Composites Processes

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.

Next-gen fan blades: Hybrid twin RTM, printed sensors, laser shock disassembly
RTM

Next-gen fan blades: Hybrid twin RTM, printed sensors, laser shock disassembly

MORPHO project demonstrates blade with 20% faster RTM cure cycle, uses AI-based monitoring for improved maintenance/life cycle management and proves laser shock disassembly for recycling.

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Latest Processes Articles

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Molds/Tools

Techmer PM HiFill GF-PET material system bridges low, high-temp tooling gap

GF-PET compound delivers dimensional accuracy, thermal stability and accessible shape compensation data for high-performance 3D printed tooling applications.

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Wabash introduces larger custom presses up to 2,500 tons

Larger presses with platen sizes up to 10 × 10 feet and 1800°F operating temps service increasing component size, complexity and material diversity in composites manufacturing.

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Filament Winding

MFTECH makes improvements to MF3 automated filament winder 

Compact robotic winder supports optimized filament winding operations and machine use with fixed material feeding for process stability.

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Curing

Uavos composite curing ovens are awarded conformity certification

New line of products have passed Technical Testing Institute TSÚ PiešÅ¥any’s rigorous evaluation process.

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Glass Fibers

IACC NODE, Lamáquina enable functional 3D printed composite boat

Asket, the student team’s first project, is a custom, one-piece vessel featuring a 3D printed hull, real-time sensor function and adaptive robotic control.

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Filament Winding

UniSQ, iLAuNCH Trailblazer program drive digital twin innovation for composite repairs

Working with Boeing Australia, Memko and Dassault Systèmes, the University of Southern Queensland (UniSQ) has developed a digital twin via the 3DEXPERIENCE platform, digitizing processes that could lead toward more efficient and effective maintenance, repair and operations of future fleets.

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Knowledge Centers

Design, Simulation and Testing Technologies for Next-Gen Composite Structures
Design, Simulation and Testing Technologies for Next-Gen Composite Structures

Review the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

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CW Tech Days: Sustainability
CW Tech Days: Sustainability

This CW Tech Days event will explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.

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Latest Processes News And Updates

Cygnet Texkimp relaunches customer slitting trials at UK Innovation Centre

A production-scale prepreg tape slitting system featuring SAHM winding technology is available for thermoset, thermoplastic and ceramic tape trialing following an Asia contract win.

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CAMX

Composite consumables target surface improvements, infusion and RTM processes

CAMX 2025: Global technical textiles company Freudenberg Materials presents its portfolio of surfacing veils and Enka Solutions 3D polymeric filament structures used in flow media and spacers.

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Defense

Scaled Composites Model 437 aircraft to be flown for Beacon autonomy testbed

Northrop Grumman subsidiary part of Digital Pathfinder development of stealth aircraft with wings using continuous carbon fiber additive manufacturing and determinate assembly.  

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Trelleborg invests in Innovation Center expansion, remodel

An additional purpose-built space in Delano, Minnesota, by early 2027 adds a visitor center, Swiss machining, injection molding and increased space for automation.

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Sensors

Smartbeam develops HMS-embedded composite profiles for space

Project goals adapted filament winding to properly integrate optical and carbon fiber sensors and meet technical requirements, resulting in a verified, simplified process for smart composite structures at reduced cost.

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Purdue, Thermwood explore the acceleration of composites manufacturing through 3D printing

A video interview highlights how the university, the CAMS Consortium and Thermwood’s LSAM technology have enabled first-time-right production.

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Featured Posts

Aerospace

Ceramic matrix composites: Faster, cheaper, higher temperature

New players proliferate, increasing CMC materials and manufacturing capacity, novel processes and automation to meet demand for higher part volumes and performance.

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Troubleshooting thermoplastic composite stamp forming

Understand the basic science of TPC stamp forming, a manufacturing process steadily gaining momentum in aerospace and mobility applications thanks to its rapid forming, short cycle times and automated methods.

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Infusion

Automating oxide CMC for higher part volumes

FOX Composites has adapted infusion and RTM for slurry-based matrices, commercializing its VASI and IFOX technologies for automatable, scalable, serial production of high-quality oxide ceramic matrix composite parts, already proven in flight missions and a pilot-scale line.

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Focus on Design

Optimizing a CFRP landing leg demonstrator

MT Aerospace achieves design for manufacturing, integrating multiple elements into one-piece structure using AFP and 3D printed tooling to meet time and budget constraints.

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Core

Hybrid composite architecture enables rigid wind propulsion solution for maritime decarbonization

GT Wings’ AirWing leverages aerospace engineering principles combined with hybrid glass and carbon fiber composite construction to deliver up to 30% fuel savings through compact, deck-compatible wind propulsion.

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Application

Infused sandwich window frame components help double-decker buses meet weight targets

Prototype GFRP parts were evaluated by Spanish bus manufacturer Carrocerías Ayats as an initial move toward lighter, more efficient, more automated parts and processes.

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