A busy fall industry event season for the composites community kicks off with this month’s CAMX.
Source | CW

As summer winds down, the CW team is gearing up for an exciting season of industry events, innovations and celebrations. This September, all eyes turn to Orlando, Florida, for CAMX, which remains the North American composites industry’s largest, most comprehensive composites and advanced materials event — a showcase of the latest trends, technologies and applications, paired with industry education and a wealth of opportunities to connect with suppliers, partners and peers.

In this issue of CW, you’ll find our second round of CAMX exhibit previews, offering a sneak peek at some of the exhibits attendees will find on the show floor. If you missed the first roundup, the August issue is still available online. And our work doesn’t stop there — we’re putting the finishing touches on the official CAMX Show Directory and preparing our CAMX Show Daily coverage to keep you informed throughout the event.

Next up on the calendar is the latest installment of the CW Tech Days online event series on Oct. 16, with a special focus on high-temperature composite solutions for defense and space applications. As defense and space missions push materials to their limits, demand is growing for composites that can perform in extreme environments. This online program will feature six expert presentations covering topics such as:

• Composites capable of withstanding temperatures exceeding 800°C, and up to 2000°C
• The role of high-temp thermosets and ceramic matrix composites (CMC) in mission-critical components
• Challenges in design, fabrication, testing and certification
• High-rate, low-cost production of high-temp components
• Applications in hypersonics, propulsion, thermal protection and structural assemblies.

And, for a deeper look at the latest developments in this growing market, don’t miss senior technical editor Ginger Gardiner’s feature on CMC in this issue.

Looking further ahead, CW’s Carbon Fiber conference heads to Wichita, Kansas from Nov. 4-6. Attendees will hear from top experts on reducing manufacturing costs and improving production efficiency, as well as market forecasts and insights into carbon fiber innovations for aerospace, wind energy and beyond. With exclusive tours of the National Institute for Aviation Research (NIAR), plus networking with industry leaders, this is a must-attend event for anyone tracking global carbon fiber trends. Highlights include Stratview Research’s analysis of India’s composite materials market, presented by Deepak Agrawal, exploring emerging applications, growth projections, and strategic opportunities. For a preview, check out Agrawal’s Indian composite materials market forecast included in this issue.

As we move into the final months of 2025, CW remains committed to connecting the industry, sharing knowledge and recognizing those who push the boundaries of what’s possible with composites. We look forward to seeing you at CAMX, CW Tech Days and Carbon Fiber — and to celebrating the bright future of this dynamic industry together.

Sources (clockwise) | Suprem SA, Trilion Quality Systems, Loop Technology and Teijin Carbon America

We are exactly a week out from the Composites and Advanced Materials Expo (CAMX) 2025! With dozens of exhibitors and countless innovations on display, having a clear plan before you arrive can make the difference between a productive visit and a missed opportunity.

This is Part 2 of a two-part compilation (see Part 1), which is comprised of 98 solicited and received previews from CAMX 2025 exhibitors, showcasing the composites materials, processes, services and other technologies you can expect to see at the in-person event. Note that company names link directly back to the original preview article.

• Carbon Fiber Recycling LLC: Tennessee-based Carbon Fiber Recycling LLC grows its patented rCF offerings, extracting from post-industrial and EOL dry fiber, prepreg and cured composites.
• Greene Tweed: Greene Tweed highlights lightweight composite innovations such as Xycomp DLF for aerospace and advanced air mobility.
• Laser Technology Inc: Laser Technology features analysis tools like the LTI-2100 and LTI 5200, which are optimal for detecting subsurface composite flaws.
• LoneStar NDE Innovaitons: Rooted in simplifying complexity, LoneStar NDE Innovations’ Orion inspection tool is made to be rapidly deployable and intuitive, overcoming traditional inspection processes.
• Loop Technology: Loop Technology’s flagship FibreLine system, recently combined with Zünd’s Aero Q-Line, leverages a variety of automated tools to lay up very large, wide-format, multilayer plies into a mold with millimeter precision.
• Macrodyne Technologies Inc.: Macrodyne Technologies’ turnkey equipment solutions, from presses to integrated automation systems, offer a range of operational benefits that address demanding production.
• MCS Industrial Ltda: MCS Industrial supplies a variety of tubes, sheets, rings, bushings and other parts made from phenolic paper, cotton phenolic and epoxy glass.
• Metyx: Attendees can discover how Metyx continues to support composites manufacturers with production-ready innovations, including Matvantage Plus, Matvantage PV, Metybond and Metycalc.
• Mikrosam DOO: Mikrosam’s filament winding, prepreg slitting and rewinding, towpreg, AFP/ATL and flexible double-belt press prepreg equipment meet precision and quality demands.
• Mitsubishi Chemical America: Scalable, eco-conscious mobility is Mitsubishi Chemical Group’s strategic focus, which it highlights through a display of materials from PAN precursor to prepregs, and an EV battery case demonstrator.
• Muenstermann USA Inc.: Muenstermann’s custom-engineered convection- and radiation-based drying and heat treatment systems are engineered with efficiency and sustainability in mind.
• NIAR | Fiber Dynamics | Fill: Attendees are able to explore several of NIAR ATLAS’ prototype developments in person, highlighting tool-less space manufacturing, AI-enabled inspection and repair and thermoplastic overmolding.
• Olmar: Olmar is highlighting its next-gen autoclaves and industrial ovens for composites curing to improve throughput, scale production and achieve tighter quality control.
• Persico SPA: Persico Group is a technology partner providing a variety of processing platforms catering to everything from prototyping to full-scale production.
• Plasma Bound: Plasma Bound’s surface pretreatment technology using CPA cleanly and effectively energizes similar and dissimilar surfaces to enhance bonding and joining.
• Plasmatreat: Plasmatreat presents plasma breakthroughs for aerospace bonding and corrosion prevention through live demos, technical sessions and presentations, surface consulting and more.
• Plasma Etch Inc: Innovations like the Integrated Atmospheric System and a demonstration of the hand-held Plasma Wand highlight Plasma Etch’s plasma processing specialization.
• Plataine Inc.: With manufacturers face labor shortages, increasing product complexity and pressure to operate sustainably, Plataine’s AI Agents provide the agility and intelligence needed for real-time decision-making.
• PRF Composite Materials: PRF Materials is highlighting Reepreg, its novel Q.tool recycled innovation and will be providing updates on its Product Development and Innovation Centre.
• Pyromeral Technology: Pyromeral presents PyroKarb, PyroSic and PyroXide, as well as a towpreg format PyroXide for composite applications like heat shields, exhaust ducts, radomes and components that are exposed to high temperatures.
• Radius Engineering Inc.: Radius Engineering introduces Insights, integrated software that automates critical functions in RTM and SQRTM processes, boosting efficiency and reducing human error and training needs.
• Rock West Composites Inc.: Rock West strives to support next-gen space-grade materials and designs, spotlighted through the Strato product line, ecommerce supply services and two CAMX Theater presentations.
• Roth Composite Machinery GmbH: Composites machine manufacturer Roth presents itself together with technology partner Weiss Technik, offering filament winders, specialized software concepts and customer support.
• Royce Global: Royce Global adds to its epoxy product lines with toughened epoxy resins and mercaptan curing agents that assist in high-performance environments.
• Saertex USA LLC: Saertex USA is a domestic materials partner offering reliable high-quality composite reinforcements and local service, from 150-inch-wide multiaxial fabrics with Chop to comprehensive material ranges.
• Scott Bader Inc.: Scott Bader illustrates its local and global materials supply availability backed by technical support, as well as a novel composite panels development with Armacell.
• SDA Software: SDA Software presents its composite structures, materials consulting and engineering solutions leadership, delivering mission-critical designs for UAVs, manned vehicles and spacecraft.
• Sekisui Kasei USA: Sekisui Kasei USA presents ST-Eleveat RNW E foamed plastic and ST-Foamac rigid foam board products designed to support composite core needs.
• sensXPERT by NETZSCH Process Intelligence GmbH: Attendees can experience both of sensXPERT’s FlexCure and Insight sensor products, both achieving reduced waste, shorter cycle times and more actionable insights into resin curing.
• SHD Composite Materials Inc: Prepreg partner SHD Composite Materials supports tooling, component and structural needs with resin system solutions like FR308 and MTC400-1.
• SonicAire: SonicAire’s BarrierAire technology eliminates accumulation of dangerous, difficult-to-reach particulates during composites manufacturing, ensuring uninterrupted production and worker safety.
• Superior Huntingdon Composites LLC: Superior Huntingdon Composites highlights its SCS Global-certified glass-reinforced continuous filament mat and surfacing veils, whether for lightweight strength and stiffness or flawless surface finish needs.
• Suprem SA: Suprem SA exhibits its four principal UD composite formats, Suprem T, F, R and P, that can be manufactured using a wide selection of continuous fibers and thermoplastic matrices.
• TCR Composites: Flight-critical rotor blades, high-speed rotors or thermally demanding structural components can benefit from TCR Composites’ thermoset resin performance, properties and processing.
• Technical Tooling LLC: Technical Tooling is integrating advanced materials, digital process compatibilities and automation into its low-CTE Ravin layup molds and Vacu-Grip fixture offerings to meet evolving needs.
• Technology Marketing Inc: Technology Marketing Inc. presents its Armor-Vac 1K single-component elastomer that excels in complex molds and 3D surfaces, and enables effective composites processing.
• Teijin Carbon America Inc.: Teijin Carbon America is highlighting its presence in the U.S. market with Tenax Next HTS45 E23 24K, Tenax Next R2S P513 6-mm and Tenax IMS65 E23 36K technologies.
• Thermwood Corp.: Thermwood’s presence at CAMX showcases composite additive manufacturing at industrial scale, from daily LSAM Additive Printer 510 demos with various material suppliers to a complete parts display.
• THINKY USA Inc: Thinky USA provides simultaneous, closed-container mixing technologies that are repeatable and scalable for multi-part systems, filled epoxies and fiber-reinforced compounds.
• TMP, A Division of French: Learn how a custom press from French enhances the composite molding process, equipped to adhere to application/requirement needs.
• TMTP: TMTP Labs introduces two novel products specifically developed for composites, TMTP-2430 and TMTP-3550 high-purity graphene powders.
• Toray Group: Celebrating nearly 100 years of advanced materials engineering, Toray features carbon fibers and TPC, prepreg, resin systems and other innovations through its U.S. divisions. 
• Trilion Quality Systems: The Aramis system by Trilion, based on DIC and photogrammetry technology, performs high-precision measurements in the sub-micrometer range, across a wide range of testing environments and material types.
• University of Delaware: UD-CCM invites the composites industry to learn more about SPARC, an opportunity that enhances research impact by catalyzing large-scale interdisciplinary research, building strategic  partnerships and leading strategic growth initiatives.
• Vartega Inc.: Vartega’s EasyFeed Bundles now come in a wider array of rCF solutions for thermoplastic compounding, in addition to offering joint product development programs and R&D trials.
• Virtek Vision: Visit Virtek to learn more about the Iris Ai system with its new Results Projection feature in action, closing the loop between detection and resolution on the production floor.
• Vulcan Shield Global: Vulcan Shield Global displays its continuous and short alumina fibers production capabilities, ideal for high-temperature or corrosive environments.
• Wabash MPI/Carver Inc: Wabash MPI/Carver Inc.’s Genesis Series presses demonstrate its extensive product line, custom engineering solutions and the ability to deliver tailored press solutions for a wide range of industrial needs. 
• Wisconsin Oven Corp.: Wisconsin Ovens presents equipment for vacuum bag, filament-wound and honeycomb block heating technologies, offered with a variety of specific features and options.
• Zoltek: Zoltek introduces PX35 woven UD fabric which bridges the gap between performance and affordability for retrofit and new build scenarios.
• Zünd America Inc.: Zünd is showing how it combines intelligent cutting systems and software to boost productive composites environments, as well as recent technology synergies with Loop Technology.

Source (clockwise) | Firefly Aerospace, MT Aerospace, Rock West Composites

As unfolds this year and we discuss the ways in which composites exemplify “Performance With Purpose,” an exciting area of growth is the space sector. From the rise of carbon fiber rocket platforms to the proliferation of constellation satellites, the growth over the past 5 years has been explosive. According to a recent installment of The Space Report presented by the Space Foundation, space workforce employment grew by 18% between 2019 and 2024. Commercial companies are actively partnering with space agencies like NASA and the European Space Agency (ESA) in ever-evolving ways, with composites enabling a variety of mission-enabling parts and structures including launch systems, landing struts, load-bearing structures, propulsion systems, thermal protection systems (TPS), telescoping arrays on satellites and many others.

Meanwhile, NASA’s Artemis program, which features many enabling composite technologies, has had numerous successful missions — small steps setting the stage for returning humans to the moon. An exciting time, indeed.

National Composites Week is  fitting moment to look ban the year’s progress in this constantly growing area. Below is a roundup of key content to explore, read and learn more.

Note: Below covers only articles produced in 2025 for these topics. For other related content (including news and products), visit these sections of our website.

Ultrasonic welding for in-space manufacturing of CFRTP

Agile Ultrasonics and NASA trial robotic-compatible carbon fiber-reinforced thermoplastic ultrasonic welding technology for space structures.

Revolutionizing space composites: A new era of satellite materials

A new approach for high volumes of small satellite structures uses low-CTE, low-cost CFRP cellular core, robust single-ply skins and modular panel systems to cut lead time, labor and cost for reflectors, solar arrays and more.

Episode 50: Markus Rufer, Scorpius Space Launch Co.

In this episode of CW Talks, CW interviews Scorpius Space Launch Co. CEO Markus Rufer about the company’s all-composite cryogenic pressure vessels and their role in a range of applications, including recent and upcoming lunar lander missions. 

A return to the Space Symposium: Charting the next frontier

Since 2019 the space sector has been on a rapid upward trajectory. This year’s Space Symposium delivered that same optimism, celebrating the community’s continued proliferation, even as political and financial uncertainty raise new questions.

CIRA qualifies CMC structures for the reusable Space Rider

Italian team designs, builds and tests multiple large, complex thermal protection system structures made from patented ISiComp C/C-SiC ceramic matrix composites.

Composites end markets: New space (2025)

Composite materials — with their unmatched strength-to-weight ratio, durability in extreme environments and design versatility — are at the heart of innovations in satellites, propulsion systems and lunar exploration vehicles, propelling the space economy toward a $1.8 trillion future.

Ceramic matrix composites: Faster, cheaper, higher temperature

New players proliferate, increasing CMC materials and manufacturing capacity, novel processes and automation to meet demand for higher part volumes and performance.

Optimizing a CFRP landing leg demonstrator

MT Aerospace achieves design for manufacturing, integrating multiple elements into one-piece structure using AFP and 3D printed tooling to meet time and budget constraints.

Composites business growth through diversification, innovation

San Diego-based 2024 Top Shops qualifier Rock West Composites gives an overview of its relentless commitment to improvement, including its composite capabilities and its role as a trusted player in the space market.

Carbeon C/C-SiC ceramic matrix composites without fiber coating

Dutch startup Arceon is working with leaders in space, hypersonics and industry to test its Carbeon CMC, validating near-net-shape parts with <3% porosity and performance at 1600ºC, targeting UHTCMC and a presence in the U.S. in 2025.

Sources (clockwise from top left) | Exel Composites, Bryan Hall – Nox Mysterium Productions, Shutterstock, MDLR Brands

This year’s theme is “Performance with Purpose.” In infrastructure and construction applications, composite materials can offer a variety of performance benefits over traditional materials like wood or metals, including light weight, corrosion resistance, durability, higher strength and design flexibility.

These advantages can serve larger purposes like enabling infrastructure to withstand extreme weather events, speeding assembly of buildings to help combat housing shortages, contributing to sustainability goals by increasing energy efficiency or decreasing manufacturing-related carbon emissions and more.

Here are just a few recent applications of composites in infrastructure and construction:

• In building construction, structural insulation panels (SIPs) made using fiber-reinforced polymer (FRP) sheets versus traditional wood can be assembled faster and are more durable.
• Composite rebar, including potentially rebar made with recycled carbon fiber, is used to reinforce concrete buildings and bridges, marinas and other applications – reducing weight, adding durability and offering corrosion resistance versus traditional steel.
• To support growing energy needs, conductor cores made from pultruded composites can significantly increase transmission capacity of electrical utility infrastructure, reduce electrical losses and enhance grid resilience to extreme weather events.
• Composite pedestrian bridges offer fast assembly and high strength.
• Pultruded or filament-wound composite utility poles can be tailored in their design and materials to suit a variety of needs, including resiliency in extreme weather conditions like storms and wildfires.
• Composite materials can enable the design of complex interior and exterior architectural elements not possible to achieve without composites’ tailorability, light weight or strength.

This NCW, we celebrate the ways composites are enabling these and many other infrastructure and construction applications, and aim to continue advocating for their increased adoption.

Want to dive deeper? Below are links and summaries to a few of CW’s most recent articles covering innovations in this field. For more content (including company news and new product announcements), visit our Infrastructure and Construction topic pages.

Composite SIPs for more affordable, efficient and sustainable buildings

Modular Brands’ LiteSIP panels and modules enable framing for residential and commercial buildings in days, cutting structural labor and total cost by up to 70% and 30%, respectively, while increasing energy efficiency and durability.

The potential of rCF in fiber-reinforced concrete

This column by recycling company Carbon Fiber Recycling takes a look at how emerging technologies for FRP concrete provide alternatives to traditionally used steel and glass fibers that are more cost-effective and address the sustainability challenge.

CW Talks podcast interview with Francesco Ierullo, Exel Composites

In this podcast interview, Francesco Ierullo, vice president of sales and marketing at Exel Composites discusses the role the composites manufacturing processes of pultrusion and pullwinding are playing in infrastructure and renewable energy applications today.

Sources (clockwise) | Kautex Textron, Getty Images, CRRC Corp. Ltd. and Bucci Composites

Since their conceptualization, fiber-reinforced composite materials were born with a purpose: to fill the high-performance materials gap where traditional mediums, like metals and unreinforced plastics, have often fallen short. Since then, CFRPs, GFRPs, CMC, aramid and natural fibers, bio-based and graphene-enhanced fibers and many others have not only filled this gap — they’ve surpassed it, enabling a paradigm shift in engineering design that has positively transformed a majority of industries and applications, including transportation markets.

For commercial automotive applications, a recent review by CW’s Stewart Mitchell sums up this sector’s focus over the past year: 

“The automotive composites sector … is characterized by a dynamic interplay of business considerations, material performance, cost and sustainability imperatives. The proliferation of EVs is intensifying the demand for lightweight materials, particularly in battery construction, where composites can achieve substantial weight reductions compared to traditional metals. Concurrently, advancements in automated production techniques are focusing on high-performance applications, while innovations in recycling technologies are addressing EOL material waste effectively.

“Global market dynamics are in flux, with fluctuations in the demand for composite materials and an uptick in strategic acquisitions. The automotive landscape of 2025 suggests that composites will see broader integration across diverse vehicle architectures. However, the pace of adoption will largely hinge on ongoing improvements in manufacturing efficiencies and efforts to reduce material costs, making composites more viable for wider market applications.”

As of 2025, in other transportation sectors — mass transportation options like rail and bus — composites are also increasingly gaining traction, driven by intensifying regulatory pressure to reduce emissions, the need for lightweighting to improve energy efficiency and growing urbanization requiring higher-capacity, lower-maintenance fleets. Though long considered too expensive for large-scale transit use, ongoing material and process advancements and life cycle cost analyses have begun shifting the cost-benefit balance in favor of these advanced materials.

Purpose in hand, composite materials are on the cusp of widespread adoption in this sector, already providing measurable value. This is why CW editors have highlighted transportation as a prominent end market for this year’s (NCW). Below is a roundup of key content to explore, read and learn more.

Note: Below covers only August 2024 – August 2025 articles for these topics. For other related content (including news and products), visit these sections of our website.

Composites end markets: Automotive (2025)

Composites manufacturing intelligence drives circular economy solutions as automotive industry balances technical demands with sustainability mandates. 

Infused sandwich window frame components help double-decker buses meet weight targets

Prototype GFRP parts were evaluated by Spanish bus manufacturer Carrocerías Ayats as an initial move toward lighter, more efficient, more automated parts and processes.

Bucci Composites expands automotive production capabilities with facility addition, new high-ton presses

CW Top Shops recipient Bucci Composites shares an update on its facility expansion, automotive composites applications, sustainability, education initiatives and more.

A new generation of PP foam core for lightweight truck trailers, RVs

Extruded PP (XPP) foam core offers lightweight, high-performance monomaterial panels that are easily recycled for truck flooring, sidewalls or cabinet/furniture boards as the transportation industry seeks a replacement for plywood.

Moving toward sustainable automotive parts manufacturing

How can the automotive supply chain prepare for future sustainability requirements? Tier 1 Kautex Textron discusses emissions reduction, design for circularity and transition to recycled/bio-based plastics.

Pultruded CFRP chassis enables 36% payload increase for specialized commercial vehicles

CarbonTT’s quadraxial NCF composite chassis adds 185-kilogram capacity to Borco Höhns’ 3.5-ton Fiat Ducato market vehicle.

PUR composite sandwich panels for 3D automotive parts, high-volume panels and more

At its U.S. sites, Ascorium produces glass fiber/PUR 3D parts via semi-automated molding, high-volume flat panels via a continuous line while working toward bio-based PUR and recycling.

Bladder-assisted compression molding derivative produces complex, autoclave-quality automotive parts

HP Composites’ AirPower technology enables high-rate CFRP roof production with 50% energy savings for the Maserati MC20.

Composite materials, design enable challenging Corvette exterior components

General Motors and partners Premix-Hadlock and Albar cite creative engineering and a move toward pigmented sheet molding compound (SMC) to produce cosmetic components that met strict thermal requirements.

(Manufacturing, Overhaul, Repair for Prognosis Health Overreach) was a Horizon 2020 funded research project (September 2021 – January 2025) that aimed to optimize the manufacturing and life cycle management of carbon fiber-reinforced polymer (CFRP) aeroengine fan blades. It would thus extend European industrial leadership by advancing cost-effective, flexible and ecological manufacturing, maintenance and recycling processes for the next generation of multifunctional composite airframe parts.

Consortium and objectives

The MORPHO consortium comprised 10 partners from six countries. Led by the (ENSAM, Paris, France) it included aeroengine manufacturer (Paris, France), Fraunhofer IFAM (Bremen, Germany), (TU Delft, Netherlands) and the (Patras, Greece), as well as sensor suppliers Synthesites (Piraeus, Greece), (Châtelet, Belgium) and (Braunschweig, Germany) as well as Spanish partners , responsible for communications and dissemination, and simulation software supplier .

“The goal was to define an industrial process for producing a multifunctional (or “smart”) composite fan blade, which is also multi-material, because the leading edge is titanium,” explains Nazih Mechbal, director of the 180-person (PIMM) laboratory at ENSAM. “We wanted to give it cognitive function, from its manufacture to end of life [EOL], by embedding sensors and enabling life cycle management through data-driven hybrid twins and machine learning [ML] algorithms. We also wanted to develop a disassembly process that could be industrialized for separating and recycling the titanium leading edge and composite structure.”

The MORPHO demonstrator was a foreign object damage (FOD) panel representing a section of a LEAP engine fan blade.

To demonstrate this, the MORPHO consortium developed a foreign object damage (FOD) panel, “representing a fan blade for the LEAP engine,” says Mechbal, “and used by Safran to test all this capability.” The project succeeded in multiple achievements including:

• Optimized RTM process with 20% shorter cure cycle using advanced dielectric sensors and real-time data analytics for monitoring viscosity, T_g and cure.
• Hybrid twin of RTM process predicted resin flow and cure with <1% error in under 1 millisecond; combining high-fidelity physics-based simulations with real-time process data enabled identifying local permeabilities in woven preforms which significantly enhanced quality control during production.
• Novel AI-based structural prognostics and health monitoring (SHPM) system for aeroengine fan blades that integrates low-frequency fatigue testing, advanced sensing techniques and deep learning architectures to predict stiffness degradation and remaining useful life (RUL) based on strain and other measurements.
• Demonstrated laser shock disassembly of CFRP blade from titanium leading edge, with process parameters tuned using simulation to ensure no damage to composite materials for recycling/reuse.

Hybrid twins for RTM

“A digital twin is when you use digital models to create a replica of your system using simulation,” says Mechbal. “In a hybrid twin, we enable dialog between this digital data and physical data obtained from sensors. To do this, we first build the physics-based RTM process simulation and finite element [FE] simulation, and then add data-driven online learning to create a hybrid twin.”

Virtual twin. The virtual twin of the RTM process is a digital twin developed as a multiphysics model comprising multiple steps:

• Resin injection (Newtonian fluid flow into 3D woven fabric, Darcy’s law, potential to form racetracks or dry spots)
• Curing (kinetics of polymerization, Kamal-Souror model)
• Heating/cooling (conduction + convection, thermo-dependent mechanical properties).

“From this complete physical model, which requires time and computing power, we extract a reduced model using proper general decomposition [PGD] or any other physics-informed reduction method,” says Mechbal. “Although these reduced models are quick and can be run on the fly during the RTM process, there will be discrepancies with the physical data. This is where we use AI and use it only to estimate these discrepancies. Thus, we retain as much physical knowledge as possible and only use ‘blind’ methods for discrepancies that may arise from the model reduction and unmodeled phenomena such as noise, environmental conditions, etc.”

Physical measurements. For this second part of the hybrid twin, MORPHO used two kinds of sensors during the RTM process. Dielectric analysis (DEA) sensors from Synthesites were used for process monitoring and measuring the resin flow front. The image at left describes the equipment setup.

As I explained in my 2020 blog on Synthesites, DEA has been used for decades. For MORPHO, Synthesites supplied durable in-mold sensors and in-line sensors at the inlet and outlet gates which fed data into Optiflow and Optimold data acquisition units. Optiflow units monitor resin arrival and temperature and can identify production deviations during resin infiltration. Optimold units use temperature and resin resistance measurements to make calculations and monitor the state of the resin including mix ratio, chemical aging, viscosity, T_g and degree of cure. The data is then analyzed and results are displayed on a laptop using Synthesites’ ORS software.

In addition, this setup used an additional piece of equipment, the . As explained in my 2022 blog on the SuCoHS project, using only one thermocouple, the Cure Simulator can copy the cure process taking place inside the RTM mold (or in that case, the autoclave) and determine the cure level of the composite to identify the point at which it is cured. As explained by Wilco Gerrits, senior R&D engineer and SuCoHS program manager at Royal Netherlands Aerospace Centre (NLR, Marknesse), “this enables ending your autoclave process when it meets your cure requirements instead of keeping it at temperature for an extra half an hour just to be on the safe side.”

 “But we also looked at a process to put fiber optics with FBG [fiber Bragg grating] sensors from FiSens inside the 3D woven composite preform,” says Mechbal. “We did this using a manual method as proof of concept and also used a more automated weaving process. Because it’s a 3D preform, we are just weaving another fiber there. We did a lot of tests in the 3D woven preform and there was no noticeable impact from integrating the FBG sensors.”

RTM trials

Using a steel matched mold set designed by Safran, MORPHO completed multiple RTM trials to develop a sensor and hybrid twin approach that was reproducible and robust. “For example, we used the virtual twin to predict in real time physical parameters like resin permeability of the preform,” Mechbal explains. “We also had the input coming from the DEA and FBG sensors, which gave us the actual resin flow that we could compare in real time to what we simulated. And due to the layout of our sensors, this included a display of how the permeability changed by zone.”

A specific data acquisition interface was developed in MATLAB to gather data from all sensors (fiber optic/FBG, resin arrival, flow rate, pressure and temperature). This interface, also connected to the hybrid twin, can predict — in real time — flow front position and local material properties, says Mechbal. It also enables real-time dialogue between the RTM trial and the hybrid twin, handling both reduced models and data from experimental measurements simultaneously thanks to parallel processing. It can also be used offline to load both reduced models and sensor/process data measurements during RTM for further analysis, and is able to read HDF5 files as well as all raw source files.

The vision, he adds, is to keep advancing this technology so that the RTM process can be adapted as needed in situ

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SHM using printed PZT sensors

The original vision of the MORPHO project was always to use sensors, not only to enable a more efficient manufacturing process, but to also impart cognitive function while the part is in service, including structural health monitoring (SHM) and prognostic capability for maintenance. “The sensors we used to optimize the RTM process will also be used for SHM to detect impacts, etc.,” says Mechbal. “But for this, we added other types of sensors, including piezoelectric [PZT] sensors, which were printed on the surface of FOD panels.”

Although FBG for SHM has reached TRL 8-9 in the aerospace industry, Mechbal’s expertise is in PZT technology. Thus, his team at ENSAM worked with MORPHO partner Fraunhofer IFAM to advance PZT sensors for SHM. “While we knew that FBG sensors would give a lot of information on strains and could be used to predict the remaining life of the structure,” he explains, “we saw an ability for PZT sensors to complement this.”

Printing PZTs. Screen printing with silver conductive paste and piezoelectric lacquer on FOD panels was used to create three-layer sensors comprising a top electrode, a 135-micrometer-thick piezoelectric layer and a bottom electrode. “After printing, the part goes into an oven to achieve polarization,” says Mechbal. This induces the piezoelectric effect, enabling the sensors to convert mechanical stress into electrical signals and vice versa. For MORPHO, the printed sensors were processed at 100°C for 30 minutes. “This is a process that could easily be industrialized for composite fan blades,” he adds. “We can also print the wires on the part, but for MORPHO, we didn’t want to have a lot of variables, so we just used regular wire and connectors, to reduce complexity.”

PZT sensor testing

Multiple tests were performed on FOD panels with printed PZT sensors on the surface, including:

• Electromechanical impedance to detect impact events and determine their location and impact energy.
• Acoustic emission as a passive method for monitoring the damage process.
• Lamb wave interrogation for active monitoring of damage onset and evolution.

“Using FOD panels with a titanium and aluminum leading edge, we proved that we can detect damage from impact with a hammer,” explains Mechbal, “including the position and level of energy. And this can be done automatically, because the PZT sensors are a passive approach. In this case, we didn’t send waves but just listened and applied algorithms based on correlation with parameters such as time of flight. These then gave the position and level of impact energy that the FOD panel was subjected to.”

Test panels were also subjected to fatigue testing, performed by TU Delft. “These panels were equipped with PZT and FBG sensors,” notes Mechbal. “We used a hydraulic machine to perform calibrated impact and then recorded this with a camera as well as collecting the sensor data. We also tested to see if we could use these sensors to send and receive lamb waves.” These have been proven effective for detection and quantification of damage in composite laminates.

The image above shows measurements that proved the printed PZT sensors can both correctly emit and sense lamb waves.

 “We then tested some probabilistic approaches for damage detection,” says Mechbal. “We started with a pristine panel, created impact damage and then looked to see if there is a difference in the measurements between them. We were checking to see if the structure was okay or not. The green diamond is where we estimated to have the location of damage with the yellow field of probability around it. And the cross in black is the actual damage that we detected with the sensors. These were good results for this kind of system, which wasn’t optimized in terms of sensor placement.”

“We have developed a good database of how these sensors perform with various damage detection methods that we’re now trying to share with the community,” he notes. “This technology of using printed PZT sensors for SHM is a new paradigm for SHM, enabling a more automated approach as we can print the sensors as quickly as we want and also the wires. Not only can this single sensor type handle several functionalities, but it’s fast and affordable to place as many sensors as we want, so that even if we have a part where some sensors are damaged and lost, we have enough redundancy to always detect and locate damage.”

“… we can print the sensors as quickly as we want and also the wires … it’s fast and affordable to place as many sensors as we want, so that even if … some sensors are damaged and lost, we have enough redundancy to always detect and locate damage.”

“The printing also makes it easy to place the sensors where we can easily plug into them to interrogate the parts when the aircraft is on the ground,” says Mechbal. “For example, the plane docks at the airport, and we simply plug into it and test by sending waves and taking measurements. We can then see if there is damage, or perhaps a change of stiffness in certain areas of the fan blade, as well as the amount. We can then try to quantify the severity of the damage using algorithms.”

Disassembly and recycling

The last part of the MORPHO project dealt with disassembling of the part for recycling or reuse. “The first route we proposed for the FOD panel was to disassemble the titanium leading edge from the composite and also use the sensors that are embedded to monitor this process,” says Mechbal.

“The disassembly was done here at ENSAM using laser shock dismantling, where a high-power laser beam creates a wave that we send to a sacrificial layer on the composite side of the specimens,” he continues. In this case, the sacrificial layer was a thin aluminum tape adhesively bonded to an eight-ply-thick CFRP coupon representative of the FOD panel. “This setup was just to prove that disassembly was possible.”

“We exposed the samples to the laser beam, which created a small plasma wave resulting from the temperature dilatation (thermal expansion),” notes Mechbal. “The setup includes using a laser-transparent material, such as water, to confine the expansion and further increase the pressure induced by the expanding plasma. This results in the generation of a compressive shock wave in the bulk of the material that propagates inside depending on the density of the material and other parameters.”

”We proved that we can create delamination at any layer in the composite,” he continues, “and control both the location and size of the delamination by tailoring the laser parameters. We then used this process to go further than delamination and actually disassemble the titanium leading edge from FOD panels. We also tested FOD panels with an aluminum leading edge. The method is the same — it just required new calibration.”

Mechbal explains how this tuning of parameters enables dismantling the components without damaging the composite, adding that MORPHO project partner University of Patras also developed a good FE simulation that predicts how this process achieves the dismantling, including damage results.

After the separation, the composite was processed by Comet Group, one of the MORPHO partners in Belgium, which used a pilot production line to pyrolyze the resin and reclaim the fiber. It developed an optimal process of pyrolysis for 2 hours followed by 30 minutes of oxidation. This resulted in recycled carbon fiber (rCF) with mechanical property degradation limited to around 10%. The idea, says Mechbal, is to use this in automotive or aeronautic interior parts but not structural parts.

Challenges, achievements, possible application for open rotor engines?

Overall, the MORPHO project was successful, says Mechbal, with multiple technologies demonstrated and moved forward, although there were significant challenges. ”The RTM process was easy to monitor using sensors, but integrating the sensors into the process was difficult. Integrating FBG sensors into the process was very laborious, requiring several specific developments and tests. The same was true for developing printed PZT sensors for SHM,” he notes. “We spent a lot of time developing how to integrate FBG and PZT sensors for the SHM process.”

He also notes that for the RTM process, the sensors are being used in an open loop. “The vision was to provide a control feedback loop to optimize the process, but that is not easy to do and requires more development,” he says.

“The process of printing PZT sensors is something that really changes the paradigm for SHM … including how to optimize their placement and interrogation.” 

Meanwhile, he sees the printed PZT sensors as one of the project’s largest achievements. “The process of printing PZT sensors is something that really changes the paradigm for SHM,” says Mechbal. “I have been developing this technology for 10 years, including how to optimize their placement and interrogation. Now, it’s very easy to print and use them. This is something that can be done at the end of any structure manufacturing process.”

“For recycling hybrid composite/metal parts, I think the laser dismantling process opens a lot of possibilities,” he continues. “Also, Comet has completed a business study to quantify the energy required for pyrolysis and what is possible to earn from rCF. Their analysis shows recycling using pyrolysis could be feasible for these fan blade type structures, reusing the fibers in other composites.”

Will ENSAM and other MORPHO partners continue with any of the technologies demonstrated? “This was our vision at the beginning of the project,” says Mechbal, “in alignment with Safran’s priorities at the time. We have given them the software for the hybrid twin of the RTM process and we’re now discussing how to mature the TRL further for the sensor technologies. We didn’t do any tests on an actual fan blade — only the demonstrator panels. So, it is still necessary to see what happens when you use these technologies in an actual flying part.”

“... without a nacelle, the blades are exposed and can experience a lot of FOD impacts. ... even small effects can have a large consequence during operation. For example, they can change the equilibrium of the rotation … But we have proven SHM is possible that can see these damage events and changes in structure.”

The use of these sensors to detect damage is indeed interesting because  for the next-generation single-aisle aircraft, slated to enter service after 2035. “I don’t know if open rotor is the future,” says Mechbal, “but it was still a priority project for Safran at the beginning of the MORPHO project. However, open rotor designs present a challenge, because without a nacelle, the blades are exposed and can experience a lot of FOD impacts.” And such impacts can create issues for all CFRP parts.

For aeroengine fan blades, however, even small effects can have a large consequence during operation. For example, they can change the equilibrium of the rotation, which can be very serious, says Mechbal. “When there is large damage, you can see it,” he explains. “You don’t need SHM. But when you have a small impact and perhaps only barely visible damage on the outside, there could be delamination and/or change of stiffness on the inside that you cannot see. And this is something that changes the rotation of the fan blade. But we have proven SHM is possible that can see these damage events and changes in structure. I think MORPHO has advanced technologies that will create new opportunities and possibilities for composites.”

Sources (clockwise) | HERWINGT project, Airborne, Loop Technology

As  (NCW) unfolds this year and we discuss the myriad ways in which composites exemplify “Performance With Purpose,” one of the first areas that demands attention is the use of composite materials in the aerospace and advanced air mobility (AAM) sectors. Often innovations in materials are driven by the demands in this sector, are proven out in the qualification of prototypes and pushed to their limits in defense applications as part of their pathway toward commercialization. Today, new innovations aimed at manufacturing for scale, including ever-evolving automation solutions are propelling the industry forward.

A central theme echoed in recent ÂÌñÏ×ÆÞ reporting — including CW’s coverage of this year’s Paris Air Show — is the industry’s decisive shift toward high-rate production. Demand for commercial airliners is a driving force behind a trend where aerospace manufacturers are increasingly integrating automation, robotics and digital process controls to boost output, repeatability and precision. Advances in automated fiber placement (AFP), stamp forming and in-line inspection systems, and the growing use of thermoplastic composites (TPCs) and ultrasonic welding is helping cut cycle times and scale composite manufacturing to levels more closely aligned with metal-intensive assembly lines. While thermoset composites continue to be widely used in aerospace applications, TPCs are gaining traction for their recyclability, toughness and production efficiency — qualities that align well with the aerospace sector’s goals for sustainability and volume manufacturing.

Rising to the challenge of passenger growth and fleet modernization, OEMs are envisioning next-generation single-aisle airliners that blend efficient aerodynamics, lightweight structures and modular composites. Coverage during industry showcases — like those at the Paris Air Show — highlight OEMs and suppliers exploring the use of composites for new wing designs, structural parts and composite-intensive fuselages that cut weight without compromising strength.

Meanwhile, emerging from the AAM realm, vertical take off and lift (VTOL) programs — though still in prototype stages — are already serving as experimental platforms for high-rate composite production. This new emerging class of aircraft offers new insights into workflow optimization, tooling reusability and scale-up strategies. As these programs move toward certification and potentially small-scale production, the lessons learned — particularly in balancing structural complexity with manufacturability — will cross-pollinate back to traditional aerospace programs scaling to meet commercial airline demand.

NCW provides a fitting moment to reflect on all of this progress. Automation isn’t optional — it’s driving production rates to meet the demand for these applications. Thermoplastic composites aren’t niche — they’re increasingly vital to scalable, sustainable aerospace systems. Next-generation single-aisle platforms continue to serve as the proving ground for composite-driven design and manufacturing. VTOL efforts aren’t just flying taxis — they’re laboratories for next-level composite production.

Together, these themes encapsulate a dynamic era — one in which composite materials and production innovation coalesce to help redefine aerospace manufacturing. This year’s NCW is a great time to reflect on some of the progress we’ve seen in the aerospace sector this year. Below is a roundup of key content to explore, read and learn more.

Note: Below covers only articles produced in 2025 for these topics. For other related content (including news and products), visit these sections of our website.

Paris Air Show highlights advanced materials, industry momentum

This year’s international air show offered a glimpse of the rapidly expanding future for composites in aerospace.

What you might have missed at Paris Air Show 2025

A surge in defense spending, partnerships in hydrogen propulsion and new combat aircraft agreements, many backed by composites industry leaders, culminated the 55th Paris Air Show.  

Ceramic matrix composites: Faster, cheaper, higher temperature

New players proliferate, increasing CMC materials and manufacturing capacity, novel processes and automation to meet demand for higher part volumes and performance.

Cutting 100 pounds, certification time for the X-59 nose cone

Swift Engineering used HyperX software to remove 100 pounds from 38-foot graphite/epoxy cored nose cone for X-59 supersonic aircraft.

Clean Aviation Pax Cabin Demonstrator uses biocomposites to cut weight, environmental impact

Full-scale regional aircraft fuselage equipped with cabin structures and systems demonstrates next-gen interiors to TRL 6 with successful FST, noise and vibration testing performance.

Advancing thermoplastic composite primary structure and morphing wings

The HERWINGT project in Clean Aviation seeks to ready technologies — including at least 16 composite demonstrators — for a hybrid-electric regional aircraft with 50% less fuel burn to be launched by 2035.

Aerospace prepregs with braided reinforcement demonstrate improved production rates, cost

A recent time study compares the layup of a wing spar using prepreg with A&P’s TX-45 continuous braided reinforcement versus traditional twill woven prepreg.

Inside the MFFD — CW's coverage of the Clean Aviation multifunctional fuselage demonstrator

CW rounds up coverage of the MFFD project over the past decade. Now complete, the MFFD illustrates numerous processes and technologies for manufacturing primary aerospace structures using thermoplastic composites. 

Plant tour: Collins Aerospace, Riverside, Calif., U.S. and Almere, Netherlands

Composite Tier 1’s long history, acquisition of stamped parts pioneer Dutch Thermoplastic Components, advances roadmap for growth in thermoplastic composite parts.

VIDEO: Installing the world’s largest thermoplastic composites press at Airbus Bremen

At JEC World 2025, Pinette PEI detailed its latest turnkey system for future aircraft serial parts production.

ASCEND program completion: Transforming the U.K.'s high-rate composites manufacturing capability

GKN Aerospace, McLaren Automotive and U.K. partners chart the final chapter of the 4-year, £39.6 million ASCEND program, which accomplished significant progress in high-rate production, Industry 4.0 and sustainable composites manufacturing.

Prepreg compression molding supports higher-rate propeller manufacturing

To meet increasing UAV market demands, Mejzlik Propellers has added a higher-rate compression molding line to its custom CFRP propeller capabilities.  

Agile Ultrasonics has developed an advanced ultrasonic welding system that is integrated with a robotic arm. This innovation enhances precision and efficiency in welding applications. Source | Agile Ultrasonics

In-space manufacturing (ISM), the concept of producing materials and components beyond Earth’s atmosphere, emerged in the 1970s, and has since advanced from theoretical research to practical experimentation. The primary goals of ISM include reducing launch costs by fabricating parts directly in orbit, enabling on-demand production for long-duration missions and harnessing the advantages of space environments — such as microgravity and vacuum conditions — for producing materials.

Thermoplastic composites (TPC), which have seen substantial advancement in aerospace and space applications within the last decade, show potential for ISM. They provide several key advantages over conventional thermoset systems, including ease of joining and processing through melting and fusion bonding/welding, enhanced recyclability and improved fracture toughness. However, they also face a critical challenge: Achieving reliable, repeatable and automated joining of structural components under the extreme conditions prevalent in space environments.

To tackle this challenge, NASA’s (Washington, D.C., U.S.) Game Changing Development (GCD) Program, operational since 2011 under the Space Technology Mission Directorate, has initiated multiple projects exploring advanced materials and joining methodologies for in-space assembly. The program emphasizes versatility over specific flight hardware applications, aiming to enhance future mission capabilities across diverse scenarios.

One notable initiative started in October 2021, the Thermoplastic Development for Exploration Applications (TDEA), focused on examining the structural integrity, processing characteristics and in situ joining techniques of carbon fiber-reinforced thermoplastics (CFRTP). NASA pursued TPC welding, aligning with its strategic objective to advance materials and manufacturing methodologies for space exploration.

“The capabilities of TPC welding can significantly streamline in-space assembly operations,” highlights Dr. Sandi Miller, a chemical engineer at NASA’s Glenn Research Center (Cleveland, Ohio, U.S.). “Instead of managing individual components like bolts and predrilled holes, the process simplifies to melting the thermoplastic and applying pressure. This approach not only enhances ease of assembly but also allows for easier construction of larger structures.”

TDEA program background

Under the TDEA framework, teams from NASA’s Glenn Research Center, Langley Research Center (Hampton, Va., U.S.), Goddard Space Flight Center (Greenbelt, Md., U.S.) and Marshall Space Flight Center (Huntsville, Ala., U.S.) conducted an in-depth investigation into the performance of TPC in lunar and orbital conditions. The research encompassed laminate processing, mechanical characterization and the evaluation of joining techniques. Various welding methods were scrutinized, including resistance, ultrasonic and induction welding. Although resistance and induction welding exhibited high mechanical strength, they also posed significant challenges related to power consumption and feasibility for space applications. In contrast, ultrasonic welding showcased robust joining capabilities that align well with robotic operations and the environmental constraints inherent in space missions.

(Columbus, Ohio, U.S.) initiated a collaborative effort with NASA under the TDEA framework in 2022, aimed at exploring the potential of the company’s ultrasonic welding technology for CFRTP. The partnership’s primary goal is not to deliver a conclusive solution, but to accumulate foundational data, refine process control methodologies and evaluate the technique’s viability for structural joining applications in space environments.

Agile’s work commenced with a series of small-scale experiments, including single-lap shear coupon tests, flat panel weld evaluations and initial single-lap shear testing. Encouraged by results that confirmed the feasibility of welding thick TPC laminates, NASA subsequently expanded its collaboration with Agile Ultrasonics to incorporate structural-scale trials and environmental validation studies.

Welding approach

Ultrasonic welding is a proven technique for joining TPC materials, especially prevalent in the automotive and consumer goods sectors (learn more about welding). Here, traditional applications generally target thin components made from low fiber-content substrates, using high-frequency vibrations to generate localized heating at the interface. Even when used in aerospace applications, conventional processes typically deploy geometric features such as energy directors or resin-rich film inserts to facilitate melting and material flow at the bondline, especially for continuous ultrasonic welding applications.

Agile Ultrasonics contends that the potential of ultrasonics remains largely untapped by traditional OEM system manufacturers. As an innovative enterprise, Agile’s strategy is to adapt the technology for underexplored application areas, informed by the properties of the composite materials at hand. The company has demonstrated that by customizing the ultrasonic stack and developing novel methodologies, it can yield results previously deemed unachievable, such as continuous ultrasonic welding without energy directors or polymer films.

“Our approach is to prioritize understanding the material properties and work backward from there,” notes Jim Stratton, president and CEO of Agile Ultrasonics. In the context of high-performance TPC, particularly those with a high fiber fraction, the central challenge lies in delivering precise heating to the material in a controlled manner, while advancing with optimal speed and pressure/force to fulfill the weld requirements.

Agile’s system is designed to achieve through-thickness heating by employing a specialized ultrasonic end effector, coupled with tailored process parameters and methodologies. This technology is adaptable across various robotic platforms and delivers programmable ultrasonic energy via modular sonotrode designs, which maintain contact with the composite surface while following the weld path.

In contrast to traditional ultrasonic welders that rely on off-the-shelf components, Agile Ultrasonics’ systems are custom-engineered to align with the thermal and mechanical properties of aerospace-grade composites. These advanced materials, including prepregs using low-melt polyaryletherketone (LMPAEK) polymer from Victrex (Cleveleys, U.K.), can contain up to 60% carbon fiber by volume and demonstrate low melt flow characteristics compared to standard TPC. Agile adjusts its ultrasonic stack and welding parameters according to the specific resin behavior, fiber architecture and laminate thickness of the components being joined.

This versatility makes the technology suitable for joining pre-consolidated plates, preforms, braided sleeves and unidirectional tape layups,  offering flexibility across diverse composite formats. The technology enables meticulous control over frequency, amplitude, force and welding speed, with operational capabilities in both ambient air and vacuum environments. Typically, the system operates at 20 kilohertz and exerts force ranging from 45-150 pounds (200-670 newtons).

Material selection and characterization

The TDEA project assessed five TPC material systems to pinpoint the most viable options for application. Following rigorous testing of more than 600 coupons, the research team identified Toray Advanced Composites USA’s (Morgan Hill, Calif., U.S.) T700 carbon fiber-reinforced LMPAEK prepreg as the leading candidate.

“Our choice to advance with LMPAEK was driven by its optimal processability and the substantial material characterization data accumulated during the down-selection phase,” notes Miller. “Despite successful welding with the other materials evaluated, LMPAEK’s ability to be processed at lower temperatures than PEEK and PEKK stands out, as it minimizes residual stresses in the final components.”

The material testing regimen also encompassed an evaluation of outgassing properties, a critical factor for space applications. All TPC materials tested exhibited negligible outgassing levels in accordance with ASTM E595, which measures mass change of the sample and mass of collected condensed volatiles.

From 2022 to early 2024, Agile Ultrasonics’ collaboration with NASA evolved from initial small-scale feasibility studies to intricate structural evaluations. During this period, multiple design of experiments were executed to establish baseline performance metrics of weld joints across diverse materials and laminate configurations. The initial focus included single-lap shear (SLS) coupons, specifically sized at 1 × 1 inch (25.4 × 25.4 millimeter) bond areas, composed of carbon fiber-reinforced LMPAEK composites. These coupons underwent welding using Agile’s technology and were subsequently tested following standardized mechanical protocols.

Joint trials and results

The trials used a series of ultrasonic welding techniques including plunge welding (static or spot welding of clamped parts in a fixture) and continuous ultrasonic welding methods. Iterative modifications of process cycles were carried out in collaboration with the NASA research team to enhance joint quality by investigating various interface configurations.

“While earlier ultrasonic welding process models addressed some aspects of the physics involved, they failed to encapsulate all the critical mechanisms,” remarks Andrew Bergan, analysis lead at NASA Langley Research Center. “Our modeling efforts revealed some deficiencies in conventional approaches to heating mechanisms, particularly as they relate to the melt temperature range. This insight highlighted the necessity for improved process models to more accurately predict and control heat generation during the ultrasonic welding of these advanced thermoplastic [composites].”

In terms of performance, initial tests using LMPAEK film interlayers revealed shear strengths ranging from 3-8 MPa, with predominant adhesive failure modes at the bond interface. Notably, by incorporating an LMPAEK film layer into the adherend to enhance polymer chain entanglement, the research team attained lap shear strengths of up to 2.9 ksi (20 MPa) using four layers of LMPAEK film. However, this improvement came at the expense of introducing an unpredictable and potentially catastrophic failure mode that could compromise the adherends.

By mid-2024, the initiative progressed from coupon testing to the welding of structural components. This next phase involved the welding of prototype L-brackets, structured to simulate a joint within a theoretical space framework. These components featured 60-ply, 8.59-millimeter-thick CFRTP laminates welded to 52-ply, 7.58-millimeter-thick CFRTP laminates, closely resembling those intended for use in a lunar tower designed for assembly on the Moon’s South Pole.

“The L-section was chosen for its structural openness, facilitating a dual-sided pressure application during welding,” explains Ken Segal, design lead at NASA Goddard Space Flight Center. “This configuration strikes a balance between structural efficiency and access for welding operations.”

During this phase, NASA selected plunge welding methodologies to further investigate, guided by considerations of part thickness and scale-up efforts. Tensile testing on the plunge-welded brackets demonstrated the highest strengths, exceeding 2.7 times the designated limit load, with failures occurring in the parent laminate rather than at the weld interface. These findings suggest that the integrity of the welded joint is sufficient, and not the primary limiting factor in overall structural performance.

Environmental testing and in-space relevance

Following the completion of the TDEA project in January 2025, NASA transitioned its collaborative efforts with Agile Ultrasonics to a new initiative titled “Structural Materials Joining in Space,” which receives partial funding from the Ohio Federal Research Network (OFRN). This initiative continues the focus on generating baseline weld data under controlled thermal-vacuum conditions, with future plans to integrate microgravity scenarios, potentially through parabolic flight tests or experiments conducted in orbit.

As part of this new program, Agile Ultrasonics has engineered a custom vacuum chamber designed to emulate the in-space temperature range of -190°C to +120°C, reflecting the thermal conditions encountered on the lunar surface. This chamber is capable of operating in both ambient and vacuum conditions and features integrated sensor arrays for real-time monitoring and control of in-weld temperatures.

“The thermal dynamics on the lunar surface present significant challenges, particularly due to the potential for rapid temperature fluctuations,” says Bergan. “Our analysis indicates that if welding operations can be strategically scheduled within a 3-week window in the year, the operational temperature may hover around -80°C as opposed to the more extreme cold associated with other times. This insight allows for the development of more advantageous welding strategies for construction activities.”

Future research and development

Despite achieving promising outcomes, several critical challenges persist in the field. A primary technical hurdle is the precise measurement of temperature at the bondline during the welding process. Glenn Research Center’s Miller emphasizes that advancements in temperature measurement techniques could represent a substantial leap forward in ultrasonic welding and welding technologies at large. Currently, existing methods typically depend on indirect measurements to assess when temperatures surpass optimal processing thresholds.

Additionally, the evaluation of bond quality through nondestructive testing remains problematic. While techniques such as X-ray computed tomography and ultrasonic scanning are effective at identifying voids and delamination, they often fall short in accurately predicting bond strength. Researchers have encountered cases where interfaces that appeared well-bonded in imaging showed unexpectedly low mechanical strength, commonly referred to as “kissing bonds.” This highlights the need for the development of more reliable defect detection methodologies.

Agile Ultrasonics aims to enhance its technology readiness level (TRL) from the current TRL 4 to TRL 6 or higher. This will be achieved through ongoing in-house development, collaborative efforts with NASA and the OFRN, rigorous validation testing and system integration initiatives. Key focal points for this development include the implementation of novel temperature measurement, closed-loop control, automated process monitoring and thermal compensation algorithms, which are essential for deployment in flight-critical or automated manufacturing environments.

Collaborative efforts between NASA and Agile Ultrasonics have demonstrated the significant potential of ultrasonic welding for TPC in-space applications, especially where portability and minimal auxiliary equipment provide notable advantages. Although challenges remain, this work not only bolsters capabilities for space exploration but also enriches the broader understanding of TPC joining technologies, with promising implications for other applications in advanced structures both in space and on Earth.

After exploring national startup ecosystems — including France, Switzerland and Germany — in previous columns, I’d like to shift the lens from geography to purpose, and focus on composites impact, a theme that sits at the crossroads of deep tech innovation, industrial necessity and investment opportunity.

A high-need, high-potential market

Composites are already recognized as critical enablers of sustainability in transport, energy, aerospace, defense and beyond. But their end-of-life (EOL) challenges are equally well known — most of today’s composite waste was never designed to be recovered or reused.

This gap has triggered a wave of entrepreneurial activity. In my three previous columns alone, more than 20 of the highlighted startups are actively tackling composites recycling specifically, or sustainability generally. These activities span from durable materials (CompPair, Bcomp, Carbon Conversion) to complex materials separation (ADN Group, Resolve Composites), innovative recycling processes (Infinici, Composite Recycling, Fairmat, Extracthive, Carbonauten), post-recycling material reconditioning (Nova Carbon, Verretex) and even design for sustainability (Holy Technologies). These startups are responding to real industrial demand, for cost efficiency, regulatory compliance and  reputation protection.(For more information about all companies involved in th recycling landscape, please refer to CW’s Sustainability List.)

“Recycled materials often struggle to move from collection and depolymerization to industrial use,” says Hugo Cartron, co-founder and CEO, Nova Carbon. The company is one example of many that are developing a range of high-performance semi-finished products made from carbon fiber waste. “Our mission at Nova Carbon is to create that missing link by producing high-performance technical textiles made from recycled carbon fiber, ready for industrial applications. This enables part manufacturers to adopt more sustainable materials without compromising on performance or facing prohibitive costs. Our approach is deeply collaborative. We work hand in hand with recyclers, processors and OEMs to co-develop solutions.”

With companies like Nova Carbon, investors are taking note. Funds with a circularity or impact thesis are increasingly entering the sector: from Supernova and Circular Innovation Fund to High-Tech Gründerfonds, Capricorn and Mirova. Strategic investors, too, are scouting early movers for future supply chain advantage with the likes of Airbus Ventures, Syensqo Ventures, Safran Ventures and Diamond Edge Ventures.

Why sustainability is more than just “green”

A few days ago, I was listening to “Equity Conversations,” a podcast hosted by Louis Soris. There, Philippe Zaouati (managing director of Mirova) made a comment that resonates deeply in the world of composites: “Sustainability and resilience are two things that are extremely close.”

With critical materials dependencies and supply chain risks on the rise, the ability to recover, reuse and repurpose composite materials has become not just a nice-to-have, but a strategic imperative.

That’s why sustainability is no longer a niche. It’s the smart entry point for investors wanting exposure to the composites space. It opens the door to technologies that are scalable, industrially relevant and aligned with EU strategic objectives and beyond.

“There are several factors driving the aerospace and defense sectors to engage more actively with composite recycling,” says Florian Hesselbach, senior manager predevelopment materials and technologies, Diehl Aviation (Laupheim, Germany). “First, there’s a clear need to anticipate future regulatory requirements. Second, sustainability efforts contribute positively to public perception — both among passengers and airline partners. And perhaps most strategically, securing access to scarce raw materials like high-performance polymers is critical for maintaining material sovereignty. When it comes to applications, recycled composites can be used either for moderately loaded components, such as injection molded parts, or in combination with virgin material to meet the requirements of highly stressed parts. These use cases provide a practical starting point for piloting circular materials within existing production systems.”

From curiosity to capital: The investor movement has begun

My journey into this space with Catalysium began by openly sharing insights . This kind of public content has proven to be a real magnet for investor attention. A great example is how my relationship with Infinity Recycling, a fund focused on advanced recycling technologies, first began.

In December 2024, while conducting a deep dive into the recycling landscape during a due diligence on Extracthive, I published a LinkedIn post titled That post sparked a direct outreach that would evolve into a meaningful collaboration. This swift engagement is a clear sign of the growing investor curiosity around composites, increasingly driven by impact-focused investment theses.

I continue to be impressed by the depth of knowledge and engagement across the investment landscape. I’ve had insightful conversations with people like Marine Glon (Supernova), Benoit Forcier (Circular Innovation Fund), Benoît Praud (Innovacom), Michael Blank (Verve Ventures), Niels Lang (HTGF), Saimon Satyanathan (EIT Manufacturing), Constantin de Chaudenay (AFI Ventures), Sébastien Léger (Slate), Alexander Rietz (KGAL), Wouter Van de Putte (Capricorn) and many more.

Some are already invested. Others are just starting to explore. But all share the same question: Where is this ecosystem going? And how can we be part of it?

“The sector holds strong appeal for several reasons,” explains Alexander Rietz, managing director at KGAi GmbH (KGAL Industries). “First, composites are increasingly integral to high-performance applications across various industries. However, their recycling and EOL management remains an unresolved issue — this creates both a sustainability imperative and a compelling investment opportunity. Innovative technologies that enable efficient and economically viable recovery and reuse of such materials not only enhance environmental outcomes but also improve the competitiveness and lifecycle sustainability of the underlying assets.

“Second, with the global push for decarbonization and resource efficiency, circular economy technologies can play a pivotal role in improving supply chain resilience,” Rietz continues. “For instance, recycled carbon fiber can help mitigate raw material shortages and reduce dependency on virgin resources — factors that are becoming increasingly important amid geopolitical tensions and climate policy shifts.”

This curiosity from investors gave rise to something bigger: the first JEC Investor Day, held at JEC World 2025, which gathered dozens of investors to explore composites innovation and meet emerging players. The feedback was resounding: “We want more.”

Whether you’re a fund focused on climate, industrial deep tech, the circular economy or strategic autonomy, composites belong on your radar. And there’s no better place to start than to read this column, my Linkedin posts and to join the upcoming JEC Investor Day in March 2026 in Paris.

Let’s build a more sustainable and resilient materials future, together.

Sources (clockwise) | Broetje-Automation, Additive Engineering Solutions (AES), UD-CCM and Abaris Training Resources

This year’s Composites and Advanced Materials Expo (CAMX) promises to be an unmissable gathering for professionals in the composites and advanced materials industry. With hundreds of exhibitors showcasing the latest in materials, equipment and processes, attendees have a unique opportunity to explore emerging trends, connect with industry experts and discover tools that can transform their operations.

Maximizing the value of this experience requires preparation — researching exhibitors, planning booth visits and setting objectives — and ensures participants can navigate the show floor efficiently and leave with actionable insights that drive business growth. That’s why CW editors have taken the time to solicit and curate several exhibitor previews from companies that will be present at the show in Orlando. These previews, while only a small portion of CAMX’s complete exhibitor list, aim to provide additional insight into technology and service highlights so that you can come prepared and ready as soon as the exhibit hall opens. (For a complete exhibitor list, .)

Note: This is a two-part article (second one goes out Sept. 1) with exhibitor previews listed in alphabetical order. Click on hyperlinked text to learn more. 

• 3M: Whether through weight reducing or strength enhancements, 3M designs its microspheres, ceramic fibers, films and LSP materials and composite resins to meet its customers application demands.
• A&P Technology: A&P Technology highlights its QISO and slit tape thermoplastic material capabilities through customer examples and industry applications.
• A+ Composites GmbH: A+ Composites is featuring thin-ply UD TPC tapes engineered with the inherent benefits of thermoplastics, but with individual ply thicknesses below 50?µm and fiber volume contents up to 68%.
• Abaris Training Resources Inc: Set up in its new facility in Spark, Nevada, Abaris is highlighting its training capabilities, course offerings, and customer consultation and technical assistance.
• Accudyne Systems Inc.: From supporting civilian and DOD programs to everyday customer needs, Accudyne Systems strives to deliver production improvements over existing composites manufacturing systems.
• Additive Engineering Solutions: AES is committed to driving technological advancement and application development in 3D printing, distinguishing its diverse capabilities through several tooling examples.
• Akarmak: Turnkey Akarmak autoclaves support various composite curing needs with enhanced process control, international specification compliance and optimal heat distribution.
• AKPA Kimya Ambalaj Sanayi ve Ticaret A.S.: The phthalate- and solvents-free Akperox ST-CL200 presented by AKPA Chemicals provides a reliable, user-friendly polymerization alternative while enabling high-performance production processes.
• Allied UV: Allied UV’s comprehensive production checklist reflects its vision to deliver the most efficient, tailorable UV LED coating systems for composites manufacturers.
• Ascorium Industries: Ascorium Industries is highlighting CompoLite technologies for the production of lightweight, dimensionally stable automotive components and structures.
• Avient Corp.: Avient Corp. is bringing its latest composites innovations including Polystrand, GridCore and Hammerhead solutions.
• Belotti America Inc.: The Belotti ARC is an integrated system that rapidly and automatically manages multiple types of rivets and Time-Serts.
• Big Dog Adhesives: Big Dog Adhesives’ Sausage System redefines fabricators and manufacturers’ adhesive process, delivering control, consistency and high performance for large or detailed work.
• Breton: Breton highlights how the Hawx E2 five axis can elevate trimming, milling and drilling operations.
• Brighton Science: Explore reliable, scalable and data-driven tools by Brighton Science that address adhesion and surface quality challenges, from the Surface Analyst to BConnect.
• Broetje-Automation GmbH: From fiber to flight, Broetje-Automation innovates composites manufacturing with integrated AFP, drilling and sealing technologies.
• BYK USA: BYK USA introduces Garamite-1958, a clay-based additive optimal for applications where high anti-sag, anti-settling or anti-separation performance is required.
• Cambium: Cambium’s ApexShield 1000 system, cutting carbon/carbon production time by up to 80%, gives engineers and OEMs scaling high-temperature composite solutions a step up in survivability, processability and performance.
• Carbon Fiber Conversions GmbH: Work with Carbon Fiber Conversions, a supplier and a strategic partner, to transform carbon fiber waste into a valuable resource, strengthening both business and sustainability credentials.
• Chem-Trend LP: Chem-Trend’s 2775W represents a solution for composites manufacturers who want high performance without the operational changes required by solvent technologies.
• Coastal Enterprises: For more than 50 years, Coastal Enterprises has supported design, prototyping and composite layup applications with its Precision Board urethane tooling board and custom bonding offerings.
• Composites One: Learn more about Composites One’s comprehensive expertise, support and resources, and watch complex manufacturing processes live on the show floor. 
• Concordia Engineered Fibers: Concordia Engineered Fibers exhibits its semi-consolidated towpreg innovation that reduces the bulk of commingled towpreg while maintaining a more flexible tow than fully consolidated prepreg.
• De-Comp Composites Inc: De-Comp’s blend of skilled representatives, a comprehensive suppliers base and well-rounded materials supply are at the heart of the company’s composites supply activities.
• Dieffenbacher: Dieffenbacher presents a comprehensive range of products and services geared toward construction and infrastructure applications, including customer projects, production lines, AR innovations and hydraulic presses.
• Design Concepts: Design Concepts invites attendees to learn more about its comprehensive infusion part fabrication capabilities, spanning design, engineering, tooling and composite parts manufacturing.
• Dickinson Corp.: Dickinson presents its portfolio of “metamaterials,” looking to collaborate with industry partners to demonstrate their scaled-up mechanical capabilities and potential.
• Endeavor Composites Inc: Through a reclaiming and reengineering process, Endeavor Composites creates nonwoven preforms from unused carbon fiber waste, reducing costs and environmental impact while still meeting stringent design requirements. 
• Engineering Technology Corp.: Engineering Technology Corp. strives to raise the bar with precision-engineered solutions like Tape Wrappers, which are built for propulsion systems, structural components or thermal protection solutions.
• Eurovac Inc.: Eurovac’s objective is to design, develop and supply quality dust and fume extraction systems for customers, backed by a comprehensive facility, knowledgeable engineering team and growing distribution network.
• Extec Corp.: Extec is building testing capabilities with a focused lineup of composite sample prep solutions and live demos.
• Fairmat Inc.: Fairmat exhibits FairPly, a scalable, versatile material engineered from cured CFRP chips that releases 90% less manufacturing emissions and can be incorporated with a variety of other virgin material systems.
• Fibro Grats Private Ltd.: The highly controlled system highlighted by Fibro Grats is engineered to precisely dilute concentrated acid solutions and transfer them into various containers.
• French Oil Mill Machinery Co. (TMP): Learn how a custom press from French enhances the composite molding process, equipped to adhere to application/requirement needs.
• Freudenberg Performance Materials: Global technical textiles company Freudenberg Materials presents its portfolio of surfacing veils and Enka Solutions 3D polymeric filament structures used in flow media and spacers.
• Hawkeye Industries: Hawkeye Industries exhibits Duratec, Styrosafe, Styroshield and Aqua-Buff brands for optimal composites coating, compounds and polish solutions options.
• Heatcon Composite Systems: Dual-zone hot bonders and multizone composite repair systems are a couple product options featured by Heatcon that offer flexible repair of composite structures in diverse scenarios.
• Incoa Performance Minerals: Sustainability and cost-effective manufacturing is embedded in every stage of Incoa’s InCal product line, meeting the diverse processing needs of resins, adhesives and fibers.
• James Cropper Advanced Materials: New opportunities in healthcare are unlocked with James Cropper’s Optiveil surface veil technology’s validation for use in sensitive medical environments.
• Janicki: From concept to completion, Janicki highlights its ability to bring expertise, scale and agility to tooling, parts, prototypes and assemblies production.
• Johns Manville: Johns Manville displays its portfolio of glass fiber reinforcements including MultiStar, StarRov and ThermoFlow, which were manufactured with thermoplastic and thermoset composites in mind.
• Kaneka Aerospace LLC: Kaneka Aerospace 250°F BMI prepreg tooling, developed in collaboration with Janicki Industries, elevates composite tooling capabilities.
• L&L Products: Through interactive demos, hands-on materials and chats with experts, L&L is demonstrating its composite materials portfolio, purpose-built for a diverse range of industries and applications.
• Langzauner USA Inc.: Precision and power is part of Langzauner’s engineering-driven philosophy, characterized through its high-performance press systems and turnkey automation solutions for aerospace and automotive.
• Lanulfi Moulds s.r.l.: Lanulfi Moulds, serving a diversified portfolio, is available to discuss and demonstrate how its custom RIM/RTM molds can elevate performance, shorten cycle times and reduce overall production costs.

Visit CW’s CAMX page for more info.