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Goodman Technologies, partners scale up AI-empowered 3D printing of nanocomposites for spacecraft TPS
NASA project addresses the capability gap in TPS production and installation for space exploration and hypersonic systems, delivering an ARMs system, nanopaste and prepreg tapes, manufacturing verification coupons and more.
Goodman Technologies LLC (Largo, Fla., U.S.), a rapid growth nanocomposite ecosystem platform company, with the University of Hawaii at Manoa Hawaiian Nano Laboratory (UHM-HNL) and the Wichita State University (WSU) National Institute of Aviation Research (NIAR), performed work under a NASA (Washington, D.C., U.S.) Phase II STTR that sought to explore the AI-empowered scale-up of additively manufactured continuous fiber ceramic nanocomposites (CFCNC) to revolutionize the manufacturing of thermal protection systems (TPS). These efforts addressed the critical capability gap in the production and installation of these advanced materials for NASA space vehicles and beyond that is affordable and non-labor intensive.
The advanced materials and manufacturing techniques developed in this project are expected to play a critical role in NASA’s Human Exploration and Operations Mission Directorate (HEOMD) Lunar and Mars missions, as well as the Science Mission Directorate (SMD) planetary missions, which require hypersonic entry through an atmosphere.
The overarching objectives of this project, spanning Phase I through Phase III, focused on:
• Manufacturing efficiency of TPS approaches: A comparative study of “top-down” and “bottoms-up” TPS approaches was conducted, with the aim of mitigating any disadvantages associated with each method. This dual approach ensured that the most efficient and effective manufacturing process was identified and implemented.
• Design of GTNANO automated robotic manufacturing system (ARMS): This system incorporates a range of advanced manufacturing techniques, including milling, fiber patch placement (FPP) of ceramic nanocomposite prepreg and the printing of ceramic nanopastes. The integration of these processes into a single automated system represents a significant advancement in the field of composites manufacturing.
• Development of nanopaste and prepreg tapes: Critical to the success of the project was the development of a low-shrinkage printable silicon carbide (SiC) nanopaste, as well as continuous roll-to-roll ceramic nanocomposite prepreg tapes. These materials are essential for producing a new category of high-quality continuous fiber ceramic nanocomposites (CFCNCs) with consistent properties.
• Production of a manufacturing verification coupon: Using the ARMS system, an 18-inch manufacturing verification coupon was produced. This coupon serves as a proof of concept, demonstrating the capabilities of the manufacturing process at scale.
During the past 4 years, the GT/UHM-HNL Team has multiple patent filings on the topics of SiC-based nanopastes which are 3D printable, moldable via a proprietary Z-process and have been used to make SiC (Hi-Nicalon)-reinforced prepreg for the molding, curing and joining of CFCNCs. CFCNCs are said to overcome the issue of delamination and segment separation, advancing the potential of spacecraft TPS and hypersonics in general.
NASA project addresses the capability gap in TPS production and installation for space exploration and hypersonic systems, delivering an ARMs system, nanopaste and prepreg tapes, manufacturing verification coupons and more.
Goodman Technologies LLC (Largo, Fla., U.S.), a rapid growth nanocomposite ecosystem platform company, with the University of Hawaii at Manoa Hawaiian Nano Laboratory (UHM-HNL) and the Wichita State University (WSU) National Institute of Aviation Research (NIAR), performed work under a NASA (Washington, D.C., U.S.) Phase II STTR that sought to explore the AI-empowered scale-up of additively manufactured continuous fiber ceramic nanocomposites (CFCNC) to revolutionize the manufacturing of thermal protection systems (TPS). These efforts addressed the critical capability gap in the production and installation of these advanced materials for NASA space vehicles and beyond that is affordable and non-labor intensive.
The advanced materials and manufacturing techniques developed in this project are expected to play a critical role in NASA’s Human Exploration and Operations Mission Directorate (HEOMD) Lunar and Mars missions, as well as the Science Mission Directorate (SMD) planetary missions, which require hypersonic entry through an atmosphere.
The overarching objectives of this project, spanning Phase I through Phase III, focused on:
• Manufacturing efficiency of TPS approaches: A comparative study of “top-down” and “bottoms-up” TPS approaches was conducted, with the aim of mitigating any disadvantages associated with each method. This dual approach ensured that the most efficient and effective manufacturing process was identified and implemented.
• Design of GTNANO automated robotic manufacturing system (ARMS): This system incorporates a range of advanced manufacturing techniques, including milling, fiber patch placement (FPP) of ceramic nanocomposite prepreg and the printing of ceramic nanopastes. The integration of these processes into a single automated system represents a significant advancement in the field of composites manufacturing.
• Development of nanopaste and prepreg tapes: Critical to the success of the project was the development of a low-shrinkage printable silicon carbide (SiC) nanopaste, as well as continuous roll-to-roll ceramic nanocomposite prepreg tapes. These materials are essential for producing a new category of high-quality continuous fiber ceramic nanocomposites (CFCNCs) with consistent properties.
• Production of a manufacturing verification coupon: Using the ARMS system, an 18-inch manufacturing verification coupon was produced. This coupon serves as a proof of concept, demonstrating the capabilities of the manufacturing process at scale.
During the past 4 years, the GT/UHM-HNL Team has multiple patent filings on the topics of SiC-based nanopastes which are 3D printable, moldable via a proprietary Z-process and have been used to make SiC (Hi-Nicalon)-reinforced prepreg for the molding, curing and joining of CFCNCs. CFCNCs are said to overcome the issue of delamination and segment separation, advancing the potential of spacecraft TPS and hypersonics in general.
Composites
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GT’s TPS uses the 3D printable and moldable nanopaste for the shell and the Hi-Nicalon SiC/nanoSiC prepreg CFCNCs for the structural layer, which is bonded to a high-temperature CFOAM insulation core with a nanopaste adhesive. The process is amenable with other types of lightweight insulation. According to GT, the nano particulate used in the shell layer enables the system to have increased thermal conductivity, thermal stability and density. GT’s TPS is designed such that during entry through an atmosphere the outer shell will ablate and sublimate leaving the hot structure, which can then have a new shell 3D printed onto the surface for reuse. Arc-jet testing at NASA Ames Research Center proved that the hot structure was reusable. Notably, other printable ablation layers could be deposited on GT’s reusable hot structure.
The GT team was selected for a Phase II award where the automated manufacturing of the improved TPS was scaled up to about a half meter, though it is reported that there is really no limitation of scale for the process. To accomplish this, GT developed a large-scale ARMS which consisted of a six-axis robotic arm with the capability of swapping between a nanopaste extrusion end effector, milling attachment and FPP attachment. Alternately, multiple robots and cobots can perform the process.
Ultimately, FPP offers improved performance over the alternative of tape laying. The robotic arm places patches of material in a programmed pattern over the surface of the CFOAM core. Each patch was about 2 × 4 inches and was placed in such a way as to strengthen the areas of the TPS surface which GT has identified will be under higher levels of loading. The use of AI was pervasive throughout the process.
Partners note that each deliverable in this project represents “a quantum leap” in the field of composites manufacturing, particularly for spacecraft and hypersonic systems, including:
• The design of industrial large-scale printer/end effector: The development of a large-scale printer and end effector capable of handling the demands of ceramic nanocomposite materials is a critical step forward. This printer enables the production of large-scale components with the precision and consistency required for aerospace applications. Notable, the robotic arm introduces multiple degrees of freedom beyond the Cartesian and Polar coordinates systems that constrain 3D printers. Likewise, robots and cobots allow scaling of 3D printing beyond conventional build beds.
• Optimized low shrinkage printable SiC nanopaste: This nanopaste reportedly addresses one of the most significant challenges in additive manufacturing — material shrinkage. By optimizing the paste formulation, this project ensures that components maintain their intended dimensions and properties, even after processing.
• Design of scalable roll-to-roll ceramic nanocomposite prepreg: The development of a scalable roll-to-roll prepreg enables the continuous production of ceramic nanocomposite tapes. This capability is essential for manufacturing large components and structures, reducing costs and production times.
• Two-inch ceramic nanocomposite T300/n-SiC prepreg tape: This deliverable provides a practical and scalable material solution for aerospace applications. The 2-inch prepreg tape combines the strength of T300 carbon fibers with the thermal and mechanical properties of SiC, making it ideal for use in high-temperature environments.
• Four-inch bottoms-up and top-down TPS approaches: By refining the bottoms-up and top-down approaches to TPS, this project ensures that the most effective method can be selected based on specific mission requirements. These approaches offer flexibility in design and manufacturing, accommodating a wide range of applications.
• Eighteen-inch ARMS produced manufacturing verification coupon: The production of this coupon demonstrates the viability of the ARMS system for manufacturing large-scale components. This coupon will be subjected to rigorous testing to validate the material and manufacturing process.
The GT team was selected for a Phase II award where the automated manufacturing of the improved TPS was scaled up to about a half meter, though it is reported that there is really no limitation of scale for the process. To accomplish this, GT developed a large-scale ARMS which consisted of a six-axis robotic arm with the capability of swapping between a nanopaste extrusion end effector, milling attachment and FPP attachment. Alternately, multiple robots and cobots can perform the process.
Ultimately, FPP offers improved performance over the alternative of tape laying. The robotic arm places patches of material in a programmed pattern over the surface of the CFOAM core. Each patch was about 2 × 4 inches and was placed in such a way as to strengthen the areas of the TPS surface which GT has identified will be under higher levels of loading. The use of AI was pervasive throughout the process.
Partners note that each deliverable in this project represents “a quantum leap” in the field of composites manufacturing, particularly for spacecraft and hypersonic systems, including:
• The design of industrial large-scale printer/end effector: The development of a large-scale printer and end effector capable of handling the demands of ceramic nanocomposite materials is a critical step forward. This printer enables the production of large-scale components with the precision and consistency required for aerospace applications. Notable, the robotic arm introduces multiple degrees of freedom beyond the Cartesian and Polar coordinates systems that constrain 3D printers. Likewise, robots and cobots allow scaling of 3D printing beyond conventional build beds.
• Optimized low shrinkage printable SiC nanopaste: This nanopaste reportedly addresses one of the most significant challenges in additive manufacturing — material shrinkage. By optimizing the paste formulation, this project ensures that components maintain their intended dimensions and properties, even after processing.
• Design of scalable roll-to-roll ceramic nanocomposite prepreg: The development of a scalable roll-to-roll prepreg enables the continuous production of ceramic nanocomposite tapes. This capability is essential for manufacturing large components and structures, reducing costs and production times.
• Two-inch ceramic nanocomposite T300/n-SiC prepreg tape: This deliverable provides a practical and scalable material solution for aerospace applications. The 2-inch prepreg tape combines the strength of T300 carbon fibers with the thermal and mechanical properties of SiC, making it ideal for use in high-temperature environments.
• Four-inch bottoms-up and top-down TPS approaches: By refining the bottoms-up and top-down approaches to TPS, this project ensures that the most effective method can be selected based on specific mission requirements. These approaches offer flexibility in design and manufacturing, accommodating a wide range of applications.
• Eighteen-inch ARMS produced manufacturing verification coupon: The production of this coupon demonstrates the viability of the ARMS system for manufacturing large-scale components. This coupon will be subjected to rigorous testing to validate the material and manufacturing process.
Composites
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Building on the success of this project, GT plans to participate in an investor-matched NASA Commercialization Readiness Pilot Program. This program will combine and test NASA’s 3D printable phenolic with GT’s reusable Hot Structure, with material validation at NASA Ames ArcJet facility. The ultimate goal is to manufacture a spaceflight test demonstrator using the ARMS system.
Moreover, the project has garnered interest from “New Space” companies in exploring GT’s CFCNC materials. These materials also offer retrofit opportunities for missiles, missile fairings, aeroshells and other strategic air platforms, particularly for hypersonic applications in Department of Defense (DOD) Programs of Record and System Primes.
#composites #NASA #nanocomposites
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Moreover, the project has garnered interest from “New Space” companies in exploring GT’s CFCNC materials. These materials also offer retrofit opportunities for missiles, missile fairings, aeroshells and other strategic air platforms, particularly for hypersonic applications in Department of Defense (DOD) Programs of Record and System Primes.
#composites #NASA #nanocomposites
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Composites
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Low-dielectric quartz fibre prepreg from Teijin Group’s Renegade Materials Corp. is first to achieve NCAMP certification
Teijin Limited announced that an epoxy thermoset prepreg on quartz fabric from its carbon fibre subsidiary, Renegade Materials Corporation, is the first such material to qualify for certification by the U.S. National Center for Advanced Materials Performance (NCAMP).
The high-performance, low-dielectric prepreg, made by impregnating woven quartz fabric with epoxy resin, is used for aircraft radar domes (radomes).
NCAMP is a private certification organization run by Wichita (Kansas) State University in the United States. NCAMP works with the U.S. Federal Aviation Administration (FAA) to qualify material systems and populate a shared database. Both the FAA and the European Aviation Safety Agency (EASA) accept composite specification and design values developed using the NCAMP process.
NCAMP certification of Renegade Materials’ low-dielectric prepreg benefits aircraft manufacturers and aircraft part suppliers by reducing production costs and accelerating the process from design to production. By utilizing the database published by NCAMP, they avoid having to perform time-consuming certification work on individual materials in house. This approach helps them obtain certification from government agencies that oversee civil aviation safety with greater efficiency and lower costs.
Renegade Materials’ low-dielectric prepreg certified by NCAMP not only provides excellent electrical insulation and enhanced signal integrity, but also has value-added capabilities such as reducing electromagnetic interference (EMI).
Renegade Materials is a leading U.S. manufacturer of high-heat-resistant thermoset prepregs for aerospace applications. Established in 2007, it has been part of the Teijin Group since 2019. Through successful applications, Renegade Materials’ products have earned the trust of aircraft manufacturers and aircraft engine manufacturers in Europe and the United States.
The Teijin Group aims to become “a company that supports the society of the future” according to its long-term vision, and will continue to provide solutions in a variety of fields.
#composites #Teijin #FibrePrepreg
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Teijin Limited announced that an epoxy thermoset prepreg on quartz fabric from its carbon fibre subsidiary, Renegade Materials Corporation, is the first such material to qualify for certification by the U.S. National Center for Advanced Materials Performance (NCAMP).
The high-performance, low-dielectric prepreg, made by impregnating woven quartz fabric with epoxy resin, is used for aircraft radar domes (radomes).
NCAMP is a private certification organization run by Wichita (Kansas) State University in the United States. NCAMP works with the U.S. Federal Aviation Administration (FAA) to qualify material systems and populate a shared database. Both the FAA and the European Aviation Safety Agency (EASA) accept composite specification and design values developed using the NCAMP process.
NCAMP certification of Renegade Materials’ low-dielectric prepreg benefits aircraft manufacturers and aircraft part suppliers by reducing production costs and accelerating the process from design to production. By utilizing the database published by NCAMP, they avoid having to perform time-consuming certification work on individual materials in house. This approach helps them obtain certification from government agencies that oversee civil aviation safety with greater efficiency and lower costs.
Renegade Materials’ low-dielectric prepreg certified by NCAMP not only provides excellent electrical insulation and enhanced signal integrity, but also has value-added capabilities such as reducing electromagnetic interference (EMI).
Renegade Materials is a leading U.S. manufacturer of high-heat-resistant thermoset prepregs for aerospace applications. Established in 2007, it has been part of the Teijin Group since 2019. Through successful applications, Renegade Materials’ products have earned the trust of aircraft manufacturers and aircraft engine manufacturers in Europe and the United States.
The Teijin Group aims to become “a company that supports the society of the future” according to its long-term vision, and will continue to provide solutions in a variety of fields.
#composites #Teijin #FibrePrepreg
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Composites
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Taiwanese company AIM manufactures high-tech wheels with KraussMaffei
Golf clubs, bicycles – and now automotive too: together with KraussMaffei, the Taiwanese composite specialist Advanced International Multitech (AIM) is expanding its portfolio to include High Pressure RTM. AIM is now producing high-quality carbon rims on a complete system with sophisticated tools.
Anyone who plays golf and is thus aware of the importance of weight has (most certainly) had an AIM product in their hands. The company has a market share of around 80 percent of carbon-fibre golf clubs (under different brand names), and also has success in the bicycle market. For around 30 years, various composite technologies have been a part of the standard repertoire. When AIM first ventured into the automotive sector, however, know-how from KraussMaffei was in demand. This would be the first time they put a high-pressure system (HP-RTM / High Pressure Resin Transfer Molding) into operation.
In comparison to low-pressure processes, HP-RTM requires more complex dosing technology, but also delivers consistently high-quality components with particularly precise surface quality – and with shorter cycle times. Short cycle times are particularly important in the automotive industry. In the beginning, the AIM team first wanted to get to know the new technology of the system. As Tyson Hsiao, R&D Manager explains: “Fredrick Su, our sales partner at KraussMaffei, listened carefully, and then put together a package that we could use in an HP-RTM cell to recreate both high-pressure transfer molding as well as wet molding and compression RTM for small production series. We were really impressed by this.
A concrete project was soon to follow. Carbon rims tend to occupy a niche in the automotive sector, yet are extremely lucrative because they are in the high-price segment. A material mixture is common in this case: A rim body made of CFRP (carbon fibre reinforced plastic), to which the visually-appealing aluminum wheel spider is bolted. These wheels are approximately 20 to 30 percent lighter than those made of pure aluminum and, at the same time, are around 20 percent stronger than aluminum rims. Sporty and ambitious drivers can accelerate faster thanks to the reduced weight and, with more of the unevenness of the road able to be dampened by the suspension, the driving experience is also more pleasant. If you want to deck out your vehicle with carbon rims, you have to dig deep into your pockets: 10,000 to 15,000 € per set is common.
The entire production cell for the carbon rims measures just 16 x 12 meters, including the enclosure, and is therefore very compact.
Overall expertise from KraussMaffei
So, when the time came to implement the AIM project, KraussMaffei demonstrated its expertise. Project Manager Thomas Eilhammer actively supported the customer and coordinated the comprehensive package consisting of an MX press with a clamping force of 10,000 kN, the RimStar Compact 8/4 HP-RTM metering system, two robots for metering and handling (with different grippers) and a sophisticated mold solution. His enthusiasm has not faded. “The system now has, at 16 x 12 meters, quite a compact design, and all its components are perfectly well tuned to one another. This, simply said, reflects our strength as a full-service provider“.
The mold carrier forms the heart of the system. The MX press has a clamping force of 10,000 kN.
Golf clubs, bicycles – and now automotive too: together with KraussMaffei, the Taiwanese composite specialist Advanced International Multitech (AIM) is expanding its portfolio to include High Pressure RTM. AIM is now producing high-quality carbon rims on a complete system with sophisticated tools.
Anyone who plays golf and is thus aware of the importance of weight has (most certainly) had an AIM product in their hands. The company has a market share of around 80 percent of carbon-fibre golf clubs (under different brand names), and also has success in the bicycle market. For around 30 years, various composite technologies have been a part of the standard repertoire. When AIM first ventured into the automotive sector, however, know-how from KraussMaffei was in demand. This would be the first time they put a high-pressure system (HP-RTM / High Pressure Resin Transfer Molding) into operation.
In comparison to low-pressure processes, HP-RTM requires more complex dosing technology, but also delivers consistently high-quality components with particularly precise surface quality – and with shorter cycle times. Short cycle times are particularly important in the automotive industry. In the beginning, the AIM team first wanted to get to know the new technology of the system. As Tyson Hsiao, R&D Manager explains: “Fredrick Su, our sales partner at KraussMaffei, listened carefully, and then put together a package that we could use in an HP-RTM cell to recreate both high-pressure transfer molding as well as wet molding and compression RTM for small production series. We were really impressed by this.
A concrete project was soon to follow. Carbon rims tend to occupy a niche in the automotive sector, yet are extremely lucrative because they are in the high-price segment. A material mixture is common in this case: A rim body made of CFRP (carbon fibre reinforced plastic), to which the visually-appealing aluminum wheel spider is bolted. These wheels are approximately 20 to 30 percent lighter than those made of pure aluminum and, at the same time, are around 20 percent stronger than aluminum rims. Sporty and ambitious drivers can accelerate faster thanks to the reduced weight and, with more of the unevenness of the road able to be dampened by the suspension, the driving experience is also more pleasant. If you want to deck out your vehicle with carbon rims, you have to dig deep into your pockets: 10,000 to 15,000 € per set is common.
The entire production cell for the carbon rims measures just 16 x 12 meters, including the enclosure, and is therefore very compact.
Overall expertise from KraussMaffei
So, when the time came to implement the AIM project, KraussMaffei demonstrated its expertise. Project Manager Thomas Eilhammer actively supported the customer and coordinated the comprehensive package consisting of an MX press with a clamping force of 10,000 kN, the RimStar Compact 8/4 HP-RTM metering system, two robots for metering and handling (with different grippers) and a sophisticated mold solution. His enthusiasm has not faded. “The system now has, at 16 x 12 meters, quite a compact design, and all its components are perfectly well tuned to one another. This, simply said, reflects our strength as a full-service provider“.
The mold carrier forms the heart of the system. The MX press has a clamping force of 10,000 kN.
Composites
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René Ring’s team at the plant in Georgsmarienhütte, Harderberg was responsible for the mold development. “We apply a master mold and use several mold packages for the different rim diameters. This gives the customer a lot of flexibility.” The subsequent process is then as follows: A carbon preform, prepared by the customer, is placed over the inner core of the mold, and four sliders, which form the round outer contour of the rim, then move simultaneously. The press closes and the epoxy matrix material is metered through a distribution star. After a curing time of approximately 15 minutes, the mold opens, the sliders open and an ejector ring presses the rim body, which has shrunk to the core (diameter 20 inches), upwards. The mold is flexible from diameter 18 inches to 22 inches with the rim width from 8 inches to 12 inches. The finishing takes place through a series of downstream processes.
Care was taken to minimize space when installing the system components.
The know-how is in the mold
The many moving parts in the mold were cause for the greatest challenge, which was to seal the complete system at a high cavity pressure. Normally, the pressing force alone is sufficient to seal a mold, where the horizontal sealing surface is located solely between the upper and lower parts of the mold. In the case of the rim project, however, the undercuts and C-shaped contours of the part required the four sliders to make demolding possible at all, not to mention the moving ejector ring. To retain the vacuum in the mold and thus prevent low-viscosity material from escaping, the team strove to achieve the best possible manufacturing precision and with it a good design. The locking force is generated by four barrels on the top of the master mold, and locking elements mounted underneath, which move into recesses on the sliders and block them. With a mold temperature of 120 to 130 degrees Celsius, it was necessary to protect the pneumatic and electronic components with insulation boards.
The team came up with something special for the rim tool: The movable cylinders lock and unlock it and thus ensure the seal
The mold weighs a total of 4.9 tons. It was manufactured in 2023 in Harderberg, then prototyped in the KraussMaffei TechCenter in Munich, where it was optimized once again, and finally delivered with the complete system to the customer. Since the fundamental requirement of a rim is that it is round, René Ring’s team is particularly proud of the fact that, “we achieved a concentricity precision of less than 2/100 millimeters.” But not only that. Another remarkable achievement was successfully producing a good part with the very first shot.
Ready from the mold carrier: the carbon rim.
The carbon rim has already been exhibited at the JEC Composites Show in Paris and R&D Manager Tyson Hsiao praised the excellent collaboration. “It was important for us to have an experienced, full-service provider for HP-RTM at our side, who offered great proficiency in systems, processes and mold technology. This gave us the ability to concentrate on our role: the production of the carbon blanks. As a result, the cogs meshed, producing a perfect wheel.”
#composites #KraussMaffei
Photo: KraussMaffei.
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Care was taken to minimize space when installing the system components.
The know-how is in the mold
The many moving parts in the mold were cause for the greatest challenge, which was to seal the complete system at a high cavity pressure. Normally, the pressing force alone is sufficient to seal a mold, where the horizontal sealing surface is located solely between the upper and lower parts of the mold. In the case of the rim project, however, the undercuts and C-shaped contours of the part required the four sliders to make demolding possible at all, not to mention the moving ejector ring. To retain the vacuum in the mold and thus prevent low-viscosity material from escaping, the team strove to achieve the best possible manufacturing precision and with it a good design. The locking force is generated by four barrels on the top of the master mold, and locking elements mounted underneath, which move into recesses on the sliders and block them. With a mold temperature of 120 to 130 degrees Celsius, it was necessary to protect the pneumatic and electronic components with insulation boards.
The team came up with something special for the rim tool: The movable cylinders lock and unlock it and thus ensure the seal
The mold weighs a total of 4.9 tons. It was manufactured in 2023 in Harderberg, then prototyped in the KraussMaffei TechCenter in Munich, where it was optimized once again, and finally delivered with the complete system to the customer. Since the fundamental requirement of a rim is that it is round, René Ring’s team is particularly proud of the fact that, “we achieved a concentricity precision of less than 2/100 millimeters.” But not only that. Another remarkable achievement was successfully producing a good part with the very first shot.
Ready from the mold carrier: the carbon rim.
The carbon rim has already been exhibited at the JEC Composites Show in Paris and R&D Manager Tyson Hsiao praised the excellent collaboration. “It was important for us to have an experienced, full-service provider for HP-RTM at our side, who offered great proficiency in systems, processes and mold technology. This gave us the ability to concentrate on our role: the production of the carbon blanks. As a result, the cogs meshed, producing a perfect wheel.”
#composites #KraussMaffei
Photo: KraussMaffei.
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Composites
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Toray Advanced Composites announces launch of high-performance Toray Cetex® PESU thermoplastic composite material
Toray Advanced Composites, a leading innovator in advanced material technology, today announces the launch of Toray Cetex® TC1130 PESU thermoplastic composite material. This high-performance thermoplastic composite material is specifically engineered to address the growing need for lightweight and environmentally sustainable materials in aircraft interior applications, offering significant benefits to the aerospace industry.
Suited for monolithic and thermoplastic-based sandwich panel constructions, Toray Cetex® TC1130 PESU (PolyEtherSulphone) continuous fiber reinforced thermoplastic composite enables the creation of mono-material sandwich structures when combined with core materials of the same chemistry. Compared to materials currently used, this not only achieves additional weight savings and cost-effective post-processing, but also ensures fully recyclable homogeneous sandwich structures. Additionally, Toray Cetex® TC1130 offers excellent fire, smoke, and toxicity (FST) performance, outstanding impact resistance, and toughness, which are essential for demanding interior applications.
“We are excited to share our latest product development with the world,” states Marc Huisman, Director Research and Development, Toray Advanced Composites Europe. “As a leading material supplier, we understand the challenges faced by the aerospace industry to achieve full circularity. We’re proud to continue our long legacy of material technology innovation by bringing this latest generation of sustainable material solutions to market.”
Toray Advanced Composites’ global technical and commercial teams are ready to support immediate demand for Toray Cetex® TC1130.
#composites #Toray #ThermoplasticCompositeMaterial
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Toray Advanced Composites, a leading innovator in advanced material technology, today announces the launch of Toray Cetex® TC1130 PESU thermoplastic composite material. This high-performance thermoplastic composite material is specifically engineered to address the growing need for lightweight and environmentally sustainable materials in aircraft interior applications, offering significant benefits to the aerospace industry.
Suited for monolithic and thermoplastic-based sandwich panel constructions, Toray Cetex® TC1130 PESU (PolyEtherSulphone) continuous fiber reinforced thermoplastic composite enables the creation of mono-material sandwich structures when combined with core materials of the same chemistry. Compared to materials currently used, this not only achieves additional weight savings and cost-effective post-processing, but also ensures fully recyclable homogeneous sandwich structures. Additionally, Toray Cetex® TC1130 offers excellent fire, smoke, and toxicity (FST) performance, outstanding impact resistance, and toughness, which are essential for demanding interior applications.
“We are excited to share our latest product development with the world,” states Marc Huisman, Director Research and Development, Toray Advanced Composites Europe. “As a leading material supplier, we understand the challenges faced by the aerospace industry to achieve full circularity. We’re proud to continue our long legacy of material technology innovation by bringing this latest generation of sustainable material solutions to market.”
Toray Advanced Composites’ global technical and commercial teams are ready to support immediate demand for Toray Cetex® TC1130.
#composites #Toray #ThermoplasticCompositeMaterial
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Recycling composites thanks to bamboo
French start-up Bambooneo recycles composite waste by incorporating it into walls made from bamboo strips. It also offers bamboo compounds as reinforcements for composites, helping to reduce the carbon footprint of certain products.
A bamboo prison for composite waste. That’s how you might describe the new innovative solution of french start-up Bambooneo. Intended for the building and public works sector, it is based on a patented process that enables panels to be produced industrially from small bamboos, 20 mm in diameter, grown in Europe.
“We’re working on building blocks, a sort of exoskeleton or carapace made of bamboo strips, which will be able to trap aggregates from wind turbine blades to be recycled, for example”, explains Bernard Derrien, founder of the start-up, which was set up in June 2024 and employs around ten people, some of them also carpenters or recyclers.
A bamboo frame
The first stage of the patented process involves the splitting and fully automated gluing of 32 bamboos per second. The bamboo is then transformed into 80x120cm panels made up of 2 overlapping layers bonded with an 80% biobased polyurethane glue.
Glued together, these panels can replace OSB (Oriented Strand Board) for formwork, facades and beams.
Bambooneo then uses them to make 40×20 cm, 40 mm-thick bricks made from 25 strips of bamboo that can be criss-crossed and fitted together like Lego bricks. More rigid than wood, these bricks can then be used to make double partition walls that can be filled with dry earth mixed with bark or granulated composites.
“Soil can be replaced by granulated composites, because the weight and thermal inertia benefits are significant. Using composites as filler also means that fewer trees must be cut down to make the frames. Whenever possible, we try to use waste instead of earth. This makes the walls very solid and dense, with good insulation. Composites are in fact a better insulator than soil. You can incorporate 60 kg of composites per m2 of wall”, explains Bernard Derrien.
Reducing the footprint of composites
Bambooneo tries to find raw material directly from manufacturing sites. “We take care of everything “, says Bambooneo, “we go out to construction sites with crushers on lorries to recover wind turbine blades or catamaran rudder parts such as rudders. Then we shred them on site, with three different levels of shredding depending on requirements. We don’t need to separate the components. Our technology is equally suited to composite scrap from the automotive, aerospace and marine industries”, continues Mr Derrien. As the composites used are not mixed with other ingredients, they can be reused as they are when the walls are dismantled.
To complete its range, Bambooneo also offers a product aimed more at composite material manufacturers. These are chips made with the external faces of small bamboos less than 25mm in diameter. “These compact, dense reinforcements contain more lignin than teak, and a significant amount of silica. Some of our customers are currently testing it to improve their carbon footprint”, explains the start-up’s founder.
#composites #Recycling #bamboo
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French start-up Bambooneo recycles composite waste by incorporating it into walls made from bamboo strips. It also offers bamboo compounds as reinforcements for composites, helping to reduce the carbon footprint of certain products.
A bamboo prison for composite waste. That’s how you might describe the new innovative solution of french start-up Bambooneo. Intended for the building and public works sector, it is based on a patented process that enables panels to be produced industrially from small bamboos, 20 mm in diameter, grown in Europe.
“We’re working on building blocks, a sort of exoskeleton or carapace made of bamboo strips, which will be able to trap aggregates from wind turbine blades to be recycled, for example”, explains Bernard Derrien, founder of the start-up, which was set up in June 2024 and employs around ten people, some of them also carpenters or recyclers.
A bamboo frame
The first stage of the patented process involves the splitting and fully automated gluing of 32 bamboos per second. The bamboo is then transformed into 80x120cm panels made up of 2 overlapping layers bonded with an 80% biobased polyurethane glue.
Glued together, these panels can replace OSB (Oriented Strand Board) for formwork, facades and beams.
Bambooneo then uses them to make 40×20 cm, 40 mm-thick bricks made from 25 strips of bamboo that can be criss-crossed and fitted together like Lego bricks. More rigid than wood, these bricks can then be used to make double partition walls that can be filled with dry earth mixed with bark or granulated composites.
“Soil can be replaced by granulated composites, because the weight and thermal inertia benefits are significant. Using composites as filler also means that fewer trees must be cut down to make the frames. Whenever possible, we try to use waste instead of earth. This makes the walls very solid and dense, with good insulation. Composites are in fact a better insulator than soil. You can incorporate 60 kg of composites per m2 of wall”, explains Bernard Derrien.
Reducing the footprint of composites
Bambooneo tries to find raw material directly from manufacturing sites. “We take care of everything “, says Bambooneo, “we go out to construction sites with crushers on lorries to recover wind turbine blades or catamaran rudder parts such as rudders. Then we shred them on site, with three different levels of shredding depending on requirements. We don’t need to separate the components. Our technology is equally suited to composite scrap from the automotive, aerospace and marine industries”, continues Mr Derrien. As the composites used are not mixed with other ingredients, they can be reused as they are when the walls are dismantled.
To complete its range, Bambooneo also offers a product aimed more at composite material manufacturers. These are chips made with the external faces of small bamboos less than 25mm in diameter. “These compact, dense reinforcements contain more lignin than teak, and a significant amount of silica. Some of our customers are currently testing it to improve their carbon footprint”, explains the start-up’s founder.
#composites #Recycling #bamboo
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Composites
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China develops first batch of carbon fibre composite heavy rail freight trains
China’s first batch of carbon fibre composite heavy rail wagons jointly developed by CRRC Qiche Company, China Energy Railway Equipment Company and the National Institute of Clean and Low Carbon Energy (both of which are subsidiaries of China Energy Group) officially rolled off the production line, marking China’s progress in heavy rail mobile equipment.
After three years of collaborative research, focusing on the core issues of lightweighting and intelligence in the field of railway equipment, the three companies developed an advanced carbon fibre-reinforced resin-based composite material suitable for heavy rail freight cars, and overcame key technical problems such as the integrated preparation of large components of composite panels. For the first time, this new material was used in the preparation of the main load-bearing structure of heavy rail freight cars.
The specific strength and specific modulus of this advanced carbon fibre-reinforced resin-based composite material are 3-5 times and 1.5-1.8 times that of aluminium alloy materials, respectively. It can better meet the production requirements of light and large parts and the use of heavy rail trucks. It is lighter, more energy efficient and more durable and has technical advantages such as greater environmental adaptability.
The weight of this type of railway freight car body is more than 20% lower than that of similar aluminium alloy material car bodies. It achieves the simultaneous synergy of vehicle weight reduction, load increase and volume increase, which is important for improving railway transportation efficiency.
China Energy Group and CRRC have a long history of cooperation in railway equipment research and development, operation and maintenance, etc. In September 2022, the two parties jointly signed the “Cooperation Agreement on the Construction of Modern Energy Transportation Industry Chain”.
#composites #Recycling #bamboo
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China’s first batch of carbon fibre composite heavy rail wagons jointly developed by CRRC Qiche Company, China Energy Railway Equipment Company and the National Institute of Clean and Low Carbon Energy (both of which are subsidiaries of China Energy Group) officially rolled off the production line, marking China’s progress in heavy rail mobile equipment.
After three years of collaborative research, focusing on the core issues of lightweighting and intelligence in the field of railway equipment, the three companies developed an advanced carbon fibre-reinforced resin-based composite material suitable for heavy rail freight cars, and overcame key technical problems such as the integrated preparation of large components of composite panels. For the first time, this new material was used in the preparation of the main load-bearing structure of heavy rail freight cars.
The specific strength and specific modulus of this advanced carbon fibre-reinforced resin-based composite material are 3-5 times and 1.5-1.8 times that of aluminium alloy materials, respectively. It can better meet the production requirements of light and large parts and the use of heavy rail trucks. It is lighter, more energy efficient and more durable and has technical advantages such as greater environmental adaptability.
The weight of this type of railway freight car body is more than 20% lower than that of similar aluminium alloy material car bodies. It achieves the simultaneous synergy of vehicle weight reduction, load increase and volume increase, which is important for improving railway transportation efficiency.
China Energy Group and CRRC have a long history of cooperation in railway equipment research and development, operation and maintenance, etc. In September 2022, the two parties jointly signed the “Cooperation Agreement on the Construction of Modern Energy Transportation Industry Chain”.
#composites #Recycling #bamboo
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Composites
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Mikrosam robotic filament winding cell to aid Cidetec composites projects
Delivery of the single-spindle robotic setup with an ATP head will advance the R&D organization’s work in CUBIC, GENEX and Carbo4power initiatives targeting sustainable composites development.
Mikrosam (Prilep, Macedonia) has deliveredy one of its robotic filament winding machine, equipped with an automated tape placement (ATP) head, to private applied research organization Cidetec (San Sebastián, Spain). The technology will support Cidetec’s projects surrounding the development of sustainable composites using its 3R (recyclable, repairable and reprocessable) epoxy resin.
Mikrosam’s single-spindle robotic setup is designed to handle wet and towpreg winding processes — for materials including carbon, glass, aramid fibers and different epoxy resin systems — as well as precise tape placement of thermoset unidirectional (UD) slit prepreg tapes, offering Cidetec optimal flexibility. There are eight interpolated axes in the winding process. Equipped with a six-axis robotic arm for accurate placement and two-axis control for spindle rotation and payout eye movement, the system can accommodate mandrels with different diameters and lengths. Mikrosam says that this enables the production of a wide range of parts, including hydrogen (H2) storage tanks — a hot topic in the market — but also another large range of products.
The single-tape placement head offers high-speed, bi-directional layup of thermoset UD prepreg tapes, emphasizing precision and adaptability for complex composite structures. Designed for both 2D and mild 3D geometries, this head is ideal for advanced aerospace and wind energy applications.
The system accommodates tapes of ½-inch width, achieving a placement tolerance of ±0.1 millimeter. A compact fiber creel minimizes material distortion and allows quick tape changes, reducing downtime. Integrated with an infrared (IR) heating unit, the system preheats the prepreg tape, ensuring optimal bonding during layup. The programmable heating power adjusts in real time to match the layup speed, ensuring consistent temperature control.
Mikrosam’s Winding Expert software further enhances the system’s capabilities with simulation and programming features, and a Quality Control System tracks and records essential production data.
Cidetec plans to use this equipment for several European epoxy development projects, starting with the CUBIC project, which focuses on the development of bio-based sustainable composites. These composites, using Mikrosam’s filament winding technology, will be a critical component in the production of H2 tanks. The goal is to offer a bio-based alternative that supports the green and digital transformation of the manufacturing industry.
According to Dr. Eva García Lecina, deputy director of Cidetec Surface Engineering, “this equipment will help us take our developments to the next level, contributing to the use of more sustainable composites in the energy, aerospace and automotive sectors.”
Cidetec will also employ this system in two other projects. The Carbo4Power project aims to manufacture sustainable wind turbine blades using the ATP machine with Cidetec’s 3R epoxy resin. This initiative seeks to enhance the performance and durability of offshore wind and tidal turbine blades while reducing energy production costs, maintenance needs and environmental impact. The project’s goal is to recycle up to 95% of blade materials thanks to the properties of Cidetec’s 3R resins, which enable debonding on demand.
The second project, GENEX, targets the aerospace sector and focuses on optimizing manufacturing and maintenance for next-generation aircraft composite structures. Cidetec has been collaborating on this project for a year, working on formulating and characterizing aeronautical-grade 3R resins and developing prepreg tapes with integrated fiber optic sensors. These materials will be used to manufacture access panels for aircraft through Mikrosam’s ATP process.
Delivery of the single-spindle robotic setup with an ATP head will advance the R&D organization’s work in CUBIC, GENEX and Carbo4power initiatives targeting sustainable composites development.
Mikrosam (Prilep, Macedonia) has deliveredy one of its robotic filament winding machine, equipped with an automated tape placement (ATP) head, to private applied research organization Cidetec (San Sebastián, Spain). The technology will support Cidetec’s projects surrounding the development of sustainable composites using its 3R (recyclable, repairable and reprocessable) epoxy resin.
Mikrosam’s single-spindle robotic setup is designed to handle wet and towpreg winding processes — for materials including carbon, glass, aramid fibers and different epoxy resin systems — as well as precise tape placement of thermoset unidirectional (UD) slit prepreg tapes, offering Cidetec optimal flexibility. There are eight interpolated axes in the winding process. Equipped with a six-axis robotic arm for accurate placement and two-axis control for spindle rotation and payout eye movement, the system can accommodate mandrels with different diameters and lengths. Mikrosam says that this enables the production of a wide range of parts, including hydrogen (H2) storage tanks — a hot topic in the market — but also another large range of products.
The single-tape placement head offers high-speed, bi-directional layup of thermoset UD prepreg tapes, emphasizing precision and adaptability for complex composite structures. Designed for both 2D and mild 3D geometries, this head is ideal for advanced aerospace and wind energy applications.
The system accommodates tapes of ½-inch width, achieving a placement tolerance of ±0.1 millimeter. A compact fiber creel minimizes material distortion and allows quick tape changes, reducing downtime. Integrated with an infrared (IR) heating unit, the system preheats the prepreg tape, ensuring optimal bonding during layup. The programmable heating power adjusts in real time to match the layup speed, ensuring consistent temperature control.
Mikrosam’s Winding Expert software further enhances the system’s capabilities with simulation and programming features, and a Quality Control System tracks and records essential production data.
Cidetec plans to use this equipment for several European epoxy development projects, starting with the CUBIC project, which focuses on the development of bio-based sustainable composites. These composites, using Mikrosam’s filament winding technology, will be a critical component in the production of H2 tanks. The goal is to offer a bio-based alternative that supports the green and digital transformation of the manufacturing industry.
According to Dr. Eva García Lecina, deputy director of Cidetec Surface Engineering, “this equipment will help us take our developments to the next level, contributing to the use of more sustainable composites in the energy, aerospace and automotive sectors.”
Cidetec will also employ this system in two other projects. The Carbo4Power project aims to manufacture sustainable wind turbine blades using the ATP machine with Cidetec’s 3R epoxy resin. This initiative seeks to enhance the performance and durability of offshore wind and tidal turbine blades while reducing energy production costs, maintenance needs and environmental impact. The project’s goal is to recycle up to 95% of blade materials thanks to the properties of Cidetec’s 3R resins, which enable debonding on demand.
The second project, GENEX, targets the aerospace sector and focuses on optimizing manufacturing and maintenance for next-generation aircraft composite structures. Cidetec has been collaborating on this project for a year, working on formulating and characterizing aeronautical-grade 3R resins and developing prepreg tapes with integrated fiber optic sensors. These materials will be used to manufacture access panels for aircraft through Mikrosam’s ATP process.
Composites
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“One of Mikrosam’s key strengths is the flexibility of its machines, which can be tailored to meet our customers’ unique requirements,” says Vele Samak, vice president of Mikrosam. “The delivery of this advanced filament winding and tape placement system will empower Cidetec to achieve the highest levels of performance and efficiency in their manufacturing processes. Additionally, our collaboration on these projects positions us at the forefront of the global challenge for a cleaner, greener future.”
#composites #Mikrosam #FilamentWinding
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#composites #Mikrosam #FilamentWinding
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Composites
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Biesterfeld to distribute Saertex on the German market
A new partnership has just been signed between specialist chemicals distributor Biesterfeld and Saertex, a manufacturer of textile reinforcements for composite materials.
Biesterfeld is Saertex’s new distributor for the German market since November. The specialist chemicals distributor had already been working with the manufacturer of multi-axial textile reinforcements on the Polish market for many years.
Biesterfeld is taking over from Halarit Composites, a subsidiary of the French Gazechim Group, which until now has been responsible for Saertex’s presence on the German market.
As part of the new cooperation, Biesterfeld will receive the distribution rights for Saertex Non-Crimp Fabrics in the German market. These include Saertex Glass and Carbon NCF as well as the Saerfix, Saerflow and Saercore product solutions. In addition, Biesterfeld will also offer other products from the Saertex portfolio.
“Biesterfeld brings valuable market knowledge and an established network, which helps us to position our products optimally. Through even closer cooperation and increased joint customer visits, we want to ensure that our customers always receive the best possible solutions” explained Steven Bakker, commercial director at Saertex.
“The demand for high-performance fiber composites is growing continuously, and we are convinced that the synergies between our two companies will offer our customers significant added value and that together we can further develop the innovation potential of the German lightweight construction market”, said Johannes Martin, market manager performance products at Biesterfeld Spezialchemie.
Heading photo: Saercore is one of Saertex products now distributed in Germany by Biesterfeld.
#composites #Biesterfeld #Saertex
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A new partnership has just been signed between specialist chemicals distributor Biesterfeld and Saertex, a manufacturer of textile reinforcements for composite materials.
Biesterfeld is Saertex’s new distributor for the German market since November. The specialist chemicals distributor had already been working with the manufacturer of multi-axial textile reinforcements on the Polish market for many years.
Biesterfeld is taking over from Halarit Composites, a subsidiary of the French Gazechim Group, which until now has been responsible for Saertex’s presence on the German market.
As part of the new cooperation, Biesterfeld will receive the distribution rights for Saertex Non-Crimp Fabrics in the German market. These include Saertex Glass and Carbon NCF as well as the Saerfix, Saerflow and Saercore product solutions. In addition, Biesterfeld will also offer other products from the Saertex portfolio.
“Biesterfeld brings valuable market knowledge and an established network, which helps us to position our products optimally. Through even closer cooperation and increased joint customer visits, we want to ensure that our customers always receive the best possible solutions” explained Steven Bakker, commercial director at Saertex.
“The demand for high-performance fiber composites is growing continuously, and we are convinced that the synergies between our two companies will offer our customers significant added value and that together we can further develop the innovation potential of the German lightweight construction market”, said Johannes Martin, market manager performance products at Biesterfeld Spezialchemie.
Heading photo: Saercore is one of Saertex products now distributed in Germany by Biesterfeld.
#composites #Biesterfeld #Saertex
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