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Filament winding is a specialized technique used in composite manufacturing, involving the precise and automated winding of continuous fibers onto a rotating mandrel or mold. This method allows for the creation of strong and seamless structures, optimizing the alignment and orientation of the fibers to meet specific design requirements. Filament winding is employed in producing cylindrical or conical composite parts, such as pipes, pressure vessels, and aerospace components, enabling engineers to tailor the strength, stiffness, and performance characteristics of the final product.

Processes in composites manufacturing encompass a diverse array of techniques employed to fabricate composite materials. These processes include methods like hand layup, where layers of resin and reinforcement materials are manually placed, and vacuum infusion, where a vacuum draws resin into a preform. Other techniques like compression molding, filament winding, and automated methods such as 3D printing are utilized to create intricate and specialized composite structures. Each process offers unique advantages in terms of precision, scalability, and efficiency, catering to diverse industry needs. As technology advances, newer methods are emerging, promising faster production cycles, reduced waste, and increased customization, driving the evolution of composite manufacturing towards more sophisticated and versatile methodologies.

The wind energy market has long been considered the world’s largest market, by volume, for glass fiber-reinforced polymer (GFRP) composites — and increasingly, carbon fiber composites — as larger turbines and longer wind blades are developed, requiring higher performance, lighter weight materials. The outer skins of wind and tidal turbine blades generally comprise infused, GFRP laminates sandwiching foam core. Inside the blade, rib-like shear webs bonded to spar caps reinforce the structure. Spar caps are often made from GFRP or, as blade lengths lengthen, pultruded carbon fiber for additional strength.

Led by the Brightland Materials Center, consortium members are developing a flexible process chain, demonstrated via battery casings and wind blades, to repurpose waste directly where it is generated.

Joint venture Kineco Exel Composites India has reached full-scale production at the Banda facility, which is now shipping IEC 61400-5-certified flats, joiners and bolt fixtures to support major wind OEMs.

Previously known as the HondaJet 2600 concept, Honda Aircraft Co. has commenced production of its first test unit starting with wing-structure assembly in N.C., and has unveiled a full systems-integration simulator.

Collaborative effort turns EOL blade into a rest area and memorial along the Meenadreen Wind Farm’s Leghowney Loop trail, blending sustainable design and functionality.

The solution combines two key composites manufacturing processes in a single system, increasing design capabilities and manufacturing efficiency.

More than $255.7 million in repairs are being undertaken this year due to lightning damage, with blade root failure in close second, suggesting needed innovation in more resilient materials, or a method for in situ repairs.

Four-person prototype is one of many in-development hulls, floating docks and pontoons comprising bamboo composites and EOL wind blades re-engineered into reliable, environmentally conscious water vessels.

Initial LCA processing carbon and glass fibers evaluates mechanical and thermal recycling methods, finds environmental reduction impact surpasses the impact associated with the recycling processes themselves.

With a new 300,000-square-foot site in Ciudad Juárez, DFS Composites boosts its global footprint and ability to supply composite tooling for wind energy across the Americas.

Fifty of the 100 wind blades installed on the Sofia offshore wind farm will feature recyclable epoxy resin, becoming a key flagship project representing RecyclableBlades at commercial scale.