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Caracol AM (Milan, Italy and Austin, Texas, U.S.) highlighted its new XHF extremely high-flow extruder for its family of Heron AM products. Its two chambers can print the same material at rates up to 75 kilograms/hour or two different materials simultaneously. Caracol AM also showcased its wide range of composite printing applications, including a railcar dashboard made with recycled PETG reinforced with short glass fiber — the company has also printed fascia/bumpers for railcars — and air grills in collaboration with Pershing Yachts.

“These parts are in production for a series, printed with a fine nozzle so that no machining is needed, just light sanding before painting,” notes Violetta Nespolo, chief marketing and strategy officer for Caracol AM. “We are also printing parts for marine interiors and exploring structural parts including laminating on top of 3D prints.” Also featured on-stand were printed body sections of a concept car to help designers visualize and refine the new model and direct-to-autoclave molds for curing composites. Caracol AM also prints Invar 36 autoclave cure tools for aerospace production using its Vipra AM systems.

(Augsburg, Germany) has developed an approach to digitalize composites manufacturing processes using AI-based algorithms. Its vision is to have the first composites platform for automated production planning ­—­ “composites at the push of a button” — initially for pultrusion and then to other processes like resin transfer molding (RTM) and compression molding. “Companies spend months developing tooling and machine setups for a new product on their pultrusion lines,” explains co-founder Niklas Paprotta. “Pultrusion dies cost $20,000 to $100,000 and are traditionally designed using CAD. That die is then trialed in production, but if something isn’t right, then the whole process has to start over.” 

Innegra engineered by Quantum Materials (Colfax, N.C., U.S.) exhibited its new patented materials which combine Quantum Fusion Technology and Innegra fiber for thermoplastic applications. PROTECC can also feature Innegra fiber hybridized with E-glass, S2-glass, basalt or aramid fibers in custom colors and weaves. PROTECC materials offer faster thermoforming cycles for products with lighter weight, increased impact resistance and extended life.

“Our patented resin systems in PROTECC enable Innegra fiber to fulfill its full potential versus some low-elongation thermosets, which can fail before Innegra,” explains Jen Hanna, business development manager for Innegra. “We are targeting luggage and applications where lightweight protection is needed, including sporting goods and military products. Thanks to Quantum Materials’ vertical integration for PROTECC, we can offer a high degree of customization for unique composite products.”

(I.S.T., Parlin, N.J., U.S. and Shiga, Japan) exhibited its made from PI polymer with service temperatures of 250-300°C, but also a lower dielectric constant than glass, aramid or quartz fiber for radio frequency transparency and vibration damping similar to thermoplastics and natural fibers. IMIDETEX has been developed not to replace glass or carbon fiber, but instead to be integrated into hybrids — either woven or by layer — offering a unique combination of properties for automotive and space applications as well as radomes, high-frequency electronics and 5G applications and sporting goods. For the latter, I.S.T. has been working with multiple brands and hopes to announce new applications in skis and tennis rackets soon.

Mitsui Chemicals (Tokyo, Japan) featured a rear lamp demonstrator using its thermoplastic composite TAFNEX CF-PP Design sheet, developed by  (ARRK VS, Nederweert, Netherlands). ARRK VS is a small series Tier 1 lighting supplier helps clients realize specific exterior and interior lighting solutions in the automotive and mobility market. 

“These are technical designs for the construction of parts with integrated electronics and lights,” explains Thomas Schneider, COO of ARRK Engineering GmbH. “We can then have these parts produced by manufacturers around the world, such as HELLA, which are able to meet requirements for high-volume models. We also take into consideration the whole life cycle of the part, including recycling.”

The demonstrator exhibited uses TAFNEX Design sheets with integrated semi-transparent glass fiber chips — produced by Van Wees UD and Crossply Technology (Tilburg, Netherlands) — enabling back illumination, which enhances the visual appeal with a sophisticated glow.

(RIL, Mumbai, India) is a conglomerate diversified into global industries including energy, petrochemicals, telecommunication, retail, media, textiles and advanced materials. It has established RELX Composites as a brand supported by what it claims is the largest integrated manufacturing site for composites in India. “We make polyester, epoxy and phenolic resins,” explains Rakeshkumar Shukla, lead sales and marketing for RIL, “as well as pultrusions, wind mill blades, tanks and pipes and FRP [fiber-reinforced polymer] grating. We buy glass fiber and use it to make woven fabrics, sheet molding compound [SMC] and parts using resin infusion. We have also been buying carbon fiber, but we will now make it ourselves and expand into new markets. We will install a clean room for making aerospace hand layup parts as well as prepreg and sandwich parts using glass and carbon fiber with epoxy and phenolic resins.

“Our carbon fiber production will begin in the second half of 2026,” Shukla continues. “We will start with an output of 4.2 kilotons/year in phase 1, adding 16 kilotons in phase 2 for a total of 20 kilotons/year. Our first products will include 24K tow and then 48K tow. Later, we will look at smaller tows like 6K. We will export pultruded profiles for wind blades, but for now, everything else will be for domestic production of composites in India.” 

RIL makes wind blades for Senvion India, but most major producers of wind turbines are now active in India with 70-80% of components made domestically. But composites in India are also experiencing high growth outside of wind, driven by use in sporting goods, electronics, corrosion resistance equipment, building and construction, space vehicles, ground transport like railcars and renewable energy, including solar and hydrogen.

(Tel Aviv, Israel) is a technology that measures milling workpiece temperature and alerts the operator with a simple red light before overheating and damage occurs. Composites can be aggressive materials to machine, driving excessive tool heating which leads to poor quality as well as tool damage and premature failure. TemperChip’s patented sensor accurately measures temperature in the composite material at the cutting edge and wirelessly transmits this data via Bluetooth to a nearby laptop, tablet, smartphone or simple screen readout attached to the machine. A red light on the tool holder illuminates when the set temperature limit has been reached. This limit can be set higher or lower as needed based on materials and parts.

“The next step is smart manufacturing, where the sensor will transmit directly to the CNC machine controller so that if the temperature exceeds the set limit and doesn’t drop, machining will stop,” says Eli Yudkevich, patent holder for the TemperChip technology. The sensor has a 20-hour battery life and is easy to recharge. “We have beta testing sites running this technology and providing the data we need for implementation with AI algorithms. Our solution is plug-and-play and improves quality. We also record the temperature for process logs providing traceability, but also data to help optimize machining parameters.”

“Understanding and predicting tool life is crucial in machining, especially for composites,” notes Beni Manes, COO at TemperChip. “Our technology significantly reduces scrap rates, rework and setup costs. Many industries are demanding lower costs and increased output. TemperChip can help.”