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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.

To meet sustainability targets and market demands, the aerospace industry is searching for alternative joining methods. Automated assembly of thermoplastic composite structures by induction welding offers a solution. (Sponsored)

Flexible welding cell developed for coupon welding to facilitate process qualification of KVE INDUCT welding technology for thermoplastic composites.

Collins Aerospace draws on global team, decades of experience to demonstrate large, curved AFP and welded structures for the next generation of aircraft.

Autoclave-free consolidation and resistance welding validated for future aircraft thermoplastic composite fuselage.

Three hands-on programs are available, covering the intricacies of thermoplastic composites, from intro to advanced levels.

Understand the basic science of TPC stamp forming, a manufacturing process steadily gaining momentum in aerospace and mobility applications thanks to its rapid forming, short cycle times and automated methods.

Novel technology forms a thermally weldable layer on the surface of carbon fiber-reinforced thermoset or thermoplastic components, further validated by demonstrators.

Major aerospace supplier commits resources to scale rate-enabling manufacturing processes for Supernal’s SA-A1 CFRTP component assembly. 

ÂÌñÏ×ÆÞ 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. 

Co-located R&D and production advance OOA thermosets, thermoplastics, welding, recycling and digital technologies for faster processing and certification of lighter, more sustainable composites.