
catamaran construction Composites’ (Molendinar, Australia) composite DuFLEX panels and

Z-press system. The vessel is a single-level sedan with a beam of 4.8
meters — a “fairly straightforward” build, Symmans notes.
New Zealand-based G&T Marine Symmans was accustomed to traditional materials like plywood,
reduces assembly and construction timber and fiberglass skins, but says he was intrigued by the reported
benefits of DuFLEX, like its precise cut, time and labor savings and
time with ATL Composites’ composite minimal waste. In addition, boat designer Roger Hill had used the
DuFLEX panels. technology before and recommended it for the project. Symmans
notes that the preliminary design for Celeste was based on standard,
foam-cored composite boatbuilding methods like infusion, and that
DuFLEX ended up being the most cost-effective option. “It’s a first
for me. It’s labor-saving, comes as a kit and the DuFLEX is light and
sturdy,” he says.
DuFLEX panels are lightweight, prefabricated custom panels
constructed from E-glass reinforcement, epoxy and a balsa or foam
core. For Celeste, DuFLEX panels are used for the superstructure,
cabin top and hulls. The hull bottom comprises 20-millimeter H100
DuFLEX strips made from 460-gsm unidirectional (UD) E-glass cored
with Divinycell foam from Diab (Laholm, Sweden). The hull sides are
Source (all images) | ATL Composites
laminated with 800-gsm quadraxial E-glass and Divinycell core to
meet performance and engineering requirements.
Specifically designed to reduce construction time, DuFLEX panels
are delivered ready to assemble, either manually with an adhesive or
with the aid of ATL Composites’ Z-press. Using ATL’s Z-Press stream-
lines the composite panel joining process, applying heat and pressure
to cure the epoxy adhesive on Z-joints pre-machined into the panels.
Joints cure fully in seven to 20 minutes, depending on the ambient
temperature, type of hardener, core type and thickness of the panel.
“Using DuFLEX has made construction a simple process, and at this
stage we’re impressed with it,” Symmans says.
Roger Hill, specialist power multihull designer, says the client
was a previous yacht owner who sought a well-appointed power
catamaran for “the next phase of his cruising lifestyle.” He notes that
displacement hull catamarans “cruise most economically around 14
to 15 knots, or about twice the speed [yacht owners] have been used
to going all of [their] previous boating life, and they are really fuel
efficient.”
The catamaran is a standard design with a few unique features
such as a swimming dive platform that lowers down to form steps and
a launching platform for a rigid inflatable boat (RIB).
The decision to use the DuFLEX system was made when the client
saw it for himself, visiting the 16-meter Omahu and speaking to its
owner who had a previous sailing cat built out of DuFLEX and was
positive about the material and process. “The client, whose father was
a New Zealand timber boatbuilder and built many cold-molded Kauri
sailing yachts, was quite tentative about the process but is now also
becoming much more relaxed and happy as he sees the boat coming
to life.”

OCTOBER 17-20
ANAHEIM, CA
2022
LAST CHANCE
To Source the Materials, Innovations, and
Connections that Drive Performance.
JOIN US IN ANAHEIM
REGISTER NOW
Sign up for CAMX Connection and follow CAMX on
social media at #CAMX2022 for live updates during
the event.
theCAMX.org/registration
COMBINED STRENGTH. UNSURPASSED INNOVATION.
Produced by Official Media Partner

MARKETPLACE / SHOWCASE
MANUFACTURING SUPPLIERS
Precision Board HDU Tooling Board

Custom Sheet Cutting
Custom Bonding
Fast Turnaround
(800) 845-0745
www.PrecisionBoard.com
SHOWCASE
VACUUM BAG
SEALANT TAPE
General Sealants industry leading portfolio includes 37 unique
product formulations showcasing products designed for cure
cycles from room temperature up to 800ºF (22ºC to 426ºC).
www.GeneralSealants.com | Contact at Sales@GeneralSealants.com or 800-762-1144
Products distributed worldwide by Airtech Advanced Materials Group www.airtechonline.com

PRESENTED BY October 27, 2022 • 11:00 AM ET
Novel Measurement Technique for
Composites Prepreg State of Cure
A new measurement technique using encapsulated rheometry enables you to handle
samples with ease, provide more accurate cure results and simplify samples setup while
meeting ASTM D7750.
PRESENTERS: RICHARD HANZLIK, Applications Engineer | Alpha Technologies

LOU DORWORTH, Direct Services Division Manager | Abaris Training Resources
PRESENTED BY November 8, 2022 • 2:00 PM ET

Achieving Sustainability with Next-Gen
Mold Release Systems
Decarbonization of a composites fabrication operation requires across-the-board
materials and process assessment to find opportunities for creating a more sustainable
manufacturing environment.
PRESENTER: RUSS POWERS, Industry Technical Manager, Composites & Aerospace |Chem-Trend
PRESENTED BY November 10, 2022 • 11:00 AM ET

Enhancements of Thermoplastic
Composites for Multifunctional
Applications
Take advantage of the strengths of multiple composite fabrication processes to reduce
metal in aerospace structures.
PRESENTERS: GABRIEL BENARROCH, Product Sales Engineer | Trelleborg Sealing Solutions Albany
JOHN MICHASIOW, Mechanical Design Engineer | Trelleborg Sealing Solutions Albany
Scan QR Code
to Register:
REGISTER TODAY FOR WEBINAR AT: SHORT.COMPOSITESWORLD.COM/CWWEBINARS

FOCUS ON DESIGN
One-shot manufacture of 3D knitted

hybrid thermoplastic composite structures
MAPICC 3D project replaces steel seat support in heavy-duty
vehicle with a 3D knitted composite made from thermoplastic
hybrid yarns comprising the matrix and reinforcing components.
By Stewart Mitchell / Contributing Writer
Composites vs steel
The MAPICC 3D project (2011-2016)
realized a process capable of
producing net-shape preforms from
topology-optimized, high-perfor-
mance structural 3D thermoplastic
textile composites. The final product, a
GF/PP Volvo truck seat reinforcement
plate, was made in one shot using a
knitting technique. At 1.3 kilograms, it
weighs 2.7 kilograms less than its steel
predecessor — a reduction of 67.5%.
Source | Institute of Textile Machinery and High
Performance Material Technology, Technische
Universität Dresden
» Heavy-duty vehicle (HDV) transport is the automotive sector’s trailer. In markets like Brazil and Australia, every kilogram above the
most prominent climate problem. To illustrate, in the European front axle weight threshold requires - kilograms off the payload.
Union (EU), HDVs account for 22% of road vehicle emissions, Composites provide a lightweighting opportunity for the
though they represent less than 5% of the vehicles on the road. HDV industry’s weight issues, especially if they are structur-
To combat their effect on climate change, emissions legislators ally optimized to the given set of loads, boundary conditions and
reduce the emissions targets for HDVs every few years, pushing constraints to maximize the system’s performance. A lightweight
manufacturers to develop cleaner technologies. The European truck chassis could accommodate new lower emission powertrain
Commission recently proposed a 15% CO2 reduction by 2025 solutions before it reaches a weight threshold. This could also
compared to 2019, and a 30% reduction by 2030. enable increased payload, so transport firms could haul more
It is a similar story in the U.S. The California Air Resources cargo, improve the transport economy and reduce the number of
Board recently finalized its HDV Low NOx Omnibus Regulation, required journeys.
which phases in more stringent emissions standards starting in
model year (MY) ; these standards will be updated again in MAPICC 3D project
MY  to target a % reduction in NOx emissions by . The To help realize industrialized lightweight vehicle components,
U.S. National Highway Traffic Safety Administration and Environ- the European Commission backed a project called MAPICC 3D
mental Protection Agency, which have had emissions and fuel- (2011-2016). It sought to develop a process capable of producing
efficiency standards for HDVs across the U.S. for over a decade, net-shape, high-performance structural 3D thermoplastic textile
are poised to follow suit. composite preforms with topology-optimized fiber reinforcement
Lower emission powertrains such as hybrid and electric solu- orientation made in one shot using a knitting technique.
tions, and exhaust gas treatment technology, generally increase The project included the development of virtual tools capable of
vehicle weight. In addition, HDV gross weight and axle loads are modeling D composite structures and predicting their mechan-
limited by their class which further compounds the challenge of ical behavior according to textile architecture and resin choice,
implementing these technologies. For example, for HDVs in the allowing for customized end products and better accessibility to
EU that weigh , kilograms when laden, every kilogram on the SMEs/OEMs. It also saw the development of thermoplastic hybrid
front axle above this weight means  kilograms must be taken off yarns comprising both matrix and reinforcing fibers. The resulting
the payload to provide safe counterbalancing of the truck and the manufacturing process can precisely steer the fibers in three

MAPICC 3D seat reinforcement plate
Folded layers with

pockets for steel
inserts.
weft
Original steel warp

plate. Closeup of warp (every
third loop) and weft
(every other loop) yarns.
Commingled glass fiber- Source (original images) | Institute of Textile Machinery

and High Performance Material Technology, Technische
reinforced polypropylene Universität Dresden)
reinforcement plate.
Thermoplastic textile truck seat reinforcement plate
› Development of virtual tools to model › Development of thermoplastic hybrid › A one-shot process that precisely steers the
3D composite structures and predict their yarns comprising the matrix and fibers in three dimensions, tailoring them to the
mechanical behavior according to textile reinforcement. component’s load paths and allowing integrated
architecture and resin choice. mechanisms with minimal waste.
Susan Kraus / Illustration
dimensions, tailoring them to the component’s load paths with tons) to replace a steel plate. The resulting composite part was to
minimal raw material waste. match the steel version’s technical requirements, including the
Twenty partners from  countries fulfilled the MAPICC D strength needed to pass the mandatory ECE R seat belt anchorage
project’s manufacturing chain from raw materials to completed test for the N class vehicle, and realize significant weight savings.
component testing and verification. Key partners included Volvo Philippe Lefort, lead engineer for Volvo Group Europe, explained
Group Europe (Gothenburg, Sweden), Steiger Participations the rationale for choosing the seat reinforcement plate for the
(Vionnaz, Switzerland), Rajasthan Technical University (RTU, lightweighting study: “We developed a formula associated with
Kota, India), Institute of Textile Machinery and High Perfor- the vehicle’s balance to identify the location of the most effective
mance Material Technology at the Technische Universität Dresden weight saving. It determined that the weight reduction should be as
(TUD, Germany), Ecole Nationale Supérieure des Arts et Indus- far forward on the truck as possible for the largest axle load reduc-
tries Textile (ENSAIT, Roubaix, France), virtual testing specialist tion. The seat reinforcement plate is close to the front, has signifi-
Reden (Hengelo, Netherlands), Toray Advanced Composites (TAC, cant high-performance design criteria and is reasonably heavy. As
Nijverdal, Netherlands) and resin suppliers Axson Technologies such, it was the right challenge for this study.”
(now Sika Advanced Resins, Baar, Switzerland) and Huntsman The composite seat reinforcement plate replicates the steel
(The Woodlands, Texas, U.S.). version’s design to avoid cabin modification. As a first step to
Volvo Group Europe used the MAPICC D project to develop making the composite version, RTU conducted finite element
and validate a thermoplastic textile composite seat reinforcement analysis (FEA) on the steel reinforcement plate using Ansys Shell
plate for its N class truck (axle weight between . and . metric  (Canonsburg, Pa., U.S.). Next, VISUAL CRASH PAM (ESI Group,
77
FOCUS ON DESIGN
Modeling 3D composite structures

RTU conducted finite element analysis (FEA) and simulated the ECE
R14 seat belt anchorage test to acquire the loads produced during
the experiment. The resulting CAD and mesh with load vector map
generated by these simulations are shown on the right.
Source | Volvo Group Europe
Rungis, France) software was used to simulate the ECE R

seat belt anchorage test to acquire local loads produced during
the experiment.
A load vector map generated by these simulations indicated that
a single preform layer would not be sufficient to support some areas
of the reinforcement plate well enough to pass the seat belt pull-out
test. It was decided that extra layers of material would be placed fabric at ° to each other to reinforce the preform. A bespoke spacer
in areas with the most severe stress. Steel inserts with a threaded knitting technology with controlled fiber placement was developed
section would be incorporated into the composite for bolting the to locally knit pockets for the steel inserts and excess material to
seat to the reinforcement plate. These inserts would fit into pockets make multiple layers of foldable fabric where further reinforcement
knitted into the preform during the one-shot manufacturing process. is needed.
“An additional GF/PP yarn feed delivers adequate material locally
Manufacturing during production,” explains Truemper, describing how the yarn for
The chosen composite was a commingled glass fiber-reinforced the folded layers was integrated into the one-shot knitting process.
polypropylene (PP) at a 50% volume fraction. “We produced our “An extra needle set knits this feed into the main part to produce the
own hybrid yarn from separate glass fiber and PP yarns, which we insert pockets and foldable reinforcing layers. The machine applies
fed through an air jet texturizer, combining them at the chosen the foldable layers and pockets with a defined distance to the part’s
ratio,” explains Wolfgang Truemper, scientific director at the Insti- outer layers per the regional strength requirement. Afterward, the
tute for Textile Machinery and Textile High Performance Mate- additional yarn feed is turned off until it is needed again.”
rials Technology at TUD. “We align the glass fibers in the desired RTU built thermally resistant molds based on Volvo’s steel seat
orientation in the hybrid yarn during the air jet texturizing, and the reinforcement plate. The preform was loaded onto the tool and
PP yarns support that structure. The glass fibers were orientated vacuum bagged. Consolidation took place in an autoclave at  bar
to provide load path optimization in the final composite structure. pressure. The mold and preform were preheated at °C for 
Additionally, this interspersion means the PP protects the glass minutes, held at °C for  minutes and then cooled in the oven
fibers during fabric production and reduces the flow path length for  minutes. The mold and part were then extracted from the oven
during molding.” and cooled at room temperature for several hours before the consol-
D knitting enables one-shot production of preforms that accom- idated part was demolded. Truemper explains the reasons for the
modate the final product’s net shape. Here, the knitted element is lengthy cooling time are two-fold: “One was handling — we needed
traditional in that the fabric comprises consecutive rows of inter- to cool down the part to handle it safely without harming people
locking loops. Warp and weft yarns were woven through the knitted and the other was to prevent warpage caused by cooling the part too
fast.” Being a prototype, the MAPICC D team didn’t
want to risk damaging the parts as each was valuable
for the research goals. “We did not examine any cooling
time influence on warpage,” adds Truemper. “There was
to be some optimization during the industrialization
stage of the project to accurately define the tempera-
ture that enables detooling the composite part for each
specific application.”
RTU tested several preform coupons to validate the
final construction’s mechanical properties. The univer-
sity performed bolt pull-out tests on a one-quarter
section of the composite seat reinforcement plate. “It
Laboratory knitting machine was important to validate the construction because
the digital model did not fully integrate the stresses at
MAPICC 3D developed spacer knitting technology with controlled fiber placement to locally knit
pockets for the steel inserts and excess material to make multiple layers of foldable fabric where
the interface between steel inserts and GF/PP struc-
further reinforcement was needed. Steiger produced a bespoke laboratory knitting machine to create ture,” remarks Lefort. “The critical local load to pass the
this fabric. Source | Steiger Participations pull-out test was . kilonewtons, corresponding to the

MAPICC 3D seat reinforcement plate
Knitted preform pockets Reinforcement seat testing

The fabric preform comes out of the knitting machine with all the desired part Shown here is RTU’s bolt pull-out tests on a one-quarter section of the composite
features. As it’s manufactured from thermoplastic hybrid yarns, only consolidation is seat reinforcement plate. The critical local load to pass the pull-out test was 23.2
needed before it heads into operation. kilonewtons, corresponding to the peak load the seat bolts would see during the
Source | Institute of Textile Machinery and High Performance Material Technology,
seat belt anchorage test.
Technische Universität Dresden
Source | Institute of Textile Machinery and High Performance Material Technology,
Technische Universität Dresden
peak load the bolts would see during the seat belt anchorage test. anchorage test deemed the structure a successful replacement for
The test results showed that the composite reinforcement plate the steel version.
needed -millimeter steel inserts to achieve this. We chose this for
the final structure with nuts and captive washers in addition to the The future of 3D knitted preforms
steel inserts for extra support.” The final glass fiber-reinforced PP Volvo truck seat reinforcement
Sika Advanced Resins and Huntsman oversaw the adhesive plate weighs 1.3 kilograms, 2.7 kilograms less than its steel prede-
bonding for affixing the composite seat reinforcement plate to the cessor, for a total weight reduction of 67.5%. The MAPICC 3D tech-
truck’s steel cabin floor. The companies nology achieved its goals of producing complex, production-ready
tested several types of adhesives from 3D preforms with controlled three-directional fiber placement —
Read this article online |
various chemical families with different and with the potential to integrate third-party components — in
short.compositesworld. stiffness and behaviors. PP is difficult one shot. The technology’s high design flexibility and low manual
com/MAPICC3D to bond due to its low surface energy, operations make manufacturing composite structures using this
so surface activation was needed to technique as versatile as 3D printing is for isotropic material struc-
increase the adhesion. Flame treatment tures. The limitations associated with manufacturing preforms are
was selected for this as it performed significantly reduced and so, too, are the design limitations of the
best in shear and intersection bond structures.
strength. The chosen adhesive was “Through this project, D knitted preforms from thermoplastic
Sika’s ADEKIT AA. hybrid yarns consisting of the matrix and reinforcing components
Volvo Group Europe tested the MAPICC D composite seat becomes a tool of significant economic output for vehicle indus-
reinforcement plate in a truck cabin on a seven-actuator dynamic tries,” notes Pierre-Yves Bonvin, CEO of Steiger Participations,
shaker rig. Volvo bolted the seat to the reinforcement plate and which developed the knitting machine for the MAPICC D project.
loaded it with a total of  kilograms across the seat’s shoulder “We can now accomplish hyper-specialized workshops and make
and lap sections. Cables connected to an actuator pulled the D knitting a competitive composite manufacturing solution
weights forward in the cab during the ECE R seat belt anchorage compared to other technologies that are slower, more expensive,
test. Here, the main load interacting with the composite struc- polluting and wasteful.”
ture is a horizontal drag force. The composite seat reinforcement
plate surpassed the required N class .-kilonewton load on
the upper and lower torso without rupture, achieved . kilonew-
tons on the upper torso load and . kilonew tons on the lower Stewart Mitchell is a Bristol, U.K.-based engineering journalist
torso load before observed failure. At that load, severe deforma- with experience covering technology in Formula 1, electric and
tion of the seat rails led to complete adhesive rupture on the front hybrid powertrain and autonomous systems. He has a degree
in motorsport engineering from Oxford Brookes University
of the composite seat base. The performance of the MAPICC (Oxford, U.K.), and is a member of The Institution of Mechanical
D composite seat reinforcement plate in the ECE R seat belt Engineers (London, U.K.). smitchell@compositesworld.com
POST CURE
Post Cure
Highlighting the behind-the-scenes
of composites manufacturing
Thermoplastic composite
rebar optimizes construction
logistics
Italian building manufacturer Sireg Geotech srl

(Arcore, Italy) and Arkema (Colombes, France)
are working together to create the next genera-
tion of thermoplastic composite reinforcement
for concrete in order to tackle conventional
steel rebar’s susceptibility to corrosion and
oxidation, and thermoset FRP rebar’s lack of
logistical flexibility. Composed of glass fibers
and Arkema’s Elium resin, glass fiber-reinforced
thermoplastic (GFRTP) rebar is said to be
ultra-tough, recyclable and easy to manipulate
for hot bending on site (top image) using a
proprietary heat bending machine developed
by Sireg Geotech (bottom image), contrib-
uting to improved mechanical performance,
more sustainable, long-living structures and
optimized project lead-time. Both partners are
currently working to identify the optimal Elium
resin formulation to improve and perfect this
Source (all images) | Arkema, Sireg Geotech srl
GFRTP rebar innovation.
Show us what you have!

The CompositesWorld team wants to feature your composite part,
manufacturing process or facility in next month’s issue.
Send an image and caption to CW Technical Editor Hannah Mason at

hmason@compositesworld.com, or connect with us on social media.
@CompositesWorld CompositesWorld @CompositesWrld @CompositesWorld CompositesWorld

A d v a n c e d M a t e r i a l s
Better with Braid
Looking for Lower Cost Material Solutions?
Customization
Customized Fabrics Reduce Upfront Costs
and Eliminate Waste
A&P delivers the exact width, material type, and
architecture required to enable easy manufacture
An 11” wide hybrid fabric with fiberglass bias yarns and carbon axials
meets A&P’s customer’s cost and performance requirements and superior performance.
Automation
Cost and Production Time Reduced
Through Automation
A&P’s overbraiding equipment supports high
volume applications enabling exact placement of
fibers providing optimized architectures, efficient
use of material, and reduced manufacturing time.
Thermoplastics
A&P’s Thermoplastic Offerings Enable Rapid
Cycle Time for High Volume Production
24” diameter
slit tape sleeving
A&P produces Sleevings, Preforms, and Fabrics

using commingled fibers and thermoplastic
Fully consolidated, drapable +/-45° fabric slit tapes.
4595 East Tech Drive, Cincinnati, Ohio 45245 • 513-688-3200 • sales@braider.com • www.braider.com

Composites World October 2022

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Composites World October 2022

Uploaded by

Copyright:

Available Formats

Multifunctional

Composites One • Aerovac • MVP • RTM North Technologies

OCTOBER 2022 / Vol: 8 No

62 Plant Tour: AvCarb, Lowell,

» ON THE COVER FOCUS ON DESIGN

V.P. ADVANCED MATERIALS MEDIA GROUP Rick Brandt

Dan Adams adams@eng.utah.edu

MIDWESTERN US Jack Kline / REGIONAL MANAGER

CHAIRMAN Richard G. Kline

2 OCTOBER 2022 CompositesWorld

© Copyright 2022 Chem-Trend L.P.

4 OCTOBER 2022 CompositesWorld

STICK WITH THE BEST

• Low shrinkage during cure • Low VOCs, No HAPS

Comprehensive 3rd party testing confirms the N900 line delivers

Material selection and process methodology

6 OCTOBER 2022 CompositesWorld

Upper part of mold

Lower part of mold with integral

COMPOSITE CURING OVENS

• Certified for +/- 5° or +/- 10° F

• Factory tested PRIOR to Read this article online |

Available with DataSense™

8 OCTOBER 2022 CompositesWorld

2022 WOC CCO Ad 4.375x6.875 v2.indd 1 8/29/22 3:32 PM

Cost Savings of around

Total lead time for the part decreased from

Composites industry GBI holds

Jan Schafer, MBA, is

GBI: Composites Fabricating Toeing the line

GBI: Composites Fabricating — New Orders and Backlog Slowed expansion

Stay ahead of the curve with Gardner Intelligence.

10 OCTOBER 2022 CompositesWorld

• Demonstrated impact and

• Available with public

Material solutions for today and tomorrow.

Dustless, mobile solution for

Wind blade operators, OEMs and others in the composite

12 OCTOBER 2022 CompositesWorld

Efficiency beyond the cut.

#LetsTalkWorkflow at CAMX 2022

UniFORM: High-quality, high-complex EV battery

14 OCTOBER 2022 CompositesWorld

CAMX 2022 What:

By Hannah Mason / Technical Editor, Grace Nehls / Managing Editor,

16 OCTOBER 2022 CompositesWorld

• Complete design, engineering, build and system

2500 Ton Hydraulic

G.21.10.2.compressionmolding-HP-Composite-Molding.indd 1 8/30/22 3:17 PM

Recycled PET structural, Sustainable thermosets,

Jumbo Vacuum Visit us at CAMX booth P24

panstone.com • polymermachineryco. com • Call 330-633-5734 for more information

18 OCTOBER 2022 CompositesWorld

Aircraft structures made with thermoplastic

aircraft. And lighter means more fuel-efficient. With automated manufacturing

© 2022 Collins Aerospace

High-precision surface Heaters, tempera-

20 OCTOBER 2022 CompositesWorld

Advanced thermoplastic, ther-

High-temperature CMC structure, assembly services SIKA ADVANCED

Live demos showcase closed molding processes

every hour that the show floor is open. Cameras

22 OCTOBER 2022 CompositesWorld