The composites-intensive electric aircraft was purchased to meet the airline’s goal of flying a commercial demonstrator by 2026.
The $37 million contract will enable Piasecki to demonstrate its ARES tilt-duct VTOL aircraft and hydrogen fuel cell propulsion technologies. Oil And Gas Line Pipes
Design Organization Approval makes Lilium qualified to design and hold a type certificate for aircraft developed according to the EASA’s SC-VTOL safety objective rules.
The two-seat EL-2 Goldfinch is a blown-lift aircraft filling the gap for air travel routes between 50-500 miles. Certification and entry into service is targeted for 2028.
The Spanish electric mobility solutions developer is steadily growing its team and investments, emphasized by its rebranding from Umiles Next and the introduction of Integrity to customers.
$9.8 million will grow the eVTOL aircraft manufacturer’s footprint in Marina, California, support 690 new state jobs and accelerate early manufacturing to support initial commercial operations, targeted for 2025.
Evaluation of CFRTP m-pipe through Element’s U.K. facility aims to qualify the system for new operating environments.
Innovative prepreg tooling is highly drapable, capable of forming complex carbon fiber tooling shapes, in addition to reducing through thickness porosity and only requiring one debulk during layup.
Simutence and Engenuity demonstrate a virtual process chain enabling evaluation of process-induced fiber orientations for improved structural simulation and failure load prediction of a composite wing rib.
3D imaging and analysis capability illustrates detailed, quality characterization and performance simulation of composites and other advanced materials that properly captures the as-manufactured component.
Latest version of comprehensive simulation software speeds up computations and introduces surrogate model functionality.
As part of its efforts to automate as much of its production process as it can, Lyons Industries acquired a Massivit 10000 additive manufacturing system to quickly produce high-performance molds and support fixtures.
Qarbon Aerospace will focus on the design, development and manufacture of a thermoplastic composite structure for defense aviation components requiring icing protection.
Fraunhofer IFAM researchers and partners combine biodegradable polymer polycaprolactone and bioactive glass to 3D print custom-fit structures for bone fracture sites.
The carbon fiber wheel manufacturer and supplier has been awarded a total of 18 vehicle programs over the last couple of years, and is now looking to build capacity.
Lehvoss’ carbon fiber-reinforced thermoplastic composite materials are being used in the production of an e-bike set that will taken an expedition across North Africa.
Through the use of EzCiclio low-dielectric epoxy hardener, PCB manufactures can make recyclable, reusable products for electronic applications.
Terrene 3.0 is a compression-dominant arch developed as a multidisciplinary research project composed of natural fiber-reinforced sand and other biomaterials that delivers eco-friendly, less energy-intensive building methods.
New developments regarding productivity, maintenance and ergonomics make this enhanced composite placement system well suited for the production of complex parts.
Data collected from one year of outdoor testing reasserts the 3D-printed, bio-based structure’s viability to address housing challenges, sets the stage for future development.
Using Mechnano’s D’Func process, the new masterbatch of ogolimers enables 3D printing resin development with improved mechanical and nano-uniform electrical performance.
Collins Aerospace draws on global team, decades of experience to demonstrate large, curved AFP and welded structures for the next generation of aircraft.
Discussion of the issues in our understanding of thermoplastic composite welded structures and certification of the latest materials and welding technologies for future airframes.
The open AM innovation program welcomes all interested parties who would like to make use of the potential of 3D printing FGF or combine it with materials like carbon fiber, UD tape and other hybrid technologies.
CW explores key composite developments that have shaped how we see and think about the industry today.
Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.
As battery electric and fuel cell electric vehicles continue to supplant internal combustion engine vehicles, composite materials are quickly finding adoption to offset a variety of challenges, particularly for battery enclosure and fuel cell development.
Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.
Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.
Interest in higher performance and more sustainability drive new composite materials innovations in sporting goods and other consumer products.
Manufacturers often struggle with production anomalies that can be traced back to material deviations. These can cause fluctuations in material flow, cooling, and cure according to environmental influences and/or batch-to-batch variations. Today’s competitive environment demands cost-efficient, error-free production using automated production and stable processes. As industries advance new bio-based, faster reacting and increased recycled content materials and faster processes, how can manufacturers quickly establish and maintain quality control? In-mold dielectric sensors paired with data analytics technology enable manufacturers to: Determine glass transition temperature in real time Monitor material deviations such as resin mix ratio, aging, and batch-to-batch variations throughout the process Predict the influence of deviations or material defects during the process See the progression of curing and demold the part when the desired degree of cure, Tg or crystallinity is achieved Document resin mix ratios using snap-cure resins for qualification and certification of RTM parts Successful case histories with real parts illustrate how sensXPERT sensors, machine learning, and material models monitor, predict, and optimize production to compensate for deviations. This Digital Mold technology has enabled manufacturers to reduce scrap by up to 50% and generated energy savings of up to 23%. Agenda: Dealing with the challenge of material deviations and production anomalies How dielectric sensors work with different composite resins, fibers and processes What is required for installation Case histories of in-mold dielectric sensors and data analytics used to monitor resin mixing ratios and predict potential material deviations How this Digital Mold technology has enabled manufacturers to optimize production, and improve quality and reliability
SolvaLite is a family of new fast cure epoxy systems that — combined with Solvay's proprietary Double Diaphragm Forming technology — allows short cycle times and reproducibility. Agenda: Application Development Center and capabilities Solutions for high-rate manufacturing for automotive Application examples: battery enclosures and body panels
OEMs around the world are looking for smarter materials to forward-think their products by combining high mechanical performance with lightweight design and long-lasting durability. In this webinar, composite experts from Exel Composites explain the benefits of a unique continuous manufacturing process for composites profiles and tubes called pull-winding. Pull-winding makes it possible to manufacture strong, lightweight and extremely thin-walled composite tubes and profiles that meet both demanding mechanical specifications and aesthetic needs. The possibilities for customizing the profile’s features are almost limitless — and because pull-winding is a continuous process, it is well suited for high volume production with consistent quality. Join the webinar to learn why you should consider pull-wound composites for your product. Agenda: Introducing pull-winding, and how it compares to other composite manufacturing technologies like filament winding or pultrusion What are the benefits of pull-winding and how can it achieve thin-walled profiles? Practical examples of product challenges solved by pull-winding
Composite systems consist of two sub-constituents: woven fibers as the reinforcement element and resin as the matrix. The most commonly used fibers are glass and carbon, which can be processed in plane or satin structures to form woven fabrics. Carbon fibers, in particular, are known for their high strength/weight properties. Thermoset resins, such as epoxies and polyurethanes, are used in more demanding applications due to their high physical-mechanical properties. However, composites manufacturers still face the challenge of designing the right cure cycles and repairing out-of-shelf-life parts. To address these issues, Alpha Technologies proposes using the encapsulated sample rheometer (premier ESR) to determine the viscoelastic properties of thermosets. Premier ESR generates repeatable and reproducible analytical data and can measure a broad range of viscosity values, making it ideal for resins such as low viscous uncured prepreg or neat resins as well as highly viscous cured prepregs. During testing, before cure, cure and after cure properties can be detected without removing the material from the test chamber. Moreover, ESR can run a broad range of tests, from isothermal and non-isothermal cures to advanced techniques such as large amplitude oscillatory shear tests. During this webinar, Alpha Technologies will be presenting some of the selected studies that were completed on epoxy prepreg systems utilizing ESR and how it solves many issues in a fast and effective way. It will highlight the advantages of this technique that were proven with the work of several researchers. Moreover, Alpha Technologies will display part of these interesting findings using the correlations between the viscoelastic properties such as G’ and mechanical properties such as short beam shear strength (SBS).
Surface preparation is a critical step in composite structure bonding and plays a major role in determining the final bonding performance. Solvay has developed FusePly, a breakthrough technology that offers the potential to build reliable and robust bonded composite parts through the creation of covalently-bonded structures at bondline interface. FusePly technology meets the manufacturing challenges faced by aircraft builders and industrial bonding users looking for improved performance, buildrates and lightweighting. In this webinar, you will discover FusePly's key benefits as well as processing and data. Agenda: Surface preparation challenges for composite bonding FusePly technology overview Properties and performance data
The incorporation of EMI shielding into composites is necessary in a wide range of applications — such as electronics and battery enclosures for AAM, automotive and aerospace — where EMI could interfere with the operation of the device, vehicle or aircraft, ultimately compromising security and control. TFP’s conductive nonwoven materials provide a solution, possessing a combination of properties that make them highly infusible, flexible, lightweight and an effective EMI shield. This combination allows them to overcome challenges in both application and process that more traditional substrates such as films, foils and paints struggle to achieve. In this webinar, Dr. Mark James will introduce TFP’s conductive nonwovens, their lightweight structure and EMI shielding capability. He will discuss how they are easily incorporated into composites to impart this functionality to the surface of a part, with some typical examples. Mike Campbell and Adam Halsband will then provide a case study on a new development for TFP materials as an EMI enhanced SMC compound. This compound is designed as a scalable, cost-effective solution for high throughput BEV applications, such as battery enclosures. Agenda: An introduction to TFP’s conductive nonwovens, their structure and manufacture The key physical properties and how they are tailored to suit end-use requirements How conductive nonwovens can be used effectively in a variety of applications A case study on the development and use of TFP’s veils in an EMI enhanced SMC compound for BEV applications
ICERP India is an important event of the Indian composites industry organized by FRP Institute once in every two years and ICERP event is the biggest event on Composites in India and second biggest event in Asia.
The annual Conference on Composites, Materials, and Structures (also known as the Cocoa Beach Conference) is the preeminent export controlled and ITAR restricted forum in the United States to review and discuss advances in materials for extreme environments. The Conference started in the 1970s as a small informal gathering for government and industry to share information on programs and state-of-the-art technology. Attendance has grown to nearly 500 people while preserving this same objective to share needs and trends in high-temperature and extreme environment materials, and the latest information on advanced materials and manufacturing processes. The five-day conference program includes two to three parallel sessions per day on topics including thermal protection materials, ceramic matrix composites, carbon-carbon materials, ballistic technologies, hypersonics, and gas turbine engines. Attendees are engineers, scientists, managers, and operational personnel from the turbine engine, aviation, missiles and space, and protective equipment communities. These communities include the Navy, Air Force, Army, MDA, NASA, DARPA, FAA, DOE, engine manufacturers, missile and aircraft manufacturers, commercial space companies, and material and component suppliers. The Conference will be held in St. Augustine again for 2024! Participation is limited to U.S. Citizens and U.S. Permanent Residents only with an active DD2345 certification.
The 48th International Conference & Exposition on Advanced Ceramics & Composites (ICACC 2024) will be held from Jan. 28–Feb. 2, 2024, in Daytona Beach, Fla. It is a great honor to chair this conference, which has a strong history of being one of the best international meetings on advanced structural and functional ceramics, composites, and other emerging ceramic materials and technologies.
The Transformative Vertical Flight (TVF) 2024 meeting will take place Feb. 6–8, 2024 in Santa Clara, California, in the heart of Silicon Valley and will feature more than 100 speakers on important progress on vertical takeoff and landing (VTOL) aircraft and technology.
The Program of this Summit consists of a range of 12 high-level lectures by 14 invited speakers only. Topics are composite related innovations in Automotive & Transport, Space & Aerospace, Advanced Materials, and Process Engineering, as well as Challenging Applications in other markets like Architecture, Construction, Sports, Energy, Marine & more.
JEC World in Paris is the only trade show that unites the global composite industry: an indication of the industry’s commitment to an international platform where users can find a full spectrum of processes, new materials, and composite solutions.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.
The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.
Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.
In its latest white paper, Exel navigates the fire, smoke and toxicity (FST) considerations and complexities that can influence composites design.
New white paper authored by Eike Langkabel, Sebastian de Nardo, and Jens Bockhoff, examines the best resin formulations for composites used in automotive part production, both structural parts and body panels.
Tension control plays a vital role in composites manufacturing in order to achieve automated processing, continuous processing, reduced scrap, increased product quality, and more, says a new white paper released by The Montalvo Corp.
Austrian research institute Wood K plus makes 95% silicon carbide ceramics more sustainable (>85% bio/recycled content), enables 3D shapes via extrusion, injection molding and 3D printing.
Thermoplastic polymer resin was designed to tackle distinctive industry challenges of large-scale 3D printing while also assisting with sustainability initiatives.
The MB9, representing a combination of high performance and eco-conscious materials use, will be commercially available in time for the 2024 sailing season.
For 42 months, the Aitiip Technology Center will coordinate the EU-funded project to design a new range of intermediate materials, such as pellets or resin-impregnated carbon fibers, which will be used to manufacture more sustainable final products.
Co-located R&D and production advance OOA thermosets, thermoplastics, welding, recycling and digital technologies for faster processing and certification of lighter, more sustainable composites.
The German Institutes of Textile and Fiber Research are targeting more sustainable carbon fiber via low-pressure stabilization and bio-based precursors, and working with Saint-Gobain to commercialize oxide ceramic fibers for CMC.
During CW Tech Days: Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.
CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.
CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.
In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.
The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.
Closed mold processes offer many advantages over open molding. This knowledge center details the basics of closed mold methods and the products and tools essential to producing a part correctly.
CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.
Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.
Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
MVP's Automated Equipment: Revolutionizing Composites Part Production Through Filament Winding within CompositesWorld's CompositesWorld Collections Knowledge Center
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A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.
This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.
This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.
This collection features recent CW stories that detail a range of tooling technologies, processes and materials.
Starting with the sporting goods and bicycle market, French startup 3DiTex targets its continuous preforming system for thermoformable, thermoplastic composite tubes in complex geometries.
Thermoplastic composite preforms for tubes, bicycle frames and beyond. French startup 3DiTex has developed a continuous process for winding complex-shaped, hollow, thermoformable preforms from thermoplastic composite tapes or other materials. The company’s first target market is sporting goods, including bicycle frame components and, soon, fully integrated bicycle frames like those shown here. Photo credit, all images: 3DiTex
High-volume manufacturing capability, easily recycled materials and design freedom are three increasingly important requirements for a material to be adopted for many end markets and applications, from high-performance sporting goods to commercial and defense aerospace parts.
3DiTex (Canéjan, France) is a startup company aiming to provide all three with its process for producing hollow, tube-shaped, thermoplastic composite preforms and end-use parts, with the ability to mold into complex shapes and be manufactured from easier-to-recycle thermoplastic or even bio-based materials as well as the potential for production in large volumes.
The company’s founders, Bertrand Laine and Aymeric Azran, earned Ph.D. degrees in materials science and the mechanics of materials, respectively, and worked for a number of years in composites and technical textiles. They met while working on 3D knitted preform technology at R&D company RT2i (since acquired by Saint-Gobain), and in 2016, decided to leverage their experience to found startup company Nobrak specializing in innovations related to tailored fiber placement (TFP) technology.
“When we started Nobrak, we modified an existing TFP machine and we made flat preforms that could then be stamp formed or put through some other process to form a more complex geometry,” says Laine. While the company has seen success with this technology, he adds that it was quickly apparent that one market gap Nobrak was not able to serve was the need for hollow, tube-shaped preforms common to many applications and end markets, from bicycle frames to aerospace struts. To fill this need, Laine and Azran began investigating methods to produce hollow preforms that could then be molded into tube-shaped composite parts.
The resulting technology is a continuous, modified winding process (more on this below) designed as a modular system for manufacturing highly material-optimized, tube-shaped thermoplastic composite preforms that can then be molded into final parts — including those with complex shapes and curves.
Laine and Azran leveraged this method into a second startup in 2018, 3DiTex. Today, Laine serves as CEO of 3DiTex, and Azran as CEO of Nobrak. In the last few years, 3DiTex has been raising funds, filing patents on its technology and has grown to a team of 32 employees. With plans to open its first official pilot line in 2024 and first production plant in 2025, the company is already using its initial pilot machine to produce prototype and commercial parts for customers.
The 3DiTex system is, essentially, a continuous production line consisting of a series of winders laying down tapes or filaments onto a mandrel or support to manufacture the preform layer by layer as it is pulled through the system. The process is said to be something of a cross between a continuous pultrusion line and filament winding, combining the speed and continuous production of pultrusion with the ability to wind tapes or filaments in various orientations and angles.
One of the main innovations in the 3DiTex system is the way its winding process works to create a multilayer textile preform without the time-consuming, back-and-forth motion of a typical filament winding system. Laine explains, “The first point of the technology is to build preforms in a continuous way. That was the start. But of course other technologies can also do that, with braiding, for example. So then the challenge became how to lay down all of the layers at once. We also didn’t want to reinvent pultrusion. We wanted to be able to do complex geometries, and for the preform to be bendable to different shapes, not just straight profiles like you get with pultrusion.”
The resulting 3DiTex system is a series of winder modules — Laine calls them “discs,” referring to their round shape — that are mounted along a fixed mandrel or support structure onto which the filaments or tapes are wound. Each module works independently, positioned at equal distances along the system and programmed to rotate around the mandrel and deposit one specific layer. The preform moves continuously through the system at a specified speed, typically a meter or more per minute, with modules laying down successive layers. The modules are highly customizable, programmed to rotate at a specified speed and lay down the materials at a specified angle for each layer of each part.
Continuous winding. The 3DiTex process is said to combine the continuous production capability of pultrusion with the ability to wind tapes at optimal orientations and angles.
“Typically with winding, it’s a one-shot process with the winder going back and forth, right and left, over the support,” says Laine. “But in our case, it never goes back to the right, it just goes one way all the way through continuously, so each disk has to apply the full quantity of material that we want for each layer.”
Moving forward. Each disc-shaped winder along the line is programmed independently, laying down one material layer at a time while the preform moves continuously forward, eliminating the typical process of a filament winder going back and forth over a mandrel.
He adds that there are two options for the mandrel or support structures used in the 3DiTex system. “You can either push a mandrel — with the preform being formed on top of it — continuously through the system, or pull the preform itself, sliding along a fixed support.” This depends on the material used as the base preform.
The system operates via design and control software developed in-house by 3DiTex. For each part, inputs such as the radius of bending, diameter and more are used to create 3D models of the part “that allow us to predict trajectories for bending to accommodate all the variation,” says Laine. The preform is designed via in-house simulation software. He adds that it was a trial-and-error process at first, requiring the manufacture of physical preforms to compare to the values predicted by the simulations, in order to perfect the software.
Laine explains that many different materials can be used — carbon, glass or flax fiber; dry filaments or prepreg tapes; thermoset or thermoplastic resins, including bio-based resins; even rolls of paper or metal filaments — but the process was designed around the use of thermoplastic tapes or commingled yarns with thermoplastic filaments. “Thermoplastic tapes are a perfect fit. They’re easy to work with but also fit our strategy to use recyclable materials, and to have the ability to go toward large-volume manufacturing in the future,” he says.
Bendable, thermoplastic preforms. While other materials can also be used, the process is primarily designed for use with thermoplastic tapes. One of the benefits is the ability to bend the preforms by hand to insert into the mold for forming.
Currently, 3DiTex collaborates with resin supplier partner Arkema (Colombes, France), developing its parts and process for use with Arkema’s polyamide 11 (PA11) and polyphthalamide (PPA) products, among other materials.
Laine notes that the process enables different types of materials to be laid down on the same part in one shot — a mix of glass and carbon fiber layers, for example, or to apply a core layer such as cork or foam in between by the different independent modules.
Once the preform comes off the 3DiTex line, it is ready to be cut and then molded into a final part, either by 3DiTex or by the customer.
Laine notes that several methods could be used to manufacture these parts, and 3DiTex has mostly used thermoforming or compression molding. For each part, 3DiTex designs and orders an open or closed mold, and a bladder to fit inside the preform. The thermoplastic preforms can be bent by hand to insert into the mold, and final parts are molded under heat and pressure.
Currently, the company can offer customers preforms or hollow composite parts. Laine explains, “When we first launched the company, we didn’t know exactly what we wanted to do yet — sell the machines? Sell the preforms? Manufacture composite parts? We decided to start with selling the textile preforms, but quickly realized that because it’s a new process, if we sell only the preforms then there’s a lot of educational steps to explain to the customer how to manufacture with our preforms. So we realized the best method for now is to build the composite parts ourselves so that we can control all the steps.”
What’s the maximum length part that 3DiTex’s process can produce? “The limit is more about the tooling, and that’s based on the customer and their requirements,” Laine explains, “but the longest part we’ve produced so far is about 2 meters.”
He adds that the company is also working to develop joining methods to be able to produce more complex finished parts (more on this below).
3DiTex has targeted sporting goods as its entry-level end market, with first prototype parts produced for a customer that manufactures ski poles. Laine notes that the poles are “quite simple, but not completely straight, so you cannot make them with pultrusion.” 3DiTex is also working with customers on various other sporting goods applications, like tennis rackets, hockey sticks and baseball bats.
Looking to the future, the company sees the most potential in bicycle frames. Laine notes, “We’re targeting bicycles in particular because the frames are complex, so we saw a good opportunity for our process and products.”
3DiTex’s first customer in this market is bicycle manufacturer Caminade (Ille-sur-Têt, France), which specializes in high-end, custom-made bicycles assembled from its modular designs and components to fit a customer’s specific measurements and needs. Currently, most of the company’s bicycle frame components are straight, hollow tubes made from titanium, aluminum or short fiber pultruded composites, joined to build the full frame with injection molded plastic or titanium connectors. 3DiTex introduced Caminade to the idea of using its technology to incorporate the higher rigidity of continuous, unidirectional fiber and the possibility of molding the frame components into more complex or curved shapes.
Optimizing the design. Using its process, 3DiTex was able to optimize Caminade’s typically straight bicycle frame components (one of several pictured here) into more complex curves or shapes.
In summer 2023, Caminade provided 3DiTex with the design parameters needed for several different styles of tubes: diameter, length, shape and mechanical properties. 3DiTex then came up with a compatible design for each of the needed tube shapes and lengths, using a carbon fiber thermoplastic tape. Laine adds that not only does the company’s process enable more complex shapes, but also variation in tube thickness, flexibility or rigidity in specific areas along the part.
As of October 2023, Caminade is working toward qualification tests for the new frame components, with the goal of launching them as an option to customers for its custom bikes by the end of the year.
Getting ready to ride. Pictured here, a full Caminade bicycle frame undergoes strength testing while the company prepares the product for rollout to customers. Photo Credit: Caminade, via 3DiTex
Laine explains that as a next step for the technology, the company plans to offer not just preforms or thermoformed composite tubes, but also the capability to join its tubes to create a more complex finished part without the need for either separate connectors, fasteners or adhesive.
Adhesive- and fastener-free joining. As a next step, 3DiTex has developed a modified injection overmolding process to join its components together to manufacture full bicycle frames or other products. Shown here is a 3D model of 3DiTex’s bicycle frame concept.
The team has developed what Laine calls “a process that is similar to plastic injection overmolding” for molding an additional piece of continuous fiber material — potentially a specialized fabric produced by sister company Nobrak — over the tube joints to connect the two pieces without other bonding or fasteners. “This allows you to connect the tubes and also adds geometry to reinforce areas that need additional reinforcement with continuous fibers,” Laine says.
To demonstrate this technology, 3DiTex is building a full bicycle frame demonstrator, which will combine the original preforming technology, thermoforming of the tubes and 3DiTex’s modified injection overmolding process to join the tubes together into one final part.
“The goal is not to compete with fully injection molded plastic bike frames, or high-volume aluminum frames,” Laine notes. “We’re only planning to use injection molding in small areas where needed to combine parts of the frame. We’re competing with fully monocoque carbon fiber frames, which right now are often hand-built and custom-made, and providing a higher-volume option for that.”
In terms of performance, Laine sees this technology as a good fit for medium-volume electric city bikes, for example — where both light weight and strength to carry batteries and electronics are needed.
Currently, 3DiTex’s initial pilot machine is capable of producing prototypes and commercial parts in small volumes, up to several hundred per year.
Thanks to recently acquired funding, the company’s pre-industrial pilot line is in the works and is expected to be online by summer 2024. By mid-2025, the company plans to open its 3,000-square-meter production plant, and to double its workforce. Laine explains, “In our current space, we have the capacity to produce a few hundred parts. In our pre-industrial facility, we’ll be in the mid-volume range, with a capacity from about 1,000 to 10,000 parts per year for a customer. And then by 2025 we’ll reach our goal for high-volume capacity, between 10,000 and 100,000 parts per year.” He adds, “There’s a lot of investment involved in this process. It’s a highly optimized process and textile, with a lot of investment for the mandrels or supports, tooling for the thermoforming process and design work that goes into each part. So high-volume production runs ultimately will make the most sense economically once we have the capacity.”
For the next few years, the sporting goods market, including bicycle frames, will continue to be 3DiTex’s main focus. Further in the future, Laine says the company is in conversations with potential customers in the aerospace industry, and is also considering the possibility of expanding its business to sell machines to customers who need to produce parts on-site for confidentiality or geographical reasons.
The matrix binds the fiber reinforcement, gives the composite component its shape and determines its surface quality. A composite matrix may be a polymer, ceramic, metal or carbon. Here’s a guide to selection.
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A program from the U.S. Air Force Research Laboratory adopts automated braiding and phase-change tooling for a complex geometry unmanned aircraft part.
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