A combined 3D printing/CNC micro-milling method to fabricate a large-scale

microfluidic device with the small size 3D architectures: an application for tumor spheroid production - micro 100 carbide end mills

The current build envelope for the company’s ExAM series printers is 255 × 255 × 255 millimeters on AIM3D’s smaller printer and 510 × 510 × 400 millimeters on its newest printer. Owing to the high extrusion pressures used, the print head can move quite rapidly, laying material down at 200 millimeters/second (or 220 cubic centimeters/hour from a 0.4 millimeter nozzle) versus ~15 millimeters/second for comparable filament or stick-based systems.

The company says the process can hold tolerances as tight as ±0.05 millimeter. The smallest nozzle AIM3D offers for metal printing is 0.30 millimeter in diameter, so the company says its comfort zone is printing geometry no finer than three to four millimeters, although they also say it’s possible to build single-wall structures as thin as 0.50 millimeter — useful for thin fins on turbine parts but potentially less useful for mold components subject to high clamping and injection pressures. Finer geometry can always be EDM’d after sintering.

Because AIM3D’s process can print hollow-section parts, it can produce metal inserts with conformal cooling (or heating) channels. In fact, it’s said to be possible to print a part using multiple custom-formulated alloys, such as a high-hardness grade in combination with another of the same base alloy but infused with copper to enhance thermal conductivity without lowering the base metals’ sintering temperature. It’s also possible to print parts using the same metal but with different densities, modified by using pellets containing different particle sizes and thermoplastic binders. This enables material in one section of a part to sinter to a dense microstructure while material in another section sinters to a more porous microstructure. Hence, AIM3D’s system has an extra method for enhancing part functionality in addition to design/geometry and material selection.

Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.

EU project will develop bio-based, repairable and recyclable vitrimer composites and advanced sensors for highly reliable, sustainable wind blades.

Since a strand of flowable material is produced just prior to printing, scaffolds are needed to keep overhang/undercut geometry from slumping and, depending on geometry, support structures may also be needed during sintering. Rather than requiring a metal build plate, printing is done on a polymer sheet, which is simply peeled off the bottom of the completed part.

This symbol represents whether or not the insert has a chip breaker. It also refers to whether the insert has a hole or not. A negative insert can have one-sided or double-sided chip breaker.

Mantle’s patented TrueShape process combines custom software plus an extrusion-based printer, which uses flowable metal pastes. It is also equipped with an integral high-speed CNC mill, which shapes and refines part geometry throughout the printing process. An important benefit is that operators needn’t know how to program additive or subtractive tool paths to use the printer.

Above, three composite molds were formed in a Machina robotic cell on a 1,524 × 3,048 × 4.0-millimeter sheet of aluminum. Below is one of the finished tools laid up and vacuum bagged prior to being placed in an autoclave. Photo Credit: Machina Labs Inc. (top) and University of Dayton Research Institute (bottom)

The composites-intensive VTOL platform is next expected to undergo a series of test flights in various conditions to validate its performance, safety and reliability, leading up to eventual certification.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

This collection features recent CW stories that detail a range of tooling technologies, processes and materials.

GKN Aerospace Munich and CEAD develop printed tooling with short and continuous fiber that reduces cost and increases sustainability for composites production.

Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.

The process is said to be robot and metal agnostic, as software drives the entire system. As long as a metal can be flat rolled or formed into a sheet, it can be used. To date, stainless and mild steels, aluminum, Invar and room-temperature-forming Grade 5-equivalent titanium have been demonstrated. Even magnesium might be possible in the future. Like any forming operation, the process does leave residual stresses, benchmarked as being on par with those generated during hydroforming; stresses can be annealed, if necessary.

The symbol that represents the tolerance class is determined by a combination of three tolerances; the nose height (m), inscribed circle (d) and thickness (s). To produce close tolerance inserts, grinding is necessary.

However, for the metric coding, the diameter of an inscribed circle is represented by the cutting edge length using a two-digit number. Therefore, even if the inscribed circle is the same , the symbol for the cutting edge will vary.

Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.

This represents the corner radius (nose radius) of an insert. It is standardized in intervals, for example after 0.4mm with intervals of 0.4mm, and after 4.0mm in intervals of 0.8mm.

The insert geometry is represented using letters of the alphabet. A wide range of geometries are listed as standard for example; triangle, square, round, polygon and rhombus.

For turning operations, mainly G-class (sometimes J-class) or M-class inserts are used. Inserts with tolerance classes other than G, J and M are mostly used on face milling cutters.

Herone, Spiral RTC, Teijin Carbon Europe and Collins Aerospace Almere recycle A350 thermoplastic composite clips/cleats waste into rods for the all-thermoplastic composite Multifunctional Fuselage Demonstrator’s crown.

This represents the corner radius (nose radius) of an insert. It is standardized in intervals, for example after 0.4mm with intervals of 0.4mm, and after 4.0mm in intervals of 0.8mm.

In this report, we’ll continue our coverage of metal AM and other digital technologies and, as before, indicate which additional metal AM processes are production-proven — already used on tools producing commercial parts, often in high volumes — and which are close to or just beginning to be used on commercial programs.

Fifty years of supplying materials for composites manufacturing includes custom fabrication and now aims to advance 3D-printed tooling, parts and new resins.

In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.

A good example of the diversity of parts that have already been produced on Machina’s system include two hemispheres that are 508 millimeters in diameter (top left) and were formed in 4.0-millimeter-thick 5000 series aluminum. At top right, a series of 304L stainless steel parts, which are 1,524 × 762 millimeters, were formed in four to five hours each. At bottom left is one of a series of 1.1-millimeter-thick Invar 36 parts, and at bottom right are several hat stiffener sections for composite layup that were formed in a 2.0-millimeter-thick 5000 series aluminum alloy. Photo Credit: Machina Labs Inc.

A good example of the types of mold components produced with Mantle’s system is a slide nose detail insert that industrial cutting-systems supplier, Hypertherm Associates (Hanover, N.H., U.S.) used in a study to compare injection molded part quality and wear for an insert produced conventionally versus one printed using Mantle’s system. Inserts were then used to injection mold 30% fiberglass-reinforced polyetheretherketone (PEEK) cap shields, which form a consumable torch stack-up used in a plasma cutter. H13 was specified for printed and conventionally produced inserts owing to that alloy’s high hardness (to resist fiberglass abrasion) and resistance to temperature cycling (PEEK is injected at 382°C into a tool kept at 179°C). The printed insert was designed to incorporate integral cooling channels to improve part quality and reduce cycle time.

Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.

CW explores key composite developments that have shaped how we see and think about the industry today.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

Stephen Heinz, vice president of R&I for Syensqo delivered an inspirational keynote at SAMPE 2024, highlighting the significant role of composite materials in emerging technologies and encouraging broader collaboration within the manufacturing community.

Dieless robotic sheet forming is a fully digital process for forming large sheets of metal rapidly into complex contours. Robots fitted with various end effectors work on each side of a suspended sheet of metal to incrementally cold-form the alloy into shape one layer at a time. Photo Credit: Machina Labs Inc.

Above is half of an as-printed and sintered H13 insert with integral conformal cooling channels used by Hypertherm Associates to injection mold glass fiber-reinforced PEEK consumables used in a plasma cutter. Below is the complete insert (circled) seated in the single-cavity injection mold that, in turn, is mounted in an injection press. Photo Credits: Hypertherm Associates/Mantle Inc

An overview of ASTM Standard Guide D8509, and its coupon-level mechanical testing of design properties for analyzing composite bolted joints.

The company says the process offers greater design flexibility for creating composite tooling than machining and it does so faster, at lower cost and with less material waste and embodied energy. The company also says geometries that normally cannot be stamped are possible, an expanded range of materials and alloys can be used, the process is scalable from centimeters to many meters and both lightweighting and parts consolidation strategies can be incorporated. The fully digital manufacturing platform was even designed to accommodate other manufacturing processes (e.g., AM, joining, etc.), permitting multiple operations to be carried out within the same robotic cell.

The interesting thing about Machina’s process is that it borrows elements from conventional and digital manufacturing and yet it is neither strictly subtractive nor additive. Rather, it’s a formative (or deformative) process suitable for producing tools for high-rate composite part manufacture. It builds geometry layer by layer in a matter of hours and eliminates the need for (and investment in) sequential stamping dies and presses or CNC machining centers.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

Aerospace, defense and automotive are said to be very interested in the technology for flight hardware/part production as well as tooling owing to the process’ potential for lead time and cost reduction. Other industries evaluating or already using parts produced on the system include marine, heavy machinery, architecture and electrical/electronics.

Kennametal will cover the influence of different composite materials characteristics on drilling performance and how to optimize the process. Agenda:  Who is Kennametal? Hole making challenges in composite materials Innovations for hole making applications Upcoming events and academic partnerships

“Our patent-pending, wear-resistant extruder and simple printing process are designed to handle nearly any type of granular material up to 3 millimeters in diameter,” says Clemens Lieberwirth, AIM3D CTO. “These cost-effective and easily available pellets offer the freedom to print anything from tool steels to non-ferrous metals to plastics, composites and ceramics without having to purchase costly filaments or handle fine powders. This greatly reduces material costs as well as machining or molding time and costs. It also means customers can print prototypes in the same material as production parts without needing to adapt production steps.”

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

Celebrating National Composites Week 2024, CW looks at how composites are being used to provide the next generation of energy.

The Marservis PROeco is a mass transportation marine vessel using Bcomp natural fiber for interior parts in place of standard materials.

CEAD, GKN Aerospace Deutschland and TU Munich enable additive manufacturing of large composite tools and parts with low CTE and high mechanical properties.

Over the last 8 months, Archer Aviation has completed a total of 402 test flights with its composites-intensive aircraft, adding to key milestones.

Chip breakers play an important role in chip control. Cutting tool manufacturers employ their own breaker geometries and as such the symbol is optional.

New aircraft is expected to deliver wind turbine blades from 105 meters up to expand the reach of wind energy and achieve global climate goals.

Cemented carbide, coated carbide, cermet, ceramic and other hard material inserts have the cutting edge honed so as to prevent fracturing in the machining.

“Compared with traditional manufacturing, Mantle’s technology is dramatically lower cost, it’s significantly faster and it enables the unique geometries that only can be made by 3D printing,” explains Ted Sorom, Mantle CEO and co-founder. “That combination of factors is what our customers get really excited about. The world is moving fast, technology is moving fast, but manufacturing hasn’t kept up with the pace of innovation. Mantle’s TrueShape changes that.”

Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.

CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.

Low-melt polyaryletherketone (LMPAEK) unidirectional tapes provide outstanding thermal and fire protection, demonstrating their effectiveness through rigorous testing. These tapes are fire, smoke and toxicity compliant with FAR25.853 and meet OSU Heat Release Rate standards. The tapes were tested under ISO 2685/AC 20-135 Change 1, meeting the fireproof criteria. Additionally, they met UL 2596 requirements for battery thermal runaway tests. These tapes are crucial for high-temperature applications showcasing their resilience and safety in both aerospace and automotive applications. Part of a broader range that includes films and compounds, Victrex LMPAEK materials are valued for their excellent processability and weldability. They offer versatile solutions for complex needs beyond traditional structural parts, such as: thermal runaway and lightning strike protection, heat sinking, and intricate bracketry. Victrex LMPAEK materials facilitate automation and high-rate production while addressing performance and sustainability challenges. With reduced environmental impact, lower weight and cost-efficiency, they meet the evolving demands of the transportation industry and support innovative design solutions. Agenda:  Introduction to LMPAEK ecosystem, highlighting unidirectional tapes Thermal and fire protection performance: applications and benefits Material forms and processability Sustainability and efficiency Conclusion and future innovations

Functionally, metal parts are formed via “contact pushing” in much the way potters form clay vessels and metalworkers shape sheet metal except these sheets are huge — 3.7 × 1.5 meters, although larger sheet sizes can be accommodated — and are hung from hydraulic clamping fixtures that adjust for increased strain to prevent sagging. A robot on each side of the sheet rolls one of a series of end effectors across the metal surface, applying variable force (based on the geometry being created) over a very small area at each point in time. This effectively cold forms (at room temperature) the sheet metal, causing “significant” plastic deformation. By applying just the right amount of force — e.g., 4,000 to 15,000 newtons depending on sheet thickness and alloy properties — over an area as small as 16 square millimeters, the metal is incrementally shaped, layer by layer, and manipulated into a complex-contoured 2.5-3D part. The company reports that draws as deep as 1,000 millimeters have been achieved. Unlike progressive stamping, which is bone-rattlingly noisy, dieless robotic sheet forming is said to be virtually silent.

Base Materials introduces a high-performance, toughened epoxy tooling board designed for thermoforming and vacuum forming processes, direct-to-part applications and more.

This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.

This symbol represents the actual thickness of the insert. It works on the same principle as that of the inscribed circle.

“We’re getting very good traction on the tooling side because our process is such a good fit,” says Dr. Babak Raeisinia, Machina co-founder and head of partnerships, who adds that most of the tools the team has built to date have been for single-sided, out-of-autoclave (OOA) processes, although thermoforming tools would be a logical next step and matched tools to mold thermoplastics and/or sheet molding compound (SMC) are definitely in the pipeline.

Toolmakers and molders continue to realize the benefits of additive versus conventional/subtractive manufacturing of molds and mold components.

A Markforged digital repository and multi-material 3D printers enable faster, more accurate and less costly manufacture of a variety of tools and blade components across Vestas sites.

Composites using graphene is not a new concept — but what is new is that the industry now recognizes "graphene" as an actual family of materials with different properties and promise. A new and exciting form of graphene is made from reclaimed methane, which uses new technologies to create green carbon materials. While showing great sustainability promise, functionalization is needed to unlock graphene's full range of properties for the next generation of composites to make these carbon materials useful. In this webinar, graphene manufacturer Mito Material Solutions will discuss how to bring functionalization and multifunctionality to these new "green" graphenes to enable a stronger, more robust and sustainable world.

CompositesWorld’s Tech Days: Design, Simulation and Testing Technologies for Next-Gen Composite Structures is designed to provide a multi-perspective view of the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

An on-demand mapping tool for anisotropic materials and polymer material fracture prediction model, i-Lupe, aims to help predict impact, crash behaviors.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.

The company claims that its technology experiences the lowest shrink rate (8-10%) of any sinter-based metal AM process — as much as an order of magnitude less than other systems. Parts exit the furnace with excellent hardness, greater than 95% density and are ready to use after minimal CNC machining to help seat components in the tool’s master unit die (MUD). And unlike laser-based systems, sintered parts are said to have very low internal stresses, which helps the system hold very tight tolerances (±0.03-0.10 millimeters across a 102-millimeter part) and produce very high surface finishes (surface roughness (Ra) ~1-3 microns).

How the predictive tool “CZone” is applied to simulate the axial crushing response of composites, providing valuable insights into their use for motorsport applications.

This standalone version enables the user to easily integrate AFP technology into existing robots or gantry systems.

Closed mold processes have many advantages over open molding. In this knowledge center, learn the basics and vital tools needed to produce parts accurately.

Advanced Engineering is the UK’s largest annual gathering of engineering and manufacturing professionals. The event will help you to source new suppliers, network, build connections and learn about the latest industry developments all in one place. Get involved and exhibit alongside 400+ exhibitors offering solutions and products across all industries and sectors to help improve your productivity and inspire creativity. With over 9,000+ of your peers due to attend and ready to network with and inspire you, this is the event you can’t afford to miss!

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

This printed and sintered slide produced in 8620 steel is an example of the type of tooling component being produced on AIM3D’s printers. No post-sinter machining was needed on the component. Photo Credit: AIM3D GmbH

Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.

Chip breakers play an important role in chip control. Cutting tool manufacturers employ their own breaker geometries and as such the symbol is optional.

During this webinar, the audience will be introduced to a variety of fiber composite technologies — as well as the machines and equipment — from short fibers to continuous fibers, from thermoset to thermoplastic, as well as the according process technology, including a special focus on long-fiber injection (LFI) and structural composite spray (SCS). Focus markets include automotive, aviation and AAM, transportation, and construction. This webinar will provide a detailed overview of according application examples. Agenda: Long fiber injection (LFI) Structural composite spray (SCS) Resin transfer molding (RTM), wet compression molding, etc. Pultrusion FiberForm

LestaUSA’s self-learning robots on display at CAMX 2024 enhance composites manufacturing workflow and workforce needs.

Although just starting to ship commercial printers to initial customers, the hybrid metal AM system designed specifically for toolmakers by Mantle Inc. (San Francisco, Calif., U.S.) has already been proven with key beta customers. These early adopters are all toolmakers, some of whom also mold, and have put the technology through its paces for the past few years to verify that printed and sintered mold components machine, EDM and weld just like conventional tool steels and are just as durable. At least one beta customer has used two inserts produced on Mantle printers to injection mold well over 2.8 million commercial parts for the personal care industry.

The first project is underway to recover carbon fiber used in an A330-200 aircraft, which will then be regenerated for other end uses by HRC.

- Production proven: Hybrid extrusion/CNC machining - Production-ready: Composite extrusion modeling (CEM) - Production-ready: (De)formative manufacturing

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

A combination of Airtech’s 3D printing materials and Ascent’s production capabilities aim to support increased use of composite additive tooling in spaces like defense and aerospace.

This is the symbol that represents the clearance angle of an insert. An insert with 0° clearance angle, which is shown by symbol N, is called a negative insert. An insert with a clearance angle other than 0° is called a positive insert. Many turning inserts have clearance angles shown by symbols P, C and N.

The team is said to be working on larger pellet printers to increase build envelope and build rates. Part costs also are said to be correspondingly lower, on the order of three to four times less than filament/stick printers and half the cost of DMLS printers without that process’ high residual stresses. Materials can be printed at temperatures ranging from room temperature to 450°C depending on which type of material is used and which model printer is selected.

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

Lead time to produce the printed insert was reduced 7-11 weeks versus the conventionally produced insert, and costs were lowered 75%. The printed insert required minimal grinding and wire EDM work to adjust the taper prior to seating it in the slide carrier. Hypertherm reports that molded part quality was the same with both insert types and no observable wear was identified after 50 shots.

As reported in the December 2022 issue of CW, hard tooling is an important, potentially costly and often rate-limiting step in the process of bringing composite parts to market. However, advances in metal additive manufacturing (AM) over the past 15 years have given toolmakers, molders and OEMs many useful options for producing intricate mold components. And, with the advent of large-format AM (LFAM) technologies, it is now possible to print entire tools — albeit often single-sided only with necessarily simpler geometry.

Bavarian auto industry and TU Munich research how to reduce molding costs by combining continuous fiber and 3D-printed composites.

Additionally, stitch-bonded non-crimp fabrics (NCFs) provide manufacturers and asset owners even more ways to gain a competitive advantage with products built specifically for the environments and loading conditions in which they will be utilized. Join Vectorply Corporation and Creative Composites Group (CCG) for this in-depth webinar detailing the process of engineering NCFs to build composite parts that will stand the test of time. Unlike steel, concrete and wood, composite NCFs can be optimized utilizing various fiber types, architectures and substrates to achieve the specific goals of their application efficiently. High corrosion resistance, strength and stiffness, and longevity can all be accomplished with custom-designed laminates for these heavily abused applications. Vectorply Vice President of Engineering Trevor Gundberg and Creative Composites Group Chief Sales Officer Dustin Troutman will share their industry-leading expertise on the process of laminate design and part production. Attendees can expect to learn when to use composite NCFs in their production process and the wide range of fiber-reinforced plastic (FRP) composites that Creative Composites Group produces for the industrial and infrastructure markets. Whether you want to learn more about utilizing NCFs in your production process or why CCG’s extensive product line may be the choice for your project, this webinar is the place learn the process and how to take the next steps. Agenda:  Distinct advantages of non-crimp fabrics versus alternative materials How to design laminates for specific processes such as pultrusion and infusion Real-world success spotlights of NCFs in industrial applications

This symbol represents the actual thickness of the insert. It works on the same principle as that of the inscribed circle.

Currently, two paste formulations are available in widely used tool steels: H13, which offers the same metallurgy and performance as H13 hardened steel, and P2X, which provides the performance of P20 steel with slightly different metallurgy. The company says its material form factor eliminates the handling and storage issue of bare powders, and the high printing pressures and defects seen with filaments. Mantle’s pastes can also print thick-section parts unlike ink-based systems. With a build volume of 200 × 200 × 150 millimeters, the TrueShape process is said to be ideal for producing small- to medium-size mold components.

The symbol that represents the tolerance class is determined by a combination of three tolerances; the nose height (m), inscribed circle (d) and thickness (s). To produce close tolerance inserts, grinding is necessary.

This sidebar to CW’s August 2024 feature article reviews this technology for more efficient composites manufacturing and why it aligns with Koridion active core molding.

FAUSST technology enables fast, reliably welded connection of metal components in composite structures.

There are a number of different types of honing, for example "round" honing and "chamfer" honing. The type of honing employed is shown by the appropriate symbol. Cutting tool manufacturers amploy their own honing geometries (size and angle) according to insert grade and size. Generally the honing symbol is omitted from an identification code.

For the inch coding method, the diameter of an inscribed circle is shown by a numerical symbol. For example, an inscribed circle of  3/8 inch (9.525mm) is represented by the symbol 3. An inscribed circle of 4/8 inch (12.70mm) is shown as 4.

The JEC Forum DACH is a business meetings event organised by JEC The JEC Forum DACH is organised on October 22 and 23, 2024 by JEC, in partnership with the AVK, gathering the composite materials community from the DACH Region (Germany, Austria and Switzerland).

Cemented carbide, coated carbide, cermet, ceramic and other hard material inserts have the cutting edge honed so as to prevent fracturing in the machining.

Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.

Aerospace manufacturer joins forces with composite materials company to achieve sustainable manufacturing practices that overcome traditional composite layup tooling.

The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.

This symbol represents the direction in which the insert can machine. If the insert can be used for both left and right (thus neutral) then the symbol is generally omitted.

For the inch coding method, the diameter of an inscribed circle is shown by a numerical symbol. For example, an inscribed circle of  3/8 inch (9.525mm) is represented by the symbol 3. An inscribed circle of 4/8 inch (12.70mm) is shown as 4.

This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.

In these sessions, experts will discuss the emerging hydrogen economy and the opportunities for composites in this lucrative space.

The ITHEC 2024 will take place from the 9 to 10 October 2024 in Bremen, Germany. At the 7th International Conference, more than 300 participants from around the world will be presenting and discussing newest scientific results, meet leading international specialists, share their expertise and start business co-operations in the field of thermoplastic composite technologies. The international exhibition will feature 40+ exhibitors showcasing all steps of the supply-chain. Be it materials, machines, testing, processes, or solutions. By combining the exhibition and the conference ITHEC is further fostering the inter-connectivity between science and industry.

How the predictive tool “CZone” is applied to simulate the axial crushing response of composites, providing valuable insights into their use for motorsport applications.

Eco-friendly natural fiber range of decking, cladding, fencing, railing options ensure durable and long-lasting structures.

The insert geometry is represented using letters of the alphabet. A wide range of geometries are listed as standard for example; triangle, square, round, polygon and rhombus.

Celebrating National Composites Week, CW shares ways in which composites continue to evolve mass transit.

As part of Machina Labs’ contract with the U.S. Air Force’s Wright Patterson Air Force Base (Dayton, Ohio, U.S.) researchers at University of Dayton Research Institute (UDRI, Dayton) have evaluated a 4.0-millimeter-thick aluminum autoclave tool shell formed on Machina’s system without a backing structure. “The vacuum bag was sealed to the top of the tool such that hydrostatic pressure was applied, then we processed the tool at 100 psi and 350°F [6.9 bar and 177°C] with suitable results,” reports Brian Rice, UDRI distinguished engineer.

CW Tech Days are virtual events dedicated to the topics impacting the composites industry today. Access past event recordings and register for upcoming Tech Days.

Another innovative method for rapidly producing hard tooling (and other metal parts) is being commercialized by Machina Labs Inc. (Los Angeles, Calif., U.S.). Described as dieless robotic sheet forming, the process traces its roots to 1970s-era incremental sheet forming (ISF) — some forms of which used dies and others that did not. Machina’s contributions are in application of computational modeling and simulations, machine learning/artificial intelligence (ML/AI), sensor technologies and kinematic solutions (industrial robot arms). The entire process runs off a software stack and interfaces developed by Machina. It transforms CAD files into robot tool paths and uses sensors to interpret force and torque being applied as well as optical scans measuring deformation to incrementally manipulate sheet metal to form parts. The process creates a digital twin as the part takes shape, and a digital thread captures all relevant process characterization and part qualification information. This digital record then travels with each piece produced for full documentation.

Explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.

Six U.S. companies have proven their recycling technologies for composites and rare earth elements, and will be supported for relevant scale demonstration and validation.

Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.

Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.

CompositesWorld's Carbon Fiber conference offers you cutting-edge information and access to industry experts in streamlining manufacturing costs, market outlooks and forecasting, and more. You will make invaluable contacts as you meet and network with the industry's most innovative and influential leaders at Carbon Fiber. __PRESENT

There are many different printing systems on the market. Some print metals, some polymers, a few print composites and fewer still can print multiple categories of materials. One of the latter types was developed by AIM3D GmbH (Rostock, Germany), which has developed a novel extrusion-type printer that can print metals, plastics, composites and ceramics on the same printer as long as those materials can be supplied in a pellet format and converted into strands/filaments that fit through one of several different size nozzles. An open material system provides a broad range of printable material options while keeping production costs down, although AIM3D will also work with customers wishing to use proprietary materials.

The flexibility of Machina’s system enables it to produce parts of three different sizes and geometries in different materials in the same cell. In three days’ time, the system formed, from left to right, two 0.9-millimeter-thick aerospace parts in 304L stainless steel, a 2.0-millimeter-thick composite layup mold in aluminum and two 0.9-millimeter-thick domes in 316L stainless steel (bottom dome being formed in the picture) for an aerospace tank application. Photo Credit: Machina Labs Inc.

Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.

CompositesWorld is the source for reliable news and information on what’s happening in fiber-reinforced composites manufacturing. About Us

The system takes imported CAD models, slices the geometry into layers and automatically generates additive and subtractive tool paths in G-code, which the printer then uses to produce a part. The extrudable pastes consist of metal particles of different types and sizes in a thixotropic liquid carrier whose viscosity can be tuned. The printer extrudes paste one layer at a time, followed by a short drying cycle to remove the liquid carrier, leaving a green body with the consistency of stiff foam. Next, a quick pass from the integral high-speed mill increases the accuracy and flatness of each layer. Typically, every 10 layers, the part is also contour milled to improve surface finish and refine features on the evolving part. Green body parts move from printers to Mantle’s furnace where they undergo an integrated debinding and sintering process to achieve final part density and geometry.

Once a part is formed, the same robots trim it, cut out holes and bend edges. Should interest prove sufficient, the company can automate edge hemming. All end effectors and fixtures are produced by Machina Labs, which also produces parts in its 2,788-square-meter facility or will set up and run a custom manufacturing cell in a customer’s facility.

For turning operations, mainly G-class (sometimes J-class) or M-class inserts are used. Inserts with tolerance classes other than G, J and M are mostly used on face milling cutters.

While metal AM is a fairly young technology, and its use to produce tooling or tool components is even younger, metal printing technologies continue to evolve and those that are already commercial continue to improve. As these three technologies — along with those covered in Part I of our series — demonstrate, metal AM has much to offer toolmakers, processors and OEMs trying to bring composite products to market faster, at lower cost and with a lower manufacturing carbon footprint.

There are a number of different types of honing, for example "round" honing and "chamfer" honing. The type of honing employed is shown by the appropriate symbol. Cutting tool manufacturers amploy their own honing geometries (size and angle) according to insert grade and size. Generally the honing symbol is omitted from an identification code.

However, for the metric coding, the diameter of an inscribed circle is represented by the cutting edge length using a two-digit number. Therefore, even if the inscribed circle is the same, the symbol for the cutting edge will vary.

Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.

CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

Explore the technologies, materials and strategies used by composites manufacturers working in the evolving space market.

This session is designed to demonstrate the benefits of ultra polymers for aerospace applications with real case examples of Syensqo's polymer portfolio. Agenda:  Introduction to ultra polymers (PAEK, PEKK, PEEK, PAI) key features Application of ultra polymers in aerospace: concrete examples Benefits of ultra polymers: enhanced performance, durability and cost-efficiency

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

Metal AM tools or tool components can cut weeks or even months off lead times without sacrificing accuracy or durability, and they often do so at lower cost than similar components produced via conventional manufacturing. Many processes also enable further functionality to be added to tooling or tool components, such as the use of conformal heating or cooling channels, which can shorten molding cycles and reduce part warpage.

This symbol represents whether or not the insert has a chip breaker. It also refers to whether the insert has a hole or not. A negative insert can have one-sided or double-sided chip breaker.

This symbol represents the direction in which the insert can machine. If the insert can be used for both left and right (thus neutral) then the symbol is generally omitted.

FAUSST technology enables fast, reliably welded connection of metal components in composite structures.

During this CW Tech Days event, sponsored by Composites One, experts will offer presentations to review and evaluate the composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.

Parts in metal or ceramic require thermal or chemical debinding and sintering after printing. AIM3D doesn’t offer its own furnace, but connects customers to a network of companies offering this service. (Metal and ceramic green bodies are said to be relatively tough and can withstand shipping.) Metal shrinkage during sintering is isotropic, occurs at the same rate as for comparable MIM parts and is easily accounted for with simple geometric scaling. Post-sinter porosity is ~0.5%. Most steels are hard-phase sintered and achieve densities up to 98%, while densities for liquid-phase sintered materials like tungsten can be as high as 99.9%. Surface finishes are said to be similar to those achieved via the direct metal laser sintering/solidification (DMLS) process mentioned in Part 1 of the CW December 2022 issue. Reportedly, post-sintered metal parts machine, EDM and weld just like MIM parts and have comparable mechanical properties. Because metal powders are fully encapsulated in a thermoplastic binder, the printer does not require cleanroom conditions, inert-gas blanketing or vacuum pressure. All that is needed is power and compressed air.

American Bureau of Shipping (ABS) certifies use of jointly developed CFRP repair technique on FPSO and FSO industrial systems, addressing traditional steel restoration challenges.

Analyzing structural resonance of the aircraft under various loads becomes a critical step in obtaining flight certification.

This is the symbol that represents the clearance angle of an insert. An insert with 0° clearance angle, which is shown by symbol N, is called a negative insert. An insert with a clearance angle other than 0° is called a positive insert. Many turning inserts have clearance angles shown by symbols P, C and N.

AIM3D reports that its printers are being used to produce metal parts in the automotive industry, although several other industries are interested, including aerospace and MIM itself. Several materials suppliers use ExAM printers in their labs to develop new materials for 3D printing. Tool production is a newer use for the technology and AIM3D is working with several companies under non-disclosure agreements to develop metal AM mold components.

While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?

Reliable news and information on where and how fiber-reinforced composites are being applied — that’s just the start of what you get from our team here at CompositesWorld.

The Marservis PROeco is a mass transportation marine vessel using Bcomp natural fiber for interior parts in place of standard materials.

“The main driver for a process like ours is that it can take six months to machine a really large tool, so the costs are very high,” he continues. “With our process, we can produce a fairly large tool in a few hours. This makes it much easier, faster and less costly to iterate designs with the same kind of tooling you’ll use in production. OEMs no longer have to wait until their design is locked to start cutting hard tooling, which can really help debottleneck the process of bringing products to market.” He adds that design iterations require no hardware changes — only software.

AIM3D founders, then students at the University of Rostock, initially focused on developing a simpler and less costly metal AM printer based on the composite extrusion modeling (CEM) process, which is similar to fused deposition modeling (FDM) and selective laser melting (SLM). CEM was designed to use metal injection molding (MIM) pellets. After graduating and forming their company in 2017, the founders were asked by auto industry investors to try printing glass-reinforced polyamide 6 (GR/PA6), which led to development of a series of print heads and interchangeable nozzles using the fused granular modeling/fabrication (FGM or FGF) process to print neat or reinforced plastic injection molding pellets. The latest materials the team has printed are ceramics.

Program will focus on sustainable, next-gen wing solutions, including in wing design and manufacturing and advancements in carbon fiber-reinforced composite materials.

“Our long-term mission is to build robotic craftsmen,” explains Edward Mehr, Machina co-founder and CEO. “The art of metalworking today is under threat due to an aging population with insufficiently trained apprentices backing them up. The beauty of relying on robotics is that your supply chain is secured for generations to come and, in fact, it can add value. For example, before we had factories, we had craftsmen. The local blacksmith not only shod your horse but also made your sword and shield and plow blade. They were agile manufacturers, although they were limited in terms of throughput. Hundreds of years later, we have factories that can produce a lot of the same kinds of parts, but if you want to make a different part, you need another factory, or at least another production line. We hope to offer the best of craftsmanship and high-rate production. You no longer have to change your machines or manufacturing process, just your design and software.”