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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.
Reseachers obtained a reduction in costs and energy consumption through the manufacture of three composite prototypes and confirm the feasibility of recycling and processing the resulting material.
FAUSST weldable hybrid fabric by Hyconnect GmbH makes it possible to join metal-composite joints with reduced risk and labor.
Two materials and process approaches are demonstrated for CFRP bulkhead production.
Airbus and Siempelkamp demonstrate press process as alternative to thermoplastic welding, aimed to enable rate 100 aircraft and future mobility manufacturing.
Together with Purdue, AnalySwift aims to develop a composite heater layer and a novel software tool or module to achieve assembly, disassembly of thermoplastic composite joints in space during long-duration missions.
Project with Airbus demonstrates OOA co-consolidated stringer-stiffened skin with resistance welded frame and cleats.
New offerings include low odor, enhanced performance, high elongation and nylon bonding capabilities.
Partnership develops lightweight approaches including Conexus technology for robotic ultrasonic welding of CFRP laminates.
Cost-competitive carbon fiber-reinforced epoxy crane design uses CompoTech’s automated composites processes, eliminating welding or heat treatment and producing 50-70% stiffer structures.
Collins Aerospace in Almere has produced a 7-meter raceway for the Clean Sky 2 MFFD lower fuselage using novel CCM and tooling technology while the Riverside facility in the U.S. advances AFP and welding as part of global strategy for more sustainable airframes.
