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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.

Bonding and welding play vital roles in the assembly and fabrication of composite materials, offering methods to join components together effectively. Bonding involves the use of adhesives or bonding agents to create strong connections between different composite parts or between composites and other materials. Adhesives provide uniform stress distribution, enabling lightweight and durable structures. On the other hand, welding techniques like ultrasonic welding or induction welding are employed specifically in thermoplastic composites, where heat is used to melt and fuse the materials together.

Bimetal is an engineered carbon fiber metal laminate that offers a different solution to monolithic sheet metals. Bimetal is said to have good mechanical properties and be lighter to traditional monolithic materials.

The HiMod Advanced Composite Bearing Plus is a dual-layer bearing with a low-friction PEEK liner that doubles as an impermeable sealing surface, in addition to 50% less sliding friction, increased wear performance.

KVE Composites Group and Rescoll cooperate in GKN Fokker-led project to develop micromechanical characterization of thermoplastic co-consolidated joints for aircraft fuselages

CEAD, GKN Aerospace Deutschland and TU Munich enable additive manufacturing of large composite tools and parts with low CTE and high mechanical properties.

Adhesion Technologies Ltd. (ATL, Hampshire, UK) has developed a range of in-mold bonded fasteners, which reduce build time by eliminating the need for hole-drilling.

Suppliers of thermoplastics and carbon fiber chime in regarding PEEK vs. PEKK, and now PAEK, as well as in-situ consolidation — the supply chain for thermoplastic tape composites continues to evolve.

Clean Sky 2 project under the MFFD program produces two segments of an 8.5-meter-long, 4-meter-diameter thermoplastic fuselage skin via NLR’s in-house AFP machine, with consolidation plans this summer.

BASF, Flex-N-Gate, L&L Products and Toyota limited an all-steel assembly, cutting 60 parts down to four composite pieces for 20% weight savings.

Mexico-based automotive Tier 1 Katcon has developed a “toolbox” of material, process and joining options aiming to serve a range of electric vehicle requirements.

FST-certified Loctite EA 9365FST reinforces and bonds thermoplastic and thermoset substrates and can serve as a matrix resin on fiberglass to strengthen the thin walls of thermoplastic assemblies