Composites
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Three unknown facts about continuous fiber 3D printing from anisoprint CEO Fedor Antonov
With a decade of expertise, it’s safe to say Anisoprint knows a thing or two about continuous fiber 3D printing. The Russian manufacturer specializes in composite fiber co-extrusion 3D printers capable of fabricating high-strength reinforced parts. The company also develops and supplies the fiber-reinforced materials that enable the multitude of applications of the niche technology.
High fiber volume isn’t everything
Engineers working in composite manufacturing will know that a high fiber volume ratio means a great deal when it comes to part strength. Most professional and industrial components require around 40% – 60% when produced, for example, with traditional automated fiber placement machines. These machines systematically lay down sheets of base material alongside bundles of fibers, using a pressure roller to induce adhesion.
When it comes to additively manufactured composite parts, packing in a healthy 50% would be great but it’s simply not feasible a lot of the time. The problem is: higher fiber volume ratios require more consolidation between the layers to push out the trapped air. This just means more pressure needs to be applied after each layer to get it to bond reliably to its neighbors.
Due to the angular limitations of a roller and the stability limitations of the part being rolled, consolidating certain sections of a 3D printed part, like thin walls or overhangs, may prove difficult. With such pressure, you can’t produce lattice structures — the most optimal shape for composites — since they consist of thin walls. So, the higher the fiber volume, the more design freedom you give up – an unfortunate relationship given that this is supposed to be one of 3D printing’s main benefits.
A roller consolidating layers during automated fiber placement. Image via Anisoprint.
**Chopped fibers vs. continuous fibers
Strengthening fibers can be split up into two main categories – chopped fibers and continuous fibers. They may sound functionally one and the same but have very different effects on the mechanical properties of a part.
Antonov explains: “There is a lot of confusion between short fibers and continuous fibers. Both form composites but only continuous fibers can truly be seen as ‘reinforcements’. Chopped fibers simply fill the material matrix without any orientation while continuous fibers run end to end being oriented in the same direction. Since the strength of the composite lies along the fibers, continuous fibers are the only way to get a strong part.”
The difference is significant. Looking at Anisoprint’s very own in-house test data, a chopped fiber-filled composite tends to be about twice as strong as a pure plastic. Impressively, a continuous fiber-filled composite can be around 30x as strong – a very stark difference.
With a decade of expertise, it’s safe to say Anisoprint knows a thing or two about continuous fiber 3D printing. The Russian manufacturer specializes in composite fiber co-extrusion 3D printers capable of fabricating high-strength reinforced parts. The company also develops and supplies the fiber-reinforced materials that enable the multitude of applications of the niche technology.
High fiber volume isn’t everything
Engineers working in composite manufacturing will know that a high fiber volume ratio means a great deal when it comes to part strength. Most professional and industrial components require around 40% – 60% when produced, for example, with traditional automated fiber placement machines. These machines systematically lay down sheets of base material alongside bundles of fibers, using a pressure roller to induce adhesion.
When it comes to additively manufactured composite parts, packing in a healthy 50% would be great but it’s simply not feasible a lot of the time. The problem is: higher fiber volume ratios require more consolidation between the layers to push out the trapped air. This just means more pressure needs to be applied after each layer to get it to bond reliably to its neighbors.
Due to the angular limitations of a roller and the stability limitations of the part being rolled, consolidating certain sections of a 3D printed part, like thin walls or overhangs, may prove difficult. With such pressure, you can’t produce lattice structures — the most optimal shape for composites — since they consist of thin walls. So, the higher the fiber volume, the more design freedom you give up – an unfortunate relationship given that this is supposed to be one of 3D printing’s main benefits.
A roller consolidating layers during automated fiber placement. Image via Anisoprint.
**Chopped fibers vs. continuous fibers
Strengthening fibers can be split up into two main categories – chopped fibers and continuous fibers. They may sound functionally one and the same but have very different effects on the mechanical properties of a part.
Antonov explains: “There is a lot of confusion between short fibers and continuous fibers. Both form composites but only continuous fibers can truly be seen as ‘reinforcements’. Chopped fibers simply fill the material matrix without any orientation while continuous fibers run end to end being oriented in the same direction. Since the strength of the composite lies along the fibers, continuous fibers are the only way to get a strong part.”
The difference is significant. Looking at Anisoprint’s very own in-house test data, a chopped fiber-filled composite tends to be about twice as strong as a pure plastic. Impressively, a continuous fiber-filled composite can be around 30x as strong – a very stark difference.
Composites
Photo
Not only carbon
Carbon fiber printing is often used interchangeably with continuous fiber 3D printing. While carbon fiber is one of the more well known, there are other materials that can be used for reinforcement. Engineers looking to utilize the technology can access fiberglass, aramid, basalt, and even natural fibers as they all have varying properties and use cases.
Aramid, much like carbon fiber, is known for increasing the strength of a part but it also adds excellent impact and damage tolerance – a property not granted by carbon fibers.
Basalt, an economical alternative to carbon, may be preferred when cost-efficiency is key but part strength isn’t very high on the list of priorities. Plastic reinforced with Anisoprint’s Composite Carbon Fiber / CCF typically displays strengths of up to 860MPa. However, plastic reinforced with basalt based material (CBF) sits at 600MPa and is only two-thirds of the price, giving you more bang for your buck.
Readers interested in learning more about the continuous fiber 3D printing technologies currently in the market can sign up for next week’s webinar here. The speaker, Fedor Antonov, holds a Ph.D in Fundamental Mechanics and has over ten years of academic and industrial experience working with composite materials.
> source
Carbon fiber printing is often used interchangeably with continuous fiber 3D printing. While carbon fiber is one of the more well known, there are other materials that can be used for reinforcement. Engineers looking to utilize the technology can access fiberglass, aramid, basalt, and even natural fibers as they all have varying properties and use cases.
Aramid, much like carbon fiber, is known for increasing the strength of a part but it also adds excellent impact and damage tolerance – a property not granted by carbon fibers.
Basalt, an economical alternative to carbon, may be preferred when cost-efficiency is key but part strength isn’t very high on the list of priorities. Plastic reinforced with Anisoprint’s Composite Carbon Fiber / CCF typically displays strengths of up to 860MPa. However, plastic reinforced with basalt based material (CBF) sits at 600MPa and is only two-thirds of the price, giving you more bang for your buck.
Readers interested in learning more about the continuous fiber 3D printing technologies currently in the market can sign up for next week’s webinar here. The speaker, Fedor Antonov, holds a Ph.D in Fundamental Mechanics and has over ten years of academic and industrial experience working with composite materials.
> source
Composites
Photo
Scott Bader joins CHAMPION project to research novel bio-based polymers
The bio-based polymers aim to replace conventional polymers in a variety of applications and promote alternative to end-of-life waste.
On July 28, Scott Bader Co. Ltd (Wellingborough, U.K.) announced that it is one of fourteen partners to have joined the Circular High-performance Aza-Michael Polymers as Innovative materials Originating from Nature (CHAMPION) project, a research and innovation project that aims to replace conventional polymers with novel bio-based polymers for coatings, textiles, homecare and structural adhesive applications.
Scott Bader says the project will run for three and a half years with the objective of improving the sustainability credentials of polymer-based products. So far, the project has been awarded Horizon 2020 Bio-based Industries Joint Undertaking (BBI JU) funding and includes fourteen partners from six European countries coordinated by the University of York (York, U.K.).
"The current approaches to polymer production are not compatible with the EU’s circular economy and green ambitions; the CHAMPION project will develop suitable, even superior replacements,” notes Professor James Clark, CHAMPION project coordinator.
According to Scott Bader, novel CHAMPION bio-based polymers obtained via the aza-Michael addition reaction (a simple, accessible addition reaction performed at moderate temperature, possibly without a catalyst and without releasing by-products) will be evaluated as sustainable replacements for polymers used in furniture coatings, home and personal care products, car interior surfaces and structural adhesives. The company says recovery, reuse and recycling (with the option of controlled energy recovery) are the end-of-life (EoL) options planned for the design of products using CHAMPION polymers. All products will be evaluated for sustainability via Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA).
“The composites industry is an enabler of a sustainable society however we must end the reliance on fossil derived chemicals while promoting alternatives to end-of-life waste. This multi-partner EU funded project will show us that we don’t have to compromise on performance to achieve a balance with nature,” says Dr. Steven Brown, technology development manager at Scott Bader, and chair of CompositesUK Sustainability Group.
Scott Bader says the CHAMPION project is another sign of its continued commitment to invest in new technology platforms following the recent creation of Polymer Mimetics, a joint venture with the University of Liverpool (Liverpool, U.K.).
> source
The bio-based polymers aim to replace conventional polymers in a variety of applications and promote alternative to end-of-life waste.
On July 28, Scott Bader Co. Ltd (Wellingborough, U.K.) announced that it is one of fourteen partners to have joined the Circular High-performance Aza-Michael Polymers as Innovative materials Originating from Nature (CHAMPION) project, a research and innovation project that aims to replace conventional polymers with novel bio-based polymers for coatings, textiles, homecare and structural adhesive applications.
Scott Bader says the project will run for three and a half years with the objective of improving the sustainability credentials of polymer-based products. So far, the project has been awarded Horizon 2020 Bio-based Industries Joint Undertaking (BBI JU) funding and includes fourteen partners from six European countries coordinated by the University of York (York, U.K.).
"The current approaches to polymer production are not compatible with the EU’s circular economy and green ambitions; the CHAMPION project will develop suitable, even superior replacements,” notes Professor James Clark, CHAMPION project coordinator.
According to Scott Bader, novel CHAMPION bio-based polymers obtained via the aza-Michael addition reaction (a simple, accessible addition reaction performed at moderate temperature, possibly without a catalyst and without releasing by-products) will be evaluated as sustainable replacements for polymers used in furniture coatings, home and personal care products, car interior surfaces and structural adhesives. The company says recovery, reuse and recycling (with the option of controlled energy recovery) are the end-of-life (EoL) options planned for the design of products using CHAMPION polymers. All products will be evaluated for sustainability via Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA).
“The composites industry is an enabler of a sustainable society however we must end the reliance on fossil derived chemicals while promoting alternatives to end-of-life waste. This multi-partner EU funded project will show us that we don’t have to compromise on performance to achieve a balance with nature,” says Dr. Steven Brown, technology development manager at Scott Bader, and chair of CompositesUK Sustainability Group.
Scott Bader says the CHAMPION project is another sign of its continued commitment to invest in new technology platforms following the recent creation of Polymer Mimetics, a joint venture with the University of Liverpool (Liverpool, U.K.).
> source
Composites
Photo
Carbon Fiber in Clear View on New Donkervoort Supercar
The core of Donkervoort Automobielen’s JD70 is a hybrid chassis built of a tubular steel ladder frame reinforced with carbon fiber for added strength and reduced weight. That’s just the beginning of the use of carbon fiber in the D8 GTO-JD70 Bare Naked Carbon Edition (BNCE) of the supercar.
A carbon fiber Kevlar weave makes up the bodywork of the JD70, including the cycle wings. The front design of the car includes vented hexagonal pieces made from 3D-printed carbon fiber. In all, carbon fiber is used in more than 95 percent of the JD70 bodywork.
The JD70 runs from zero to 100km/h in 2.7 seconds, and from 0-200km/h in 7.7 seconds, with a 280km/h maximum speed. The JD70 can pull more than 2G of lateral acceleration in corners in its standard trim and on its standard Nankang tires, and more than 1G of acceleration. A 2.5-liter, in-line five-cylinder motor generates 415bhp (310kW) of power and 520Nm of torque. Loaded with speed and power, the JD70’s CO2 emissions figure per kilometer is only 191 grams. Donkervoort calls the supercar the world’s first 2G production car.
The BNCE offers numerous options and upgrades to highlight the use of carbon fiber in the design including: the Exposed Carbon Upgrade exposing the carbon fiber for the side panels, the engine-bay wings, the bonnet scoop, the triangular cover scoops and the full interior; the Full Exposed-Carbon upgrade showing the complete car in exposed carbon, including the exhaust cover which reduces weight even further; and the Full-Exposed Coloured Carbon option delivering the complete car in colored carbon fiber including the side-exhaust cover. Lightweight carbon fiber rims are yet another option. Managing director of Donkervoort Automobielen, Denis Donkervoort, said, “The woven carbon remains the same. We use specially developed inks mixed into the clear coat to create the look of the colour in the fibre. We can also match the interior coloured carbon pieces to the exterior bodywork.”
> source
The core of Donkervoort Automobielen’s JD70 is a hybrid chassis built of a tubular steel ladder frame reinforced with carbon fiber for added strength and reduced weight. That’s just the beginning of the use of carbon fiber in the D8 GTO-JD70 Bare Naked Carbon Edition (BNCE) of the supercar.
A carbon fiber Kevlar weave makes up the bodywork of the JD70, including the cycle wings. The front design of the car includes vented hexagonal pieces made from 3D-printed carbon fiber. In all, carbon fiber is used in more than 95 percent of the JD70 bodywork.
The JD70 runs from zero to 100km/h in 2.7 seconds, and from 0-200km/h in 7.7 seconds, with a 280km/h maximum speed. The JD70 can pull more than 2G of lateral acceleration in corners in its standard trim and on its standard Nankang tires, and more than 1G of acceleration. A 2.5-liter, in-line five-cylinder motor generates 415bhp (310kW) of power and 520Nm of torque. Loaded with speed and power, the JD70’s CO2 emissions figure per kilometer is only 191 grams. Donkervoort calls the supercar the world’s first 2G production car.
The BNCE offers numerous options and upgrades to highlight the use of carbon fiber in the design including: the Exposed Carbon Upgrade exposing the carbon fiber for the side panels, the engine-bay wings, the bonnet scoop, the triangular cover scoops and the full interior; the Full Exposed-Carbon upgrade showing the complete car in exposed carbon, including the exhaust cover which reduces weight even further; and the Full-Exposed Coloured Carbon option delivering the complete car in colored carbon fiber including the side-exhaust cover. Lightweight carbon fiber rims are yet another option. Managing director of Donkervoort Automobielen, Denis Donkervoort, said, “The woven carbon remains the same. We use specially developed inks mixed into the clear coat to create the look of the colour in the fibre. We can also match the interior coloured carbon pieces to the exterior bodywork.”
> source
Composites
Photo
Composites Germany releases composites market survey
This is the fifteenth member survey from Composites Germany that identifies up-to-date key performance indicators (KPIs) for the fiber-reinforced plastics market.
Composites Germany (Berlin, Germany), a trade association with an aim to strengthen the German composite industry, particularly in the field of research, has made the results of its 15th Composites Market Survey available and identified the latest key performance indicators (KPIs) for the fiber-reinforced plastics market.
The survey also covers all the member companies of the three major umbrella organizations of Composites Germany including the Industrievereinigung Verstärkte Kunststoffe (AVK; Frankfurt, Germany), Leichtbau Baden-Württemberg (Stuttgart, Germany) and the VDMA Working Group (Frankfurt, Germany) on hybrid lightweight construction technologies. As before, to ensure a smooth comparison with the previous surveys, the organization notes that the questions in this half-yearly survey have been left unchanged and that the data obtained in the survey was largely qualitative and related to current and future market developments. It should also be noted that, while the current business situation is negative, the survey outlook is generally positive.
Negative rating of current business situation
Following the rather cautious rating of the prevailing business situation in the last survey earlier this year, the most recent survey is now continuing this trend. Partly due to the current impact of the coronavirus pandemic on numerous business segments and areas of application, many companies are facing negative circumstances. The general economic situation has been deteriorating further in recent weeks and months, and this is reflected in the negative ratings given by respondents. Ratings have reached the lowest figures since the surveys were started in January 2013 (see Fig.1).
However, not only did companies give rather unfavorable assessments of the general business situation, Composites Germany says they also continued to be pessimistic about their own situations (see Fig. 2).
Although the tense situation is beginning to relax, e.g. in the automotive industry, and although the crisis has not yet taken full effect in other sectors, e.g. construction, many companies are nevertheless full of uncertainty. There has been a variety of opportunities and measures to stimulate industry and the economy in general, but it seems that they have not yet had the desired positive economic impact.
Variety of developments expected in the future
When asked about their expectations for future business developments, respondents give quite contrasting answers. While they are expecting to see an improvement in the general economic situation, both in Europe and worldwide, they are still pessimistic about the outlook for Germany (see Fig. 3), and also with regard to their own business situation in the future.
Varied expectations for application industries
Like expectations for the development of the business situation, expectations for selected areas of application have also turned out to be extremely diverse.
The automotive and aviation industries are the main areas where respondents are expecting to see a deterioration in the market environment. However, other sectors, such as sports and leisure and infrastructure/construction, are expected to develop far more positively (see Fig. 4).
This is the fifteenth member survey from Composites Germany that identifies up-to-date key performance indicators (KPIs) for the fiber-reinforced plastics market.
Composites Germany (Berlin, Germany), a trade association with an aim to strengthen the German composite industry, particularly in the field of research, has made the results of its 15th Composites Market Survey available and identified the latest key performance indicators (KPIs) for the fiber-reinforced plastics market.
The survey also covers all the member companies of the three major umbrella organizations of Composites Germany including the Industrievereinigung Verstärkte Kunststoffe (AVK; Frankfurt, Germany), Leichtbau Baden-Württemberg (Stuttgart, Germany) and the VDMA Working Group (Frankfurt, Germany) on hybrid lightweight construction technologies. As before, to ensure a smooth comparison with the previous surveys, the organization notes that the questions in this half-yearly survey have been left unchanged and that the data obtained in the survey was largely qualitative and related to current and future market developments. It should also be noted that, while the current business situation is negative, the survey outlook is generally positive.
Negative rating of current business situation
Following the rather cautious rating of the prevailing business situation in the last survey earlier this year, the most recent survey is now continuing this trend. Partly due to the current impact of the coronavirus pandemic on numerous business segments and areas of application, many companies are facing negative circumstances. The general economic situation has been deteriorating further in recent weeks and months, and this is reflected in the negative ratings given by respondents. Ratings have reached the lowest figures since the surveys were started in January 2013 (see Fig.1).
However, not only did companies give rather unfavorable assessments of the general business situation, Composites Germany says they also continued to be pessimistic about their own situations (see Fig. 2).
Although the tense situation is beginning to relax, e.g. in the automotive industry, and although the crisis has not yet taken full effect in other sectors, e.g. construction, many companies are nevertheless full of uncertainty. There has been a variety of opportunities and measures to stimulate industry and the economy in general, but it seems that they have not yet had the desired positive economic impact.
Variety of developments expected in the future
When asked about their expectations for future business developments, respondents give quite contrasting answers. While they are expecting to see an improvement in the general economic situation, both in Europe and worldwide, they are still pessimistic about the outlook for Germany (see Fig. 3), and also with regard to their own business situation in the future.
Varied expectations for application industries
Like expectations for the development of the business situation, expectations for selected areas of application have also turned out to be extremely diverse.
The automotive and aviation industries are the main areas where respondents are expecting to see a deterioration in the market environment. However, other sectors, such as sports and leisure and infrastructure/construction, are expected to develop far more positively (see Fig. 4).
Composites
Photo
Growth drivers developing at different rates
While, as in the last surveys, growth stimuli for the composites segment can mainly be expected to come from Germany, Europe and Asia as global regions, we can observe a paradigmatic shift with regard to materials.
Whereas, in the first 13 surveys, respondents always believed that the composites segment would receive its prevailing growth stimuli from carbon fiber-reinforced plastics (CRP) as a material, the current survey is now the second one where respondents have mentioned glass fiber-reinforced plastics (GRP) as the most important material (see Fig. 4). Considering the number of times it is mentioned, this trend is in fact increasing.
Composites Index continues to decline
The current situation has created major uncertainty, not only in the composites sector. The mood in companies continues to be negative. This is partly due to production losses and a sharp decline in both investment and consumer confidence caused by the coronavirus pandemic, and partly also due to political uncertainties and squabbles about economic policies. Many of the measures that have been taken still seem to be insufficient to create a positive environment. Although expectations of the future business situation are generally becoming more positive, this is not yet leading to a more positive assessment of the companies’ own positions in the market. Following these assessments, the Composites Development Index is therefore continuing to fall, sometimes significantly (see Fig. 6).
It remains to be seen how the economy will develop in the rest of the year, especially in the autumn. Over the last few years there has been success in establishing composites in many new areas of application, thus achieving an almost consistently positive development. Composites therefore remain important materials for the future, not least because of their positive and diverse qualities, so that they will continue to find their way into industry, despite the current crisis.
The next Composites Market Survey will be published in February 2021.
> source
While, as in the last surveys, growth stimuli for the composites segment can mainly be expected to come from Germany, Europe and Asia as global regions, we can observe a paradigmatic shift with regard to materials.
Whereas, in the first 13 surveys, respondents always believed that the composites segment would receive its prevailing growth stimuli from carbon fiber-reinforced plastics (CRP) as a material, the current survey is now the second one where respondents have mentioned glass fiber-reinforced plastics (GRP) as the most important material (see Fig. 4). Considering the number of times it is mentioned, this trend is in fact increasing.
Composites Index continues to decline
The current situation has created major uncertainty, not only in the composites sector. The mood in companies continues to be negative. This is partly due to production losses and a sharp decline in both investment and consumer confidence caused by the coronavirus pandemic, and partly also due to political uncertainties and squabbles about economic policies. Many of the measures that have been taken still seem to be insufficient to create a positive environment. Although expectations of the future business situation are generally becoming more positive, this is not yet leading to a more positive assessment of the companies’ own positions in the market. Following these assessments, the Composites Development Index is therefore continuing to fall, sometimes significantly (see Fig. 6).
It remains to be seen how the economy will develop in the rest of the year, especially in the autumn. Over the last few years there has been success in establishing composites in many new areas of application, thus achieving an almost consistently positive development. Composites therefore remain important materials for the future, not least because of their positive and diverse qualities, so that they will continue to find their way into industry, despite the current crisis.
The next Composites Market Survey will be published in February 2021.
> source
Composites
Photo
3D printed carbon fibre e-bike blasts through Indiegogo goal
Superstrata’s 3D printed e-bike has soared past the company’s initial crowdfunding target, hitting £3.3 million in pre-orders
More than 2,800 backers from 66 countries have supported the project so far, and due to demand has decided to extend the campaign until 12th September 2020.
The Superstrata 3D printed, fully-customised bikes have attracted the attention of some major brands wanting to work in partnership with Superstrata, like SmartTech, which is currently showcasing the exclusive Superstrata Oxford in Selfridges’ new The Bike Shop on Oxford Street in London.
The exclusive Superstrata Oxford Edition includes carbon fibre wheels with a highly premium groupset, which are two of the most requested features so far.
Even Sadiq Khan, the Mayor of London, has already been along to Oxford Street to see the Superstrata Oxford in Selfridges for himself
The Superstrata’s design has no glue, joints or bolts, is stronger than Kevlar and lighter than 2 bottles of water. Superstrata’s proprietary composite 3D printing manufacturing technology makes each frame individually according to each rider’s precise body measurements.
The bike and e-bike will literally be made to measure. Buyers send in their measurements and their individual bike will be 3D printed – bespoke down to the spokes.
With more than 500,000 unique combinations, including mix and match colours, wheels, handlebars and more, the Superstrata bike and e-bike are made exclusively with carbon fibre reinforced thermoplastic technology, and 100% recyclable materials that won’t rust.
Arevo, the company behind Superstrata, automates the design and fabrication of large, geometrically complex, continuous CFRP composite products through a suite of innovations in materials science, robotics and design software.
It recently introduced its newest system, the Aqua 2, the world’s first high speed additive manufacturing system for large continuous carbon fibre composite structures, which in addition to enabling higher quality print, is able to print 4x faster than its predecessor.
This enables the rapid, on-demand production of large (up to one cubic meter) custom composite parts, making the process to scale manufacturing even easier.
> source
Superstrata’s 3D printed e-bike has soared past the company’s initial crowdfunding target, hitting £3.3 million in pre-orders
More than 2,800 backers from 66 countries have supported the project so far, and due to demand has decided to extend the campaign until 12th September 2020.
The Superstrata 3D printed, fully-customised bikes have attracted the attention of some major brands wanting to work in partnership with Superstrata, like SmartTech, which is currently showcasing the exclusive Superstrata Oxford in Selfridges’ new The Bike Shop on Oxford Street in London.
The exclusive Superstrata Oxford Edition includes carbon fibre wheels with a highly premium groupset, which are two of the most requested features so far.
Even Sadiq Khan, the Mayor of London, has already been along to Oxford Street to see the Superstrata Oxford in Selfridges for himself
The Superstrata’s design has no glue, joints or bolts, is stronger than Kevlar and lighter than 2 bottles of water. Superstrata’s proprietary composite 3D printing manufacturing technology makes each frame individually according to each rider’s precise body measurements.
The bike and e-bike will literally be made to measure. Buyers send in their measurements and their individual bike will be 3D printed – bespoke down to the spokes.
With more than 500,000 unique combinations, including mix and match colours, wheels, handlebars and more, the Superstrata bike and e-bike are made exclusively with carbon fibre reinforced thermoplastic technology, and 100% recyclable materials that won’t rust.
Arevo, the company behind Superstrata, automates the design and fabrication of large, geometrically complex, continuous CFRP composite products through a suite of innovations in materials science, robotics and design software.
It recently introduced its newest system, the Aqua 2, the world’s first high speed additive manufacturing system for large continuous carbon fibre composite structures, which in addition to enabling higher quality print, is able to print 4x faster than its predecessor.
This enables the rapid, on-demand production of large (up to one cubic meter) custom composite parts, making the process to scale manufacturing even easier.
> source
Composites
Photo
OCSiAl opens graphene nanotube R&D center in Europe
The major part of all developments in the Group’s new, Luxembourg facility will be targeted towards elastomers and thermoplastic composites enhanced with graphene nanotubes.
Global graphene nanotube manufacturer OCSiAl (Leudelange, Luxembourg and Columbus, Ohio, U.S.) announced that it has opened its state-of-the-art research and development (R&D) and technical support center designed to develop next-generation materials with graphene nanotubes. The new center is located in Luxembourg, place deemed a hub for advanced technology companies.
With other centers located in Asia and Eastern Europe, the Group’s current decision to open a new center in Luxembourg was in response to Europe’s forefront position in developing material engineering solutions, especially for the ongoing automotive industry revolution. Lightweight and smart car bodies, energy efficient and safe tires, are among the main focuses of OCSiAl’s European team of experts in nanotechnology and materials engineering.
According to the company, the new, 350-square-meter center has more than 50 items of high-end equipment. The major part of all developments will be targeted towards elastomers and thermoplastic composites enhanced with graphene nanotubes, which are said will be widely applied in the cars of the future.
“OCSiAl’s product line is constantly growing. We have developed high-performance solutions for Li-ion batteries and various polymers, many of which have already been accepted as an industry standard. And in fact, one of the best demonstrators and drivers of most nanotube developments is the automotive industry,” says Konstantin Notman, OCSiAl senior vice president, OCSiAl Europe CEO. “Graphene nanotubes significantly enhance and even grant new properties to all the materials that are being used in cars. We make it possible to make safer, lighter, smarter and more eco-friendly vehicles.”
The company plans to launch the world’s largest graphene nanotube synthesizing facility in Luxembourg in 2023. Together with the R&D and technical support center, OCSiAl says its new production facility will form a cluster for the most advanced developments in the field of materials of the future.
> source
The major part of all developments in the Group’s new, Luxembourg facility will be targeted towards elastomers and thermoplastic composites enhanced with graphene nanotubes.
Global graphene nanotube manufacturer OCSiAl (Leudelange, Luxembourg and Columbus, Ohio, U.S.) announced that it has opened its state-of-the-art research and development (R&D) and technical support center designed to develop next-generation materials with graphene nanotubes. The new center is located in Luxembourg, place deemed a hub for advanced technology companies.
With other centers located in Asia and Eastern Europe, the Group’s current decision to open a new center in Luxembourg was in response to Europe’s forefront position in developing material engineering solutions, especially for the ongoing automotive industry revolution. Lightweight and smart car bodies, energy efficient and safe tires, are among the main focuses of OCSiAl’s European team of experts in nanotechnology and materials engineering.
According to the company, the new, 350-square-meter center has more than 50 items of high-end equipment. The major part of all developments will be targeted towards elastomers and thermoplastic composites enhanced with graphene nanotubes, which are said will be widely applied in the cars of the future.
“OCSiAl’s product line is constantly growing. We have developed high-performance solutions for Li-ion batteries and various polymers, many of which have already been accepted as an industry standard. And in fact, one of the best demonstrators and drivers of most nanotube developments is the automotive industry,” says Konstantin Notman, OCSiAl senior vice president, OCSiAl Europe CEO. “Graphene nanotubes significantly enhance and even grant new properties to all the materials that are being used in cars. We make it possible to make safer, lighter, smarter and more eco-friendly vehicles.”
The company plans to launch the world’s largest graphene nanotube synthesizing facility in Luxembourg in 2023. Together with the R&D and technical support center, OCSiAl says its new production facility will form a cluster for the most advanced developments in the field of materials of the future.
> source
Composites
Photo
Machine learning replicates the secrets of composites
Aerospace and automotive applications increasingly rely on lightweight composite parts made from polymers reinforced with carbon or glass fibers. With the rise of additive manufacturing methods like 3D printing, it is becoming possible to design novel filaments and control their orientation within composites to tailor performance to specific applications. But the ease of manufacturing advanced composite parts via 3D printing has a downside. The ubiquity of 3D printers makes it much easier for counterfeiters to copy parts.
“A lot of intellectual property is invested in developing composites material and 3D printing conditions,” points out Nikhil Gupta of New York University. “Reverse engineering using imaging methods can allow this IP to be stolen. Machine learning can even automate this process… [to] produce high quality replicas by unauthorized personnel.”
Gupta and his team show that novel and innovative composite materials can be reverse engineered using three-dimensional imaging and reconstruction techniques combined with powerful machine learning [Yanamandra et al., Composites Science & Technology 198 (2020) 108318]. Not only can the size and shape of a part be reconstructed in this way, but also the tool path – or unique instructions – that the 3D printer needs to manufacture it.
The researchers took a set of scanning electron microscopy (SEM) to measure dimensions and micro-CT (µCT) scans to identify the orientation of fibers within a composite. A sub-set of these images was then used to train the machine learning algorithm. The accuracy of the algorithm in identifying the 3D printing tool path was then verified with a second sub-set of images. The team used over 78,000 images to train the algorithm and a further 5000 µCT images to test the accuracy of its predictions.
“Compared with the manual methods of reverse engineering, the machine learning algorithm is a powerful method where a few CT scan images are able to provide the part design and 3D printing tool path,” explains Gupta. “Our study shows that products developed with investment of significant amount of time and money can be easily reverse engineered.”
The work raises concerns over the security of intellectual property in 3D-printed composite parts. Modern capabilities in designing and producing high-performance fiber-reinforced composites can be harnessed to produce almost-indistinguishable high-quality replica parts quickly and cheaply.
“Machine learning methods are being used in the design of complex parts but, as our study shows, they can be a double-edged sword, also making reverse engineering easier,” says Gupta. “Awareness of security issues will encourage researchers to develop new tool paths and composite materials that consider security as a design constraint.”
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Aerospace and automotive applications increasingly rely on lightweight composite parts made from polymers reinforced with carbon or glass fibers. With the rise of additive manufacturing methods like 3D printing, it is becoming possible to design novel filaments and control their orientation within composites to tailor performance to specific applications. But the ease of manufacturing advanced composite parts via 3D printing has a downside. The ubiquity of 3D printers makes it much easier for counterfeiters to copy parts.
“A lot of intellectual property is invested in developing composites material and 3D printing conditions,” points out Nikhil Gupta of New York University. “Reverse engineering using imaging methods can allow this IP to be stolen. Machine learning can even automate this process… [to] produce high quality replicas by unauthorized personnel.”
Gupta and his team show that novel and innovative composite materials can be reverse engineered using three-dimensional imaging and reconstruction techniques combined with powerful machine learning [Yanamandra et al., Composites Science & Technology 198 (2020) 108318]. Not only can the size and shape of a part be reconstructed in this way, but also the tool path – or unique instructions – that the 3D printer needs to manufacture it.
The researchers took a set of scanning electron microscopy (SEM) to measure dimensions and micro-CT (µCT) scans to identify the orientation of fibers within a composite. A sub-set of these images was then used to train the machine learning algorithm. The accuracy of the algorithm in identifying the 3D printing tool path was then verified with a second sub-set of images. The team used over 78,000 images to train the algorithm and a further 5000 µCT images to test the accuracy of its predictions.
“Compared with the manual methods of reverse engineering, the machine learning algorithm is a powerful method where a few CT scan images are able to provide the part design and 3D printing tool path,” explains Gupta. “Our study shows that products developed with investment of significant amount of time and money can be easily reverse engineered.”
The work raises concerns over the security of intellectual property in 3D-printed composite parts. Modern capabilities in designing and producing high-performance fiber-reinforced composites can be harnessed to produce almost-indistinguishable high-quality replica parts quickly and cheaply.
“Machine learning methods are being used in the design of complex parts but, as our study shows, they can be a double-edged sword, also making reverse engineering easier,” says Gupta. “Awareness of security issues will encourage researchers to develop new tool paths and composite materials that consider security as a design constraint.”
> source
High volume fiber composites
TRB Lightweight Structures (TRB) reports that it has developed a new process to make continuous fiber thermoset composite parts at higher volume.
The process, which focuses on combining materials science with robotic manufacturing is being used to supply a powertrain manufacturer with battery components for electric buses, the company said. It involves feeding custom materials into an integrated process which covers automating cutting, layup, pressing and curing, allowing parts to be manufactured more quickly and more cost effectively, TRB said.
The manufacturing method is suitable for the high-volume production of components for electric vehicles (EV) and can be adapted to include additional material layers offering thermal, electrical conductivity and electromagnetic radiation protection.
‘While high volume composites have many applications, we have chosen to focus on the fast-expanding EV market – both on the road and in the sky – given our mission to accelerate the transition to sustainable transportation,’ said Richard Holland, MD.
This story uses material from TRB, with editorial changes made by Materials Today. The views expressed in this article do not necessarily represent those of Elsevier.
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TRB Lightweight Structures (TRB) reports that it has developed a new process to make continuous fiber thermoset composite parts at higher volume.
The process, which focuses on combining materials science with robotic manufacturing is being used to supply a powertrain manufacturer with battery components for electric buses, the company said. It involves feeding custom materials into an integrated process which covers automating cutting, layup, pressing and curing, allowing parts to be manufactured more quickly and more cost effectively, TRB said.
The manufacturing method is suitable for the high-volume production of components for electric vehicles (EV) and can be adapted to include additional material layers offering thermal, electrical conductivity and electromagnetic radiation protection.
‘While high volume composites have many applications, we have chosen to focus on the fast-expanding EV market – both on the road and in the sky – given our mission to accelerate the transition to sustainable transportation,’ said Richard Holland, MD.
This story uses material from TRB, with editorial changes made by Materials Today. The views expressed in this article do not necessarily represent those of Elsevier.
> source