A solution to a recognised new product development (NPD) cost barrier related to specialist carbon and aramid fibre technical fabrics is now accessible through the automated fibre laying (AFL) placement and winding machine technology developed by CompoTech PLUS, spol. s r.o, based in the Czech Republic. This technology provides the composites market with a reliable, commercially viable alternative, potentially unlocking innovative new NPD opportunities.
A challenge faced by OEMs and other manufacturers that can hinder the development of new high-performance composite part designs is the prohibitive cost of producing bespoke specialty fabrics in small quantities. For most technical fabric producers using current loom technology, it is not practical or viable to set up and customise small-volume batches, especially with delicate ultra-high-modulus woven fabrics or non-crimp fabrics. Therefore, many innovative composite design ideas and new product development (NPD) projects never progress to prototyping and final composite component production.
The highly versatile production capabilities of CompoTech’s automated machine and control software enables the production on the same machine of carbon and aramid fibre non-crimp fabrics, variably shaped dry fibre preforms and finished epoxy fibre composite parts. Using its unique production technology, CompoTech has been able to develop new component designs, and to work with OEM customers to provide prototypes and manufacture one-off or limited volume components for high-performance applications in aerospace, bespoke industrial production machinery and specialist metrology equipment.
Dry fabric, preform and component production
The AFL placement and winding machine technology developed by CompoTech is able to process pitch and PAN carbon fibres, aramid or other high performance fibres. Fabrics and variably shaped dry fibre preforms can be produced as part of a two stage process. The first stage uses only a single bobbin loaded with the exact quantity of fibres required to make the preform or fabric needed in the specified dimensions for the component. The machine can make dry fabrics with multiaxial or unidirectional orientation, which can be used as preforms up to 6 metres long in vacuum infusion/RTM processes.
A preform on a flat woven fabric backing can be produced to dry lay-up in a mould, or alternatively the preform can be laid directly onto a round, square or rectangular tool. The second processing stage, using the same machine, is to overwind with wet fibres in any orientation to produce the final fibre reinforced epoxy component.
CompoTech’s automated fibre placement and winding technologies are integrated with a Fanuc 6-axis robot arm that enables the wide-ranging, highly versatile production flexibility of the automated system, combined with proprietary control software that provides simple protocols for precision fibre application. With true Zero-degree carbon fibre axial placement, both PAN fibres and the more delicate “pitch” fibres are precisely placed without damaging them. As a result, highly stiffer, higher-performance CFRP components, including CompoTech’s range of standard and custom-made square epoxy CF beams and tubes, are produced with physical properties not achievable using conventional filament winding.
Superior part performance
The ability to use its unique automated AFL and winding machine technology to produce epoxy carbon parts designed with both PAN and “pitch” fibres has enabled CompoTech to replace steel components with a CRFP part with enhanced mechanical properties that is typically 25% lighter for the same stiffness. This offers customers increased efficiency and productivity, along with lower running and overall lifetime costs for the machines and production lines designed with carbon composite components. Examples of CompoTech CF composite parts specified in preference to aluminium or steel include: composite beams, rotary shafts, spindles and tools for production machines and automated lines, particularly in industrial applications where high stiffness and natural frequency are required.
Bespoke automated machines
For manufacturers looking to install in-house automated dry fabric, preform and carbon composite component production capabilities, CompoTech now also offers customers ‘turnkey’ automated fibre winding and filament placement machines. Each automated machine comes with CompoTech’s advanced winding technologies and proprietary control software included as standard, along with after-sales technical and product development support.
JEC Forum DACH 2024 Participation
CompoTech (stand B16) is participating in the JEC Forum DACH 2024, which takes place on October 22-23 in the Maritim Hotel Stuttgart, Germany. The event is a business meetings forum for the composite materials community from the DACH Region (Germany, Austria and Switzerland), organised by JEC in partnership with the AVK.
CompoTech’s founder and R&D Director Ondrej Uher and Dr Humphrey Carter will be on hand to discuss their 6-axis AFL, advanced winding technologies and automated machine production capabilities, and are interested to meet with companies during JEC Forum DACH 2024 to learn more about current and future market needs for custom-designed CF epoxy components and automated production machines.