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Every year JEC World provides insights into the latest technologies, processes and trends shaping the composites industry today. Source (All Images) | CW

JEC World is always a great way to gain insight into the trends influencing the composites industry. The 2025 installment of the international composites industry trade fair showcased the latest advancements in composites, emphasizing sustainability, automation and performance-driven innovations.

Much of the consensus at the show was that the aerospace industry remains in a transition phase, with growing interest in thermoplastic composites (TPC) and anticipation for the next-generation single-aisle aircraft. While neither Boeing or Airbus have yet to announce a next single-aisle program, composite materials, particularly TPC, are gaining traction in the aerospace sector. The supply chain is preparing for potential developments by 2030.

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In the meantime defense and space industries continue to drive demand for high-performance composites, driven by geopolitical tensions and increased commercialization of space launches, respectively.

This large eVTOL propeller showcased by Albany Engineered Composites is just one example of a growing demand for high-performance propellers that reflects advancements in aerospace manufacturing. 

While the excitement surrounding urban air mobility (UAM) has slowed with numerous players pulling back from the market in 2024, forerunners such as Joby Aviation Inc. (Santa Cruz, Calif., U.S.), Archer Aviation Inc. (Santa Clara, Calif., U.S.) and Beta Technologies (South Burlington, Vt., U.S.) continue to make significant strides toward qualification of their respective aircraft. Additionally, a growing demand for high-performance propellers further reflect advancements in aerospace manufacturing. 

Automation and digitalization were also dominant themes at JEC World, with exhibitors highlighting AI-driven manufacturing and smart composite processing. The topic of sustainability also seemed to take center stage again this year, with emphasis on bio-based resins, recyclable composites and circular economy strategies.

Below you’ll find just a few examples from the trade show exhibits that reflected some of these trends.

This MTorres/Boeing industrial mobile robot (IMR), displayed at JEC World, is engineered to automate traditionally manual executed tasks working alongside humans to improve productivity and process quality, as well as to provide enhanced ergonomics for operators.

(Torres de Elorz, Spain) showcased an industrial mobile robot (IMR) that it co-developed with Boeing Co. (Arlington, Va., U.S.). The IMR is designed to automate traditionally manual executed tasks working alongside humans to improve productivity and process quality, as well as to provide enhanced ergonomics for operators. The platform uses LIDAR to navigate through a production environment autonomously, avoiding obstacles and personnel.

The IMR can be used with different production processes by automatically changing the end effector. The platform is equipped with a vision system for detecting the part and its features, and compensating for any deviation in part position. The IMR is driven by software that enables it to perceive the environment, move safely, make decisions and execute complex tasks.

Toray Advanced Composites displayed an ENVOL project composite upper stage tank for a small launch vehicle at JEC World. The tank was designed by CT Ingenierie and manufactured by Airborne using a novel method to integrate the outer shell with the tank and enable high-volume production.

Executives at Toray Advanced Composites (Morgan Hill, Calif., U.S.)  provided a comprehensive overview of emerging trends transforming advanced materials and manufacturing. The company noted significant growth in defense and space markets, particularly in missile defense and satellite technologies. With launch costs dramatically reduced, there’s increasing flexibility in material selection, enabling more cost-effective composite solutions across different applications.

Toray had a composite upper stage tank for a small launch vehicle, part of the European Newspace Vertical Orbital Launcher (ENVOL) project, on display. The aim of ENVOL is to create a commercially competitive launch system that offers Europe affordable, frequent and flexible access to space for small satellites. Central to this initiative is an environmentally friendly hybrid propulsion system powered by liquid hydrogen peroxide.

The tank on display was designed by CT Ingenierie (Colomiers, France) and manufactured by Airborne (The Hague, Netherlands) using high-performance, epoxy-based slit unidirectional tapes from Toray. Airborne combined its automated manufacturing technology with a novel method to integrate the outer shell with the tank to successfully produce a cost-effective component capable of high-volume production.

Taking into account material properties and automated fiber placement (AFP) fiber paths, the tank is reportedly able to withstand a maximum pressure of 12 bar and heavy loads during the launch.

In addition, Toray is actively exploring growth in other market segments, including sports equipment and industrial applications. By leveraging its aerospace-grade technology in consumer markets, the company aims to build brand recognition and further demonstrate the performance capabilities of its materials.

Web Industries vice president of aerospace Jason Surman and president/CEO John Madej.

Web Industries Inc. (Marlborough, Mass., U.S.), an advanced materials converter and outsource manufacturer, showcased its innovative approach to composite materials manufacturing, emphasizing flexibility, sustainability and market diversification with an eye toward emerging trends across aerospace, space, energy and industrial sectors.

The company is developing a next-generation slitting platform designed to provide unprecedented flexibility. The new platform can handle both thermoplastic and thermoset materials, accommodating various formats from quarter-inch spools to 2-inch pads. This adaptability positions Web to support evolving manufacturing needs across multiple industries. The company is actively exploring opportunities beyond traditional aerospace, with particular focus on the space sector, renewable energy, wind turbine blades, oil and gas infrastructure and emerging markets like UAM.

Sustainability is also part of Web’s message. The company’s splicing technologies are aimed at 100% material consumption, customizing material rolls to minimize waste and optimizing formatting to reduce packaging and transportation costs.

Syensqo’s Cycom 5320- thermoset resin system and its Thornel T650 fabric were used to manufacture carbon fiber coaxial tank components — part of Scottish launcher company Orbex’s BioLPG fuel system. 

Syensqo (Alpharetta, Ga., U.S.) showcased a coaxial (liquefied petroleum gas) LPG tank dome and liquid oxygen (LOX) sealing ring manufactured by Orbex (Scotland, U.K.). The components were manufactured using Syensqo’s Cycom 5320- thermoset resin system and its Thornel T650 fabric. The parts are featured on Orbex’s carbon fiber coaxial tank. The tank design is part of Orbex’s BioLPG fuel system, a system that uses a bio-based propane fuel that is said to reduce emissions by 90% compared to traditional launch fuels. Orbex’s components are designed to withstand cryogenic temperatures and are produced using various methods including hand layup and tape winding. The components are meant to be recoverable after each Stage 1 launch, further contributing to the goal of sustainable space exploration.