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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.

A continuation of SPECTRA, this project’s technological building blocks will contribute to the deployment of a matured conduction welding solution to improve aerospace-grade TPC assembly.

Agile Ultrasonics and NASA trial robotic-compatible carbon fiber-reinforced thermoplastic ultrasonic welding technology for space structures.

Research at Faserinstitut Bremen’s ECOMAT site, alongside industry partners, aims to enable sustainable, aerospace-focused composites — including thermoplastic welding and cryogenic material testing.

Integrated solution for TPC stamp forming and part assembly via induction welding opens capabilities for increased part sizes, reduced weight and production cost, optimized cycle times.

Continuous ultrasonic welding (CUW) innovation presents the flexibility crucial for future lunar and deep-space missions, but also for composites joining in defense and commercial aerospace.

A total of six presentations — four welding and two bonding — presented by industry experts will explore the drawbacks, potential and evolving technologies available to bonding and welding methods.

Composites bonding and welding are two similar but distinct processes that overcome challenges related to fasteners or drilling. Here are some resources to get you started.

Building the all-thermoplastic composite fuselage demonstrator comes to an end with continuous ultrasonic welding of the RH longitudinal fuselage joint and resistance welding for coupling of the fuselage frames across the upper and lower halves.  

Syensqo’s fiber-reinforced polymers, specialty compounds and bio-based PPA materials earn automotive impact distinction.

Fraunhofer groups, Trelleborg and Airbus develop modular, fully automated assembly system concept to replace metals and time-consuming assembly that shows potential for scalability.