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Composites end markets: New space (2025)

Composite materials — with their unmatched strength-to-weight ratio, durability in extreme environments and design versatility — are at the heart of innovations in satellites, propulsion systems and lunar exploration vehicles, propelling the space economy toward a $1.8 trillion future.

Post Cure: CFRP landing leg supports reusable launcher capabilities

MT Aerospace AG, as part of the EU’s Horizon Europe project SALTO, has successfully developed a 7-meter-long carbon fiber-reinforced polymer (CFRP) landing leg demonstrator using advanced automated fiber placement and 3D printing technologies.

TPI, UMaine, ORNL to leverage world’s largest polymer 3D printer for wind turbine tooling

Ingersoll Masterprint LFAM printer will be used to produce and demonstrate 100% recyclable tooling that could cut large composite blade development cycles and tooling costs by as much as 50%.

VoxelMatters report reveals top companies in composites AM

The new market study identifies key players in a $785 million global market that has grown by 21% year on year.

Firefly Aerospace doubles Texas facilities to support composite rockets

Company grows test stands, further implements AFP and seven-axis robotic powermill machinery to produce rockets up to nine times faster at 1/7th of the cost.

Kanfit completes production of acceptance test part with AFP

The Ingersoll AFP machine is reported to be the first of its kind in Israel, aiding Kanfit’s R&D venture and strategy to adopt new technologies for composite production.

Formnext Chicago secures premier exhibitors

The newly announced additive manufacturing show, Formnext Chicago, will take place at McCormick Place in spring 2025.

Digital design, multi-material structures enable a quieter supersonic NASA X-plane

NASA’s composites-intensive X-59 QueSST experimental aircraft is set for its first flight by the end of 2022, after nine years of design, manufacture, assembly and testing by Lockheed Martin Skunk Works.

Additive for Composites and Composites for Additive

��ñ��’s Jeff Sloan joins Peter Zelinski in an episode of the AM Radio podcast about how composites and 3D printing are changing one another.

People in Composites: February 2022

New hires, appointments and personnel promotions have been announced by Teijin Ltd., Vectorply, Engel North America, Wisk, Trelleborg, Lockheed Martin, Thermwood, Archer and more.

Quiet supersonic demonstrator X-59 begins ground testing in Texas

Critical testing ensure the composite aircraft can withstand the loads and stresses that typically occur during supersonic flight.

NREL explores novel manufacturing approach for next-generation wind turbine blades

3D printing of thermoplastic blades enables thermal welding and improves recyclability, offering the potential to reduce turbine blade weight and cost by at least 10%, and production cycle time by 15%.

Composites AM research targets wind energy

The U.S. DOE, universities and industry leaders ramp up new efforts and funding to develop 3D-printed composite wind blade molds and end-use blade components.

Airtech 3D-printed resin delivers advanced manufacturing capabilities to U.K. defense sector

Carbon fiber-reinforced, PEI-based Dahltram I-350CF resin system enables production of high-temperature mold tooling for next-gen combat air demonstrator.

Bell, Ingersoll apply LFAM to main rotor blade component production

Collaborative effort using Ingersoll’s MasterPrint LFAM tool and five-axis milling machine completes successful manufacture of 22-foot-long vacuum trim tool in a matter of weeks.

UMaine awarded $2.8 million to accelerate AM wind blade development

Additive manufacturing with bio-based, 100% recyclable feedstocks reinforced with wood can reduce construction time by six months and cut costs by 25-50%

AFP tow steering comes of age, Part 1: Current state

It used to be enough that AFP systems could precisely and quickly place and cut multiple tows to build complex aerostructures. Now, fabricators need those tows steered, and the tighter the radius, the better.

Firefly Aerospace to automate composite rocket production with Ingersoll AFP machine

The company plans to transition manufacture of its Alpha and Beta all-composite launch vehicles to automated fiber placement starting in 2021.

The Alpha launch vehicle: Designing performance in, cost out

Firefly Aerospace’s Alpha 2.0 launch vehicle, designed to deliver satellites into low Earth orbit, gets a composites makeover in pursuit of larger payload capacity and more cost-effective performance.

New 3dpbm market analysis division presents AM industry study results

Analysis of composites additive manufacturing performed by the new market analysis and consultancy group shows the market generating $10.6 billion in yearly revenues by 2030.

3D printing with continuous fiber: A landscape

Growth continues in suppliers, part size, production volume and markets.

Racing to build tomorrow’s automotive composites workforce

Recent graduates share experiences gained from collegiate automotive design, engineering and motorsport competition Formula SAE.

On the road with ��ñ��

CW Senior Editor Scott Francis offers a recap of recent composites industries events including CAMX 2019 and SPE ACCE 2019.

CAMX Additive Manufacturing Workshop speaker: Ingersoll Machine Tools

The Additive Manufacturing Workshop for Composites at CAMX (Anaheim, Calif., U.S.) will take place on September 25 and will explore the evolution of 3D printing technology and fiber reinforcement.

CAMX to host Additive Manufacturing Workshop for Composites

Co-located with CAMX, the event explores the connection between AM and continuous fiber reinforcement.

CAMX 2019 exhibit preview: Ingersoll Machine Tools

Ingersoll Machine Tools to highlight MasterPrint, Mongoose platforms at CAMX 2019.

Big additive machines tackle large molds

In commercial aerocomposites fabrication, molds reign supreme, but they are expensive. Large-format additive manufacturing systems are poised to make production-ready molds quickly and affordably.

Moving continuous-fiber 3D printing into production

With patents proliferating and production applications emerging, 3D printing with continuous fiber reinforcement is poised for significant market growth.

Kanfit receives new AFP robot

The automated fiber placement system will be used to develop and manufacture complex carbon fiber composite structures that have traditionally been made using hand layup.

Mongoose AFP machine manufacturer announces new CEO

Ingersoll Machine Tools, manufacturer of the Mongoose automated fiber placement machine for composite part manufacturing, has appointed Chip Storie as CEO.

Composite pressure vessels take on cryogenic temperatures

Several recent innovations involving composite high pressure tanks indicate a leap forward in pressure vessel technology.

Ingersoll showcases 3D printed winglet layup tool at IMTS

The part was printed with large 3D printing technology developed by Ingersoll Machine Tools and Oak Ridge National Laboratory.

Plant tour: Spirit AeroSystems, Wichita, KS

Spirit AeroSystems was an established aerospace supplier when it earned that distinction, winning the contract for the Boeing 787’s Section 41. Now its sights are set on the next generation of aircraft.

Plant tour: Kanfit Ltd., Migdal HaEmek, Israel

Aerospace tier supplier Kanfit Ltd. is expanding, offering both composite and metal parts for applications in an expanding range of high-performance markets.

McNair Aerospace Center: Closing the composites education gap

As the composites industry in South Carolina continues to expand through Boeing and its tier suppliers, composites education follows suit through the McNair Center.

Automation: Robots taking off in commercial aircraft

Will this affordable and versatile class of multiaxis manufacturing hardware and software drivers enable airframers to reduce costs and speed deliveries?

Weber Manufacturing Technologies: Midland, ON, Canada

With a long, storied history in composites moldmaking, this rare nickel vapor deposition specialist has built a strong niche, making large, high-quality tools.

CAMX 2014 show report

Bigger, better and more inclusive than any previous U.S. composites trade event, the inaugural show turns North American eyes forward to the future.

JEC Europe 2014 Review

The composites world met again in Paris, vibrant, stronger, and more forward-looking than ever before.

SAMPE 2011 Long Beach Product Showcase

Huge show, huge new product offerings … huge success.

Status update on composites automation

Consultant Carroll Grant reviews progress made in recent years toward greater variety in automated composites processing machine sizes configurations and capabilities.

Addressing the cost of aerospace composites

In the aerospace composites industry’s history, millions of research and development (R&D) dollars have been spent addressing cost.

SAMPE 2010 Seattle Showcase

SAMPE’s first-ever foray into Boeing Country wrapped up with the M&P organization’s biggest draw this decade.

Machining carbon composites: Risky business

As composites take a larger part (and form larger parts) in the aerospace structures sector, it’s not just a make-it-or-break-it proposition.

Automating wind blade manufacture

Recent technology announcements portend a new era of more efficient blade production.

ATL and AFP: Signs of evolution in machine process control

Improved machine-control software, placement accuracy and design simulation have made automated fiber placement and tape laying machines truly production-worthy. The evolution, however, still continues.

Aviation Outlook: Fuel pricing ignites demand for composites in commercial transports

A confluence of aircraft OEM technical innovation and economic pressures on their airline customers creates increasingly favorable market conditions for aerospace composites.

JEC COMPOSITES 2008 show review

Composites professionals converged on this annual Parisian gathering in greater numbers than ever before, confident that the market’s global growth will continue.

Managing multi-axis manufacturing

Much early computer numerically controlled (CNC) machinery served short-run military and space programs where cost per part was too high to be acceptable in the manufacture of commercial aircraft. Now, Automated CNC machinery moves toward volume production and part-specific design.

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