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Industry, government, and academia partnership results in the development of new technology for complex advanced materials structures
Industry, government, and academia partnership results in the development of new technology for complex advanced materials structures
Products & Services
Conventional Matched-die RTM Process
Fiber Dynamics
This process is ideal for use in complex, lightweight-cored, and solid laminate structures. It provides more economical, high-volume production capability with excellent surface and superior structural properties.
Lost Core RTM Process (LCRTM) Technology
Fiber Dynamics
Our LCRTM Process includes:
- Proprietary manufacturing process for complex parts with hollow interior cavities and internal stiffeners.
- High-fiber volume composite geometries.
- Intricate assemblies involving metal details, inserts, and internal stiffeners with no secondary bonding or fastening.
- Superior control of wall thickness in critical thin-wall applications.
Vacuum-assisted RTM Process (VARTM)
Fiber Dynamics
Vacuum-assisted RTM Process (VARTM)
- Autoclave-quality parts at just a fraction of the cost.
- Lower cost single-sided tooling solution.
Bladewerx
Fiber Dynamics
Bladewerx is an exceptional collaboration between academia, material suppliers, and automation partners. Our approach facilitates the mass production of propellers, and other complex structures for Advanced Air Mobility (AAM) and Unmanned Aerial Vehicle (UAV) industries.
When you parter with us we will:
- Develop advanced propeller designs and methodologies to maximize the benefit of our Lost Core RTM Process (LCRTM) technology.
- Evolve and characterize next-generation materials for these structures.
- Provide design through prototyping, certification, and production services.
- Collaborate with established automation partners to create automated processes for rates of 100,000 or more units per year.
- Apply these concepts to other aerostructures.
People
Description
Researchers with NIAR’s Advanced Technologies Lab for Aerospace Systems (ATLAS) designed the inlet duct as a part of a manufacturing demonstrator called Frankenstein (FS-19), which is a 30-foot unmanned combat aircraft.
The project, part of the Air Force Research Laboratory’s (AFRL) Manufacturing for Affordable Sustainable Composites (MASC) program, is a proof-of-concept for low-cost, high-rate production worthiness. “This manufacturing demonstrator intended to generate a cost model based on manufacturing data that include various materials, manufacturing, and assembly methods so the industry can use the information for on-demand flexible manufacturing and assembly of composite structures based on volume, cost, weight, and mission requirements,” says Dr. Waruna Seneviratne, Director of ATLAS.
The complex curvature of the inlet duct demanded a novel approach to manufacture. Placement of tows using automated tape-laying is limited due to the radius of curvature; and hand placement of prepreg would result in excessive cutting and splicing. The overbraiding technology was developed by A&P Technology in Cincinnati and was identified by AFRL as a key process for high-rate production of aircraft parts. The technology is capable of producing multiple duct preforms per shift.
The demonstrator inlet duct is approximately eight inches long, with perimeters ranging from 56.5-96.6 inches. Fiber Dynamics created a melt-out mandrel using its ThermocoreTM Lost Core Tooling System. A&P Technology used this system to overbraided five layers of triaxial braid at a constant thickness of .10” thick, resulting in angle changes along the length of the part ranging from 55-74°. There were no cuts or splices created during the overbraiding process, and the precise control of fiber angle provides consistently high part-to-part repeatability.
A&P Technology and Fiber Dynamics are working through the MASC research program to develop a path to certification of overbraided structures. NIAR and A&P previously partnered to generate FAA-approved design allowables for 2x2 biaxial braid for resin transfer molding of control surfaces of a Raytheon Premier I Part 23 business jet. By creating a certification method for a more automated layup process like overbraiding, MASC continues its work to create affordable and sustainable methods of manufacture.
The proposed path to certification includes establishing a one-point certification method that fully qualifies a nominal angle with laminate analysis predictions for angle changes, similar to Advanced Fiber Placement techniques and Laminate Plate Theory rotations of flat fabrics. Once qualified, predictions will be validated through simplified bridge testing of predicted properties at various angles.
About NIAR
The National Institute for Aviation Research (NIAR) at Wichita State University provides research, design, testing, certification, and training to the aviation, defense, manufacturing, and related industries. NIAR has a $350 million annual budget, a staff of 1,200, and nearly two million square feet of laboratory and office space in six locations across the city of Wichita, the Air Capital of the World. Areas of expertise include Additive & Advanced Manufacturing; Advanced Coatings; Aerodynamics; Ballistics and Crash Dynamics; Composites and Advanced Materials; Digital Twin; Environmental and Electromagnetic Test; eXtended Reality; Flight Simulation; Full-Scale Structural Test; Non-Destructive Test; Sustainment; Reverse Engineering; Robotics/Automation and Virtual Engineering. NIAR is a department within the division of Industry and Defense Programs at Wichita State. www.niar.wichita.edu
About A&P Technology
A&P Technology is a seventh-generation, family-owned, world-leading producer of precision braided textiles. It began as an R&D division of Atkins & Pearce, America's largest and oldest braiding company and a dominant force in textile braid markets worldwide.
From the beginning, A&P concentrated its research efforts on the development of state-of-the-art braiding machinery aimed at furthering the use of braid within the composites industry. This tradition continues today with our modern facilities, industry-leading research and development, and manufacture of the world's largest and most technologically advanced braiding machinery. This machinery includes a line of Megabraiders™, the largest braiding machinery in existence, which meets composite designers' needs for braided reinforcements of large diameters with small unit cells. www.braider.com
About Fiber Dynamics
Fiber Dynamics stands at the forefront of Resin Transfer Molding (RTM), offering a comprehensive suite of services for the production of highly engineered composite structures. Our Wichita-based facility is equipped to handle the entire lifecycle of composite components, from conceptual design and certification to high-volume production, serving diverse industries with turnkey solutions.
Drawing on decades of expertise rooted in NIAR, Fiber Dynamics employs proven methodologies to deliver superior quality, innovative, and cost-effective solutions. Our pioneering Thermocore™ Lost Core Tooling System enables the creation of exceptionally complex parts, meeting the rigorous demands of aerospace applications.
Today, Fiber Dynamics designs, tests, and manufactures critical components for premier business jets, military aircraft, spacecraft, Advanced Air Mobility, and beyond. Discover more at fiberdynamics.net.
The project, part of the Air Force Research Laboratory’s (AFRL) Manufacturing for Affordable Sustainable Composites (MASC) program, is a proof-of-concept for low-cost, high-rate production worthiness. “This manufacturing demonstrator intended to generate a cost model based on manufacturing data that include various materials, manufacturing, and assembly methods so the industry can use the information for on-demand flexible manufacturing and assembly of composite structures based on volume, cost, weight, and mission requirements,” says Dr. Waruna Seneviratne, Director of ATLAS.
The complex curvature of the inlet duct demanded a novel approach to manufacture. Placement of tows using automated tape-laying is limited due to the radius of curvature; and hand placement of prepreg would result in excessive cutting and splicing. The overbraiding technology was developed by A&P Technology in Cincinnati and was identified by AFRL as a key process for high-rate production of aircraft parts. The technology is capable of producing multiple duct preforms per shift.
The demonstrator inlet duct is approximately eight inches long, with perimeters ranging from 56.5-96.6 inches. Fiber Dynamics created a melt-out mandrel using its ThermocoreTM Lost Core Tooling System. A&P Technology used this system to overbraided five layers of triaxial braid at a constant thickness of .10” thick, resulting in angle changes along the length of the part ranging from 55-74°. There were no cuts or splices created during the overbraiding process, and the precise control of fiber angle provides consistently high part-to-part repeatability.
A&P Technology and Fiber Dynamics are working through the MASC research program to develop a path to certification of overbraided structures. NIAR and A&P previously partnered to generate FAA-approved design allowables for 2x2 biaxial braid for resin transfer molding of control surfaces of a Raytheon Premier I Part 23 business jet. By creating a certification method for a more automated layup process like overbraiding, MASC continues its work to create affordable and sustainable methods of manufacture.
The proposed path to certification includes establishing a one-point certification method that fully qualifies a nominal angle with laminate analysis predictions for angle changes, similar to Advanced Fiber Placement techniques and Laminate Plate Theory rotations of flat fabrics. Once qualified, predictions will be validated through simplified bridge testing of predicted properties at various angles.
About NIAR
The National Institute for Aviation Research (NIAR) at Wichita State University provides research, design, testing, certification, and training to the aviation, defense, manufacturing, and related industries. NIAR has a $350 million annual budget, a staff of 1,200, and nearly two million square feet of laboratory and office space in six locations across the city of Wichita, the Air Capital of the World. Areas of expertise include Additive & Advanced Manufacturing; Advanced Coatings; Aerodynamics; Ballistics and Crash Dynamics; Composites and Advanced Materials; Digital Twin; Environmental and Electromagnetic Test; eXtended Reality; Flight Simulation; Full-Scale Structural Test; Non-Destructive Test; Sustainment; Reverse Engineering; Robotics/Automation and Virtual Engineering. NIAR is a department within the division of Industry and Defense Programs at Wichita State. www.niar.wichita.edu
About A&P Technology
A&P Technology is a seventh-generation, family-owned, world-leading producer of precision braided textiles. It began as an R&D division of Atkins & Pearce, America's largest and oldest braiding company and a dominant force in textile braid markets worldwide.
From the beginning, A&P concentrated its research efforts on the development of state-of-the-art braiding machinery aimed at furthering the use of braid within the composites industry. This tradition continues today with our modern facilities, industry-leading research and development, and manufacture of the world's largest and most technologically advanced braiding machinery. This machinery includes a line of Megabraiders™, the largest braiding machinery in existence, which meets composite designers' needs for braided reinforcements of large diameters with small unit cells. www.braider.com
About Fiber Dynamics
Fiber Dynamics stands at the forefront of Resin Transfer Molding (RTM), offering a comprehensive suite of services for the production of highly engineered composite structures. Our Wichita-based facility is equipped to handle the entire lifecycle of composite components, from conceptual design and certification to high-volume production, serving diverse industries with turnkey solutions.
Drawing on decades of expertise rooted in NIAR, Fiber Dynamics employs proven methodologies to deliver superior quality, innovative, and cost-effective solutions. Our pioneering Thermocore™ Lost Core Tooling System enables the creation of exceptionally complex parts, meeting the rigorous demands of aerospace applications.
Today, Fiber Dynamics designs, tests, and manufactures critical components for premier business jets, military aircraft, spacecraft, Advanced Air Mobility, and beyond. Discover more at fiberdynamics.net.
