11:50
Poster pitches
11:50
1 mins
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Automated Fabric Deposition
Matthijs Bosboom, Lex Zwang, Sjef van Breugel, Tomek Krzysztofiak
Abstract: The Automated Fabric Deposition (AFD) system is an emerging technology aimed at automating the layup of dry (glass or carbon) fabrics in large-scale composite structures, with initial focus on wind turbine blade manufacturing. The system is currently under development to address key challenges in manual layup processes, including labour intensity, variability, and material waste.
The concept builds on earlier research into automation and digitalization of composite manufacturing, which demonstrated that significant improvements in throughput, cost efficiency, and laminate quality can be achieved by addressing key process bottlenecks in manual layup.
The envisioned system architecture supports modular integration into existing production environments and is designed to accommodate a wide range of fabric types and ply shapes. By automating the layup process, AFD aims to improve process consistency, reduce cycle times, labour cost, and enhance laminate quality, while also enabling traceability and in-process quality assurance.
Although still in the development phase, AFD is being designed with scalability and cross-sector applicability in mind. Beyond wind energy, potential applications include aerospace, marine, and automotive composites, where automated layup of dry reinforcements can significantly improve manufacturing efficiency and product performance.
This research outlines the conceptual framework and development goals of the AFD system, and invites collaboration and discussion on its technical challenges, integration strategies, and future role in industrial composite manufacturing.
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11:51
1 mins
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Design of Experiments for Determining Dominant Process Parameters for High Pressure Resin Transfer Molding
Victor Gadow, Ramy Harik, Mike Maher
Abstract: Carbon Fiber Reinforced Polymers (CFRPs) are increasingly used in automotive, aerospace, defense, and energy sectors due to their high strength-to-weight ratio. Among liquid composite molding processes, High Pressure Resin Transfer Molding (HP-RTM) enables fast production of CFRP parts by using rapid-curing resins and elevated injection pressures. However, the large number of process variables in HP-RTM can significantly influence mechanical properties, processing time, and defect formation. Understanding how these parameters interact is integral to determining the dominant factors controlling part quality.
This work applies the Taguchi design of experiments to investigate five key process parameters: vacuum level, cure time, mold temperature, injection flow rate, and pressure cut-off. An L18 orthogonal array is employed to efficiently explore main effects and interactions among these factors. Dielectric sensors monitor the degree and rate of crosslinking, glass transition temperature, resin viscosity, and flow front progression during injection. Mechanical performance is assessed through tensile and flexural testing, while void content is quantified by matrix burn-off. Differential scanning calorimetry is used to validate the degree of cure and glass transition temperature. The signal-to-noise ratio serves as the response metric to assess robustness against uncontrolled noise factors, while main effects and half-normal probability plots are analyzed to identify significant parameter influences.
The results of this work provides quantitative insight into the dominant process parameters and their interactions in HP-RTM. These findings contribute to improved understanding and optimization of HP-RTM processing conditions, enabling more consistent and defect-free composite components for advanced structural applications.
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11:52
1 mins
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humm3 Xenon flash heating: single heat source for composites in automated fiber placement applications
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.
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11:53
1 mins
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Design, fabrication, and mechanical properties of Glass-Kevlar hybrid composites for tidal turbine blades
Wanting Cui
Abstract: Tidal energy is a promising renewable energy source, and tidal turbines play a critical role in harnessing this energy. However, the harsh marine environment imposes significant challenges on tidal turbine blades, such as fatigue, corrosion, and hydrodynamic loading. Fibre composites are favoured materials due to their high strength-to-weight ratio and resistance to environmental degradation. Hybrid fibre-reinforced polymer composites offer a promising approach to tailoring the stiffness, strength, and damage tolerance of tidal turbine blades through the strategic combination of complementary fibre systems. The primary aim is to develop and optimize these hybrid configurations to enhance mechanical strength, fatigue resistance, and environmental durability in harsh marine environments. In this study, glass fibre–aramid (Kevlar) hybrid composite laminates were designed, manufactured, and mechanically characterized as a first step towards optimized hybrid blade structures for marine energy applications. Laminates were fabricated using the vacuum-assisted resin transfer molding (VARTM) process, with particular attention paid to resin flow control, fibre alignment, and interfacial bonding quality.
Four different layup configurations were developed to investigate the effects of fibre type, orientation, and stacking order on mechanical properties. Specimens were prepared according to ASTM D3039 and ASTM D6641 standards and tested under tensile and compressive loads. Results showed that stiffness, strength, and failure modes were significantly dependent on the laminate structure, highlighting the effectiveness of glass-Kevlar hybrids in achieving a balance between stiffness and ductility. New static compression data are also provided, filling a gap in the literature with few reports on specific compression values for glass fibre/Kevlar.
The study establishes a robust experimental framework for hybrid composite manufacturing and testing for tidal turbine blade applications. The findings provide a baseline for ongoing work extending the material system to include carbon and basalt fibres, as well as impact, fatigue, and hygrothermal conditioning, with the ultimate aim of developing durable and high-performance composite solutions for marine renewable energy structures.
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