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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.

Fourth commercial-scale wind farm off of Rhode Island joins Vineyard Wind, South Fork Wind and Ocean Wind 1 projects, brings U.S. construction pipeline to 2.7 GW.

With a DOE grant in hand, UMaine’s ASCC seeks to develop an approach to recycle shredded wind turbine blade material as a cost-effective reinforcement and filler for large-scale 3D printing.

JEC World 2024: Roth Composite Machinery is co-exhibiting with partner mefex GmbH to present new developments to its µRoWin software for automated filament winding.

Demonstration and findings validate PECAN as a method for developing long blades that perform well with composites, outperform some resins and enable chemical recycling.

Ohio-based Canvus Inc. upcycles fiberglass wind blades, car tires and post-consumer plastics to create outdoor furniture that amplifies sustainability messages in community spaces.

Efforts are ramping up to support the growing demand for offshore wind in Europe, with the wind blade factory starting operations in 2026, and a previously announced nacelle assembly facility in the same location in 2025.

Belzona highlights the use of Belzona 5711 and 5721 to extend the lifespan of 42 wind turbine blades in Denmark facing severe erosion.

Versatile composites equipment will support the global R&T organization’s research and manufacturing of novel materials and parts for pressure vessels and pipes.

Bidding process win builds on existing multi-year contract with the global wind turbine company for the supply of spar cap components. 

Six U.S. companies have proven their recycling technologies for composites and rare earth elements, and will be supported for relevant scale demonstration and validation.