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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.

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. 

PROCOMP uses in-situ consolidation AFP and ultrasonic welding to demonstrate lightweight, novel tank design.

New Kensington site certification expands Re:Build’s aerospace and defense manufacturing footprint, offering customers an experienced, responsive partner capable of taking on mission-critical programs.

Clean Sky 2 STUNNING project will manufacture lower thermoplastic fuselage while MECATESTERS will test LMPAEK in conduction and induction welding for parameters, cyclic loading, aging and environmental effects .

Recyclable, closed-cell XPP foam offers good properties, resistance, recycled content/recyclability and thermoformability, including fusion/welding with PP-based composite skins.

CAMX 2025: 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%.

Welding Research Council (WRC) Bulletin 601 provides technical background and validation for quantitative nondestructive testing methodology for FRP composite equipment.

Clean Sky project has delivered the 8 × 4 meter welded aerostructure component, aided by advanced thermoplastic composite technologies and smart robotics.

Eight-meter-long CFRTP fuselage skin was achieved via laser-heated in-situ consolidation, with stringers, frames and cleats to be welded.