Composites Processes

Processes in composites manufacturing encompass a diverse array of techniques employed to fabricate composite materials. These processes include methods like hand layup, where layers of resin and reinforcement materials are manually placed, and vacuum infusion, where a vacuum draws resin into a preform. Other techniques like compression molding, filament winding, and automated methods such as 3D printing are utilized to create intricate and specialized composite structures. Each process offers unique advantages in terms of precision, scalability, and efficiency, catering to diverse industry needs. As technology advances, newer methods are emerging, promising faster production cycles, reduced waste, and increased customization, driving the evolution of composite manufacturing towards more sophisticated and versatile methodologies.

Prepreg compression molding supports higher-rate propeller manufacturing
Aerospace

Prepreg compression molding supports higher-rate propeller manufacturing

To meet increasing UAV market demands, Mejzlik Propellers has added a higher-rate compression molding line to its custom CFRP propeller capabilities.  

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Master Bond Epoxy Adhesives
Kent Pultrusion

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CAMX

Composite curing ovens are built for maximum performance

CAMX 2025: Wisconsin Ovens presents equipment for vacuum bag, filament-wound and honeycomb block heating technologies, offered with a variety of specific features and options.

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CAMX

LFAM specialization caters to 3D printed composite tooling, molds

CAMX 2025: AES is committed to driving technological advancement and application development in 3D printing, distinguishing its diverse capabilities through several tooling examples.

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Trends

Damen, CEAD explore composite 3D printing potential via HDPE Workboat project

Dutch innovators collaborate to investigate large-format 3D printing for functional shipbuilding at the recently opened Maritime Application Center.

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CW Top Shops

From prototypes to performance: Composites company makes inroads to new markets

Top Shops 2024 honoree Calian’s composites division blends R&D, rapid prototyping and scalable production with deep engineering integration and corporate synergy.

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Marine

Delta Marine shares 110-foot custom motor yacht with novel hull

In-progress build highlights Delta’s first hull designed entirely using CFD, a step forward in performance innovation for the shipyard known for its custom composites construction expertise.

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Marine

CEAD launches the Maritime Application Center dedicated to industrial 3D printing boat hulls

The MAC is an LFAM-powered production facility equipped with highly automated, digitally driven manufacturing processes and built around a collaborative model to develop the boats of the future.

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Knowledge Centers

Sensors for Composite Processing
Sensors for Composite Processing

Discover the types of sensors being used in composites, the physics on which they�re based, their installation, promised benefits and challenges, as well as the potential they offer for even further developments in smart structures.

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Sustainability
Sustainability

The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.

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ELFOAM rigid foam products
Industrial CNC Routers
Wickert Hydraulic Presses
Wabash
Composites One - distributor

Latest Processes News And Updates

Composites 4.0

Swinburne highlights composites and Industry 4.0 activities

Swinburne University of Technology’s facilities and research expertise have attained milestone developments in a UAV wingbox, customized carbon fiber components, digital manufacturing and 3D printing.

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Hufschmied, CMS open up advanced materials machining potential

Technical partnership combining cutting tool technology and CNC machining will open up new possibilities for comprehensive process efficiency, quality and sustainability for composite materials and engineered plastics.

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CEAD technologies supports FIDAMC advanced manufacturing

CEAD-powered microfactories for composites additive manufacturing builds the Spanish technology center’s collaborative environment, enables expansion into new industries.

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Vacuum-assisted extrusion improves performance of FRP prints

A novel 3D printing approach developed by ORNL reduced internal porosity by up to 75% in large-scale, 3D printed composites.

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Porsche develops TABASKO method for lightweight vehicle series production

Patented carbon fiber-reinforced polypropylene tape-based process supports cost reduction, light weight and thinner walls without sacrificing rigidity.

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Aerospace

Clean Sky 2 outer wing box demonstrator validates OOA LRI, shimless assembly and SHM

Full-scale wing box project achieves TRL 5 with 2% weight reduction and 4% reduction in recurring production costs through improved manufacturing efficiency and assembly processes.

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Large Scale Additive Manufacturing
Carbon Fiber 2025
Ancamine® 2337M
NewStar Adhseives - The Glue Pros
Airtech International Inc.

Featured Posts

Recycling

Spanish startup to ramp up production of “recyclable” EV prototype

Liux’s BIG electric vehicle features multiple structural components manufactured via RTM from flax fabric and a thermoset resin said to enable the entire component to be recycled and reused again.

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Sustainability

Addressing rivet hole drilling challenges for aerospace composites

Kennametal explores technological advancements in composite drilling, including stacked laminates, to meet aerospace applications and sustainability challenges.

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Wind/Energy

In oil and gas, an additive manufacturing standard (API 20T) will aid adoption of composites

Polymer AM equipment maker Roboze sees how the oil and gas industry’s way forward with additive is like that of another high-stakes industry, aerospace, and also different in important aspects.

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JEC World 2025 highlights: New thermoplastics, PI fiber, solutions for FR, machining, digitized processes and more

CW senior technical editor Ginger Gardiner discusses latest developments in composites from this year’s show.

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Coatings

Plasma moves beyond improved bonding to coatings, multifunctional composites

Plasmatreat cold plasma systems clean, activate surfaces and apply nanocoatings for dielectric barriers and more.

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ATL/AFP

Inside the MFFD — CW's coverage of the Clean Aviation multifunctional fuselage demonstrator

CompositesWorld rounds up coverage of the MFFD project over the past decade. Now complete, the MFFD illustrates numerous processes and technologies for manufacturing primary aerospace structures using thermoplastic composites. 

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Airtech
ColorForm multi-component injection
America's Composite and Advanced Materials Expo
Encapsulated Sample Rheometer (ESR)
Release agents and process chemical specialties