CAMX 2024 Part 2: Cross-industry innovations and sustainability in focus

The Advanced technologies lab for aerospace systems at Wichita State University’s National Institute for Aviation Research (NIAR-ATLAS) has been rewarded with the CAMX Unsurpassed Innovation Award. Their high-rate hybrid injection over-moulding of thermoplastic aircraft window cover meant for passenger-to-cargo haulers conversion is a proof of low-cost automotive high-rate production applied to the aerospace industry. In collaboration with 450-ton Krauss Maffei press and Victrex AETM 250 low melt PAEK organo-sheet, 2 robots worked simultaneously to carry out material transfer between heating steps, over-moulding steps, removing steps, etc to ensure high-rate continuous production.

As the composites market evolves, the cross-industry adaptation of established processes is gaining momentum. Lockheed Martin has partnered with Krauss Maffei to repurpose Long Fibre Injection (LFI) technology, originally developed for automotive and trucking industries for aerospace applications. During a recent session, the experts Dan Rozelman (Krauss Maffei), Nicholas Gagliardi (University of Dayton Research Institute), Craig Neslen (Air Force Research Laboratory) and Robert Koon (Lockheed Martin) discussed these advancements.

Robert Koon highlighted the specific challenges of applying LFI to aerospace, stating, “We don’t need 5-minute cycle times for these production lines. Sacrificing speed for performance allows this technology to work effectively on airframe applications.” As part of an Air Force program, Lockheed Martin is developing a higher Tg polyurethane resin (~135°C) and experimenting with carbon fibres from suppliers like Zoltek, Toray and Hyosung, using various tow sizes (12k, 24k, 50k), both chopped and sprayed. The focus is on optimising material characterisation and process integration.

Lockheed Martin is also exploring the integration of LFI with other fibre-oriented processes, such as spraying onto braids, fabrics or tailor fibre placement systems. Craig Neslen noted that this hybrid approach could “open the door to applications we wouldn’t have considered before,” particularly in aeromobility, including battery enclosures.

This technology is currently being used to fabricate secondary, low-load-bearing structures in aviation, with potential applications in Group 1 and Group 2 UAS components, signalling broader adoption in the aerospace sector.

Sustainability: a core focus

Caltrans, the California Department of Transportation, is actively integrating composites into its building and construction projects, aiming to enhance sustainability and innovation across sectors. By increasing the use of recycled materials like asphalt and tires, advancing cold in-place recycling technologies, and implementing ultra-high-performance concrete and Fibre-Reinforced Polymers (FRP), Caltrans is leading the way in sustainable infrastructure. Composites such as E-glass and carbon fibres are being used in various applications, including bridge strengthening, signal structures and pedestrian walkways, offering benefits like reduced construction time, cost savings and a smaller carbon footprint.

In alignment with the Buy Clean California Act, Caltrans is collaborating with the industry to develop Environmental Product Declaration (EPD) compliant materials, fostering innovation through initiatives like their vendor portal. This platform invites ideas from across sectors to further reduce environmental impact, demonstrating how composites are crucial in building a sustainable future.

The future of the freight industry is increasingly driven by sustainability goals, with composite materials playing a pivotal role across the rail, truck and trailer markets. Wabash’s EcoNex solution exemplifies this trend by offering trailer walls that are not only lightweight but also enhance thermal efficiency and reduce costs. Similar to Caltrans, which seeks innovations through collaboration and partnerships, the US rail industry is embracing composites to lower weight, cut costs and boost cargo capacity, marking a significant shift towards more sustainable transportation solutions.

Elix Polymers is advancing the use of molecular recycling to bridge the gap between renewable and fossil-based thermoplastic resins. By diversifying its feedstock sources for ABS monomers – including fossil fuels, advanced recycled materials and bio-based options – Elix aims to give used resins new life, matching the performance of virgin materials. This approach targets reducing environmental impact while addressing the complexities and economic challenges of recycling different types of plastics.

Johns Manville (JM) is advancing sustainability with recycling initiatives at its Trnava, Slovakia, and Etowah, Tennessee plants. The Trnava facility, aligned with the European Commission’s zero waste program, processes over 10,000 tons of glass fibre waste annually into raw materials, ensuring at least 6% recycled content in products. In Etowah, JM has been recycling glass waste since 1987, contributing 5% recycled content to its output. These efforts underscore JM’s commitment to reducing environmental impact while maintaining high product quality.

Johns Manville is advancing in long and continuous fibre-reinforced thermoplastic composites, which are gaining market share due to their impact resistance, thermoformability and recyclability. Senior Research Manager Mingfu Zhang highlighted innovations like Direct Long Fibre Thermoplastic (DLFT) and Fibre Direct Compounding (FDC), which have increased production efficiency and reduced costs, positioning Johns Manville as a leader in this growing market.

Owens Corning reinforces its commitment to ecological responsibility and cutting-edge innovation in the composites industry. SUSTAINA® Glass, an advanced material made from a combination of post-industrial circular content and traditional glass materials, designed to reduce environmental impact while maintaining product performance. UL-Certified through mass balance, SUSTAINA® Glass is tailored for applications like multi-end roving designed for sheet moulding compounds and single-end roving designed for pultrusion. Additionally, the company introduced HP2 Glass, a high-performance fibreglass material that enhances mechanical properties and reduces weight, further driving cost efficiency for wind OEM and design flexibility.

Needs for rapid cure solutions

To meet increasing production demands in the aerospace sector, NASA Langley Research Center is developing rapid-cure resin infusion processes. Their isothermal resins, designed to be infused and cured at the same temperature, eliminate the need for temperature ramps, thus reducing processing times and enhancing energy efficiency in the fabrication of large primary structures.

Lindau Chemicals introduced a UV-initiated anhydride epoxy capable of curing carbon fibre/epoxy components, such as pressure vessels, in a fraction of the usual time – up to 1/10, reducing cure times to under an hour. This innovation significantly speeds up the manufacturing process for similarly sized parts.

ExxonMobil showcased on the demo zone its Proxxima™ polyolefin thermoset resins, known for low viscosity and fast, controllable cure times. These resins are versatile and compatible with conventional processing equipment, making them ideal for a wide range of applications.

Automotive Innovations: Ascorium presented its CompLite composites, which feature in-house produced polyurethane (PU) in tailored constructions. These PU composites, including foam with fibre-reinforced skins and decorative surfaces, could offer the potential for full-panel recycling without material separation depending on the chemistry, advancing sustainability in automotive manufacturing.

Toray’s Advanced Materials: Toray highlighted several products:

• Ecoterra: A sustainable composite solution for automotive, consumer electronics, and footwear applications, featuring woven flax fabric and partially bio-based acrylic thermoplastic.
• Cetex PA+ / TC915: This high-performance composite is tailored for industrial, automotive, UAS, and energy sectors, offering improved shear properties, reduced weight, and a 25°C higher glass transition temperature compared to previous versions.

Thermal Protection Systems (TPS): Blueshift Materials showcased their AeroZero family, an innovative TPS composed of 85% nanosized air pockets and 15% pure polyimide. This material effectively insulates composite structures in high-temperature environments, making it suitable for aeronautics, aerospace or protecting critical battery housing for Lilium Jet eVTOL aircraft for example.

Spirit AeroSystems presented during a session third-generation lightweight TPS, including the PICA (Phenolic Infused Carbon Ablator) and 3MDCP (3D Medium Density Carbon Phenolic). These systems are engineered to withstand the extreme heat fluxes encountered during planetary re-entry, supporting NASA’s TPS heatshield projects for solar system exploration.

CAMX 2024 showcased the composites industry as it navigates technological growth and sustainable innovation. The event showcased how automation, AI-driven advancements, and cross-industry applications are setting the stage for enhanced production techniques and broader adoption. As manufacturers refine processes and adapt proven technologies to new challenges, sustainability continues to shape composite development. With these advancements maturing and integrating, composites are poised to become essential across diverse industries, steering toward a more sustainable and interconnected future.

Cover photo: San Diego Convention Center