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Session: Poster pitches
Session starts: Wednesday 15 April, 11:50
Presentation starts: 11:52
Room: Main

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Martin Brown ()
Ross Kitson ()

Abstract:
This study investigates the feasibility of using Xenon flash heating—specifically the humm3 system—as a universal thermal source for composite materials in Automated Fiber Placement (AFP) processes, without the need for absorptive additives. The motivation stems from the growing imperative to decarbonise composite manufacturing, which has led to increased exploration of alternative fiber and matrix systems with improved recyclability and mechanical performance. Thermoplastic carbon fiber-reinforced polymers (CFRPs) are among the most promising candidates for sustainable AFP applications. However, their adoption is hindered by the elevated temperatures required for in-situ consolidation, typically achieved using monochromatic laser sources. These lasers, operating at fixed wavelengths (~1000 nm), are effective primarily for materials containing carbon black, limiting their versatility. Bio-based fibers such as hemp and flax, as well as glass fiber composites, present attractive alternatives due to their lower environmental impact and potential for recyclability. Yet, their integration into AFP systems often necessitates the inclusion of additives like cobalt oxide to facilitate laser absorption. This requirement poses challenges for transparency, recyclability, and process efficiency. The humm3 Xenon flash system offers a broadband spectral output ranging from ultraviolet (~250 nm) to infrared (~1200 nm), enabling effective heating across a wide range of material absorption profiles. This capability allows for the thermal processing of translucent and additive-free composites, including bio-based and glass fiber systems, thereby expanding the material palette for AFP without compromising sustainability or performance. These findings suggest that Xenon flash heating could serve as a transformative enabler for next-generation composite manufacturing, supporting both industrial scalability and environmental objectives.