Browse Topic: Fibers
For sustainability reasons, the automotive market is requesting 100% monomaterial noise treatments, particularly for the end-of-life recycling without any part separation operation. But also, OEMs require super light, highly performance insulating noise treatments for electric vehicles in order to extend vehicle autonomy. PP melt-blown fiber felts present good mono-material characteristics with very good absorption, but generally not so good insulation properties behind an airtight barrier due to lack of stiffness. Moreover, these PP melt-blown fiber felts are relatively expensive and not thermoformable, thus forcing them to be used as 2D die-cut parts behind existing hard or soft trims classically. The shown optimization approach proposes to return to 100% thermoformable recycled and recyclable PET formulations blending unusual coarse mechanical specific fibers, in order to optimize the viscothermal exchanges, while maintaining good mechanical properties, with microfibers for best
AMS6885/1 gives information about the technical requirements and qualification procedure for unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. The repair system includes an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS6885/2 gives specific information about the qualification program for unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. The prepreg system shall include an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional sheet metal fabrication and finishing operations of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in Polyethylene Terephthalate Glycol with Carbon Fiber (PETG-CF) are compared to conventional
Healable spacecraft structures could soon be possible thanks to cutting-edge composite technology. Swiss companies CompPair and CSEM, and Belgian company Com&Sens have partnered with the European Space Agency (ESA) to modify their self-healing carbon fiber product for use in space transportation.
Researchers from CompPair and the European Space Agency have developed a new composite material for spacecraft with an embedded healing agent. European Space Agency, Paris, France Healable spacecraft structures could soon be possible thanks to cutting-edge composite technology. Swiss companies CompPair and CSEM, and Belgian company Com&Sens have partnered with the European Space Agency (ESA) to modify their self-healing carbon fiber product for use in space transportation. Project Cassandra - an abbreviation for Composite Autonomous Sensing and Repair - includes sensors and a heating element within a composite carbon-fiber material, allowing spacecraft to autonomously repair initial stages of damage.
German startup Blackwave is building carbon parts for rocket tanks. Technical University of Munich, Munich, Germany Carbon fiber has become indispensable in high-performance industries such as automotive engineering and aerospace. It's lightweight, extremely durable, and can be shaped in almost any way. The start-up Blackwave, founded at the Technical University of Munich (TUM), specializes in this versatile composite material. What began with custom components for sports cars and aircraft has evolved into the development of high-pressure tanks for space applications. As is so often the case in engineering, a small detail determines technological progress. In the case of rockets, it is the high-pressure tanks that are specially designed for the fuel systems. As rockets are designed to be as light as possible, they lose structural stability when the fuel tanks, known as primary tanks, are emptied. A trick is used to counteract this: alongside fuel combustion, noble gases are released
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI
The intent of this specification is for the procurement of plain weave fabric epoxy prepreg product with 250 °F (121 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3).
Live-line operation is a critical technique for maintaining the reliability and continuity of power supply in modern distribution networks. Insulating mats serve as essential protective equipment during such operations by providing both electrical insulation and mechanical shielding. In practical service conditions, insulating mats are subjected to repeated mechanical contact and friction against conductors, metallic fittings, and ground surfaces, which progressively deteriorates their surface integrity and compromises operational safety. Current performance standards for insulating mats emphasize dielectric and tensile properties, while tribological durability remains unaddressed. In this study, an EVA – PA6 composite film fabricated via the tape casting method was selected as the representative outer insulating layer of insulating mats. Reciprocating friction tests were conducted using an SDR339 abrasion tester to evaluate the effects of normal load and sliding speed on wear behavior
The intent of this specification is for the procurement of carbon fiber epoxy prepreg product with 250 °F (121 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3).
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
Unmanned aerial vehicle (UAV) primary structures require high specific strength and stiffness, traditionally necessitating expensive carbon fiber composites. This study evaluates simulation-driven, additively manufactured polymer alternatives fabricated from PLA and computationally optimized via macroscopic Topology Optimization (TO), mesoscopic Variable-Thickness Lattices (VTL), and uniform Triply Periodic Minimal Surfaces (TPMS). Evaluations were conducted under a superimposed, multi-axial flight envelope. Physical testing demonstrated that VTL architectures maximized the Structural Efficiency Index (SEI) by pushing mass to the extreme geometric fibers and increasing global flexural rigidity. In contrast, mass-constrained TO yielded misleading specific strength due to volumetric starvation and elevated compliance, while the uniform TPMS baseline exhibited favorable specific stiffness but lacked targeted root robustness, resulting in reduced specific strength. Off-axis testing further
This paper investigates the feasibility of using flax fiber-reinforced composites in combination with additively manufactured polymer cores for helicopter rotor blades. A new rotor blade with flax composite spar and skin laminates and a 3D-printed ASA Aero core was designed to be geometrically equivalent to an existing carbon fiber/foam reference blade of the MERIT rotor test rig and manufactured using identical tooling. Material characterization included compression testing of the printed core at ambient and elevated temperatures, single-lap shear adhesion testing with epoxy laminates, and hygroscopic conditioning of core and laminate specimens. Structural testing comprised static beam bending, experimental modal analysis with axial pre-loading to approximate centrifugal stiffening, and sustained-load creep and recovery testing of the flax blade. The results show that the 3D-printed core provides sufficient compressive stiffness at curing temperature and adhesion to epoxy laminates
Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. Auburn University, Auburn, AL In collaboration with Auburn University's Center for Polymers and Advanced Composites (CPAC) and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell - a next-generation 3D carbon fiber composites printer set to define the future of the nation's hypersonic programs. Developed by Idaho-based Continuous Composites, the CF3D system represents a highly specialized advanced manufacturing capability and is the only system of its kind currently operating in Alabama.
Carbon fiber-reinforced polymers (CFRPs) have become essential in modern aerospace structures, from fuselage skins and wing components to nacelles, interior structures, and a growing range of primary load-bearing parts. Their high strength-to-weight ratio delivers major benefits in fuel efficiency, payload capacity, and fatigue performance. Yet achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. The low intrinsic surface energy of composites - particularly under thermal cycling, vibration, and moisture exposure - limits bond durability unless surfaces are properly prepared. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. This is especially important as the aerospace industry transitions from thermoset to thermoplastic composites (TPCs), which enable faster processing, lower
The rising importance of sustainability in the automotive sector has led to increased interest in circular and environmentally responsible materials, particularly for plastic trims parts, both interior and exterior. This study focuses on developing textile solutions using recycled polyethylene terephthalate (r-PET) sourced from post-consumer plastic waste, along with bio-based fibres such as bamboo. These materials made into woven and knitted fabrics are studied to suit different vehicle interior applications. r-PET textiles show promising strength, aesthetic appeal, and durability performance. Bamboo fabrics are known for their natural antimicrobial properties and enhanced breathability. Extensive testing is performed to validate explored sustainable materials performance against key automotive requirements. With this study, we gain an understanding of the performance of variedly sourced sustainable raw materials for automotive specific textile applications by different manufacturing
EPFL researchers have engineered a fiber-based electronic sensor that remains functional even when stretched to over 10 times its original length. The device holds promise for smart textiles, physical rehabilitation devices, and soft robotics.
High-power fiber lasers have become increasingly indispensable tools in automotive manufacturing over the past two decades. They are now widely deployed in welding and brazing applications for body-in-white, powertrains, engine components, and more.
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (4.3) of this base specification, AMS6891.
Oak Ridge National Laboratory (ORNL) researchers have overcome a barrier to using a more affordable, dry process for manufacturing the Li-ion batteries used in vehicles and electronic devices. The resulting batteries provide greater electricity flow and reduced risk of overheating.
AFP can build complex, lightweight structures, but cost concerns keep its use in the automotive industry to a minimum. For now, anyway. Ramy Harik, a Fulbright alumnus and director of the Clemson Composites Center, is pushing the boundaries of manufacturing with his latest book, Automated Fiber Placement: Status, Challenges, and Evolution coauthored with Alex Brasington. The book, published by SAE in June of 2025, serves as a comprehensive guide to automated fiber placement (AFP), a cutting-edge technology crucial for building complex, lightweight structures in the aerospace and automotive industries. The book aims to offer a thorough understanding of AFP's transformative potential for students, engineers, and industry professionals. The book synthesizes a decade of research, explaining how AFP supports the rise of advanced air mobility and sustainable structures for commercial and defense aircraft, space habitats, and beyond.
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
A futuristic vehicle chassis rendered in precise detail using state-of-the-art CAD software like Blender, Autodesk Alias. The chassis itself is sleek, low-slung, and aerodynamic, constructed from advanced materials such as high-strength alloys or carbon-fibre composites. Its polished, brushed-metal finish not only exudes performance but also emphasizes the refined form and engineered details. Underneath this visually captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks are situated adjacent to the four shock absorber mounts. These jacks are designed to lift the chassis specifically at the tyre areas, and the total vehicle, ensuring that underbody maintenance is efficient and that, in critical situations, vital adjustments or emergency lifts can be performed quickly and safely. The design also incorporates an intuitive control system where the necessary buttons are strategically placed to optimize driver convenience. Whether
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