JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 24

PROCESSING engineering

24

Continual development
of fibre laying technology
Established in 1995, CompoTech's production, design engineering and R&D
facilities are located in Sušice in the
south west of the Czech Republic. The
company now has over 50 employees,
including more than 20 technical roles
in research and development, design
and production engineering. Key investments were made in recent years
to provide 6-axis fibre placement and
in-house rapid tool making capabilities
using 3D printing.
Since then, the highly technical team
has designed, manufactured and supplied a wide variety of lightweight,
vibration-damped carbon fibre (CF)
epoxy composite cylindrical and rectangular beams. All parts are made using a wet, two-part epoxy resin system
cured in two stages, first in a hot box at
50°C and then in an oven.
The company's original success was
founded on the development of its
own axial fibre layup using "pin" winding automated production technologies. The performance benefits are that
a carbon epoxy beam produced with
true 0 degree fibres in tension has 10
to 15% higher stiffness in the axial direction and up to 50% greater bending
strength compared to using conventional filament winding techniques.
By combining both ILT and axial fibre placement processes, CompoTech
can cost effectively produce high-performance complex-shaped thin- or
thick-walled FRP epoxy composite
parts with three-dimensional continuous fibre reinforcement. The adapted
filament winding technique can place
a continuous axial direction along the
length of a component. The loop technology is used to accurately place fibres
at the beam ends to create fully-integrated joint connections.

use. Successful applications include:
industrial machine tool beams; drive
shafts; automated automotive press
line booms and crossbars; crop sprayer booms; aerospace structures; yacht
masts and spars; and recently bike
frame components.

CompoTech's CF epoxy components
typically replace conventional steel and
aluminium, providing a range of vibration, deflection, distortion, speed, productivity and energy-saving benefits in

Fig. 1: Comparison of
standard versus integrated loop technology
(ILT) production - CF
epoxy composite threerung ladder section
process steps data

Joint production capabilities
ILT production processes can manufacture a single large hollow integrated
loop end joint or multiple individual
loops to accommodate specific fixings
and fastener systems. Both joining
design options are manufactured as
a seamless, integral part of the main
carbon fibre epoxy tube sub-assembly
tubular section. Rigorous ISO 9001
quality control accredited systems and
checks are in place throughout the design and production process to ensure
repeatability and the reliable provision
of the required performance properties
in each part.
Integrated loop joints are typically
formed around a metal tooling mandrel. Inserts, such as a metal sleeve,
can also be incorporated inside the
looped joint section during production. Continuous wet epoxy resin-impregnated carbon fibres are accurately placed and directional wound in
orientations to provide the required
stiffness, compression, flexural and
torsional forces. Once individual components have been fully cured, they are
ready to be assembled. The advantage

The new integrated loop manufacturing capability is the company's latest
continuous fibre placement automated
processing innovation for advanced
composites. Its proven "hybrid" automated fibre layup (AFL) processing
technologies were taken to the next level by incorporating clever 3D-printed
custom-made fibre pin tooling to create a fully-integrated joint hole with no
breaks in the carbon fibres. The ILT
process eliminates the need for moulding heavier wall thickness sections
around a fixture area and for any postmould drilling. It opens up new design
options and offers product manufacturers a more cost-effective way to take
advantage of the application benefits
from using high-performance, lightweight tubular FRP composite components.

Total no. of assembly Total no. of production Total production time
parts needed
operations
(hr.)
Standard

6

8

13.2

ILT

3

5

8

	 jec composites magazine / November 2020 / SPECIAL ISSUE Sports, Health & Leisure



JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020

Cover
Edito
Contents
TRENDS
Business - Sports and health: a wealth of opportunities for composites
e-Bike - Uncertainties over Chinese supply chains put pressure on electric bike producers
Opportunities - The Gaming industry asks composites players: are you ready?
PROCESSING
Characterization - Bamboo versus maple from a skateboard manufacturer’s viewpoint
Engineering lntegrated loop technology provides new high strength joints for carbon fibre composites
Additive manufacturing - Disrupting the composite tooling supply chain
Biocomposites - Changing the outdoor hardware industry
APPLICATION
Climbing - A mountain in the middle of the city
Acoustic - The sound of composite violins investigated
Loudspeakers - Best sound in the world
Jewellery - Shine bright like a composite
Travel - Carbon fibre composites give luggage a leg up
Watersports - Closed-loop recycling of epoxy composites
Running shoes - Composites make their own mark in China
Sprinting shoes - Future of sprinting: spikeless CFRTP sprinting shoe
Medical - Advanced composite materials for prosthetic sockets in developing countries
Prostheses - A new way to make prostheses and orthoses
Paralympics - ‘‘The company’s objective is to design a future full of choices”
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Cover
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 2
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Edito
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 4
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 5
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Contents
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Business - Sports and health: a wealth of opportunities for composites
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 8
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 9
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 10
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - e-Bike - Uncertainties over Chinese supply chains put pressure on electric bike producers
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 12
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 13
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Opportunities - The Gaming industry asks composites players: are you ready?
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 15
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 16
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 17
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 18
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 19
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 20
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Characterization - Bamboo versus maple from a skateboard manufacturer’s viewpoint
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 22
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Engineering lntegrated loop technology provides new high strength joints for carbon fibre composites
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 24
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 25
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 26
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Additive manufacturing - Disrupting the composite tooling supply chain
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 28
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 29
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Biocomposites - Changing the outdoor hardware industry
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 31
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Climbing - A mountain in the middle of the city
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 33
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Acoustic - The sound of composite violins investigated
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 35
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 36
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 37
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 38
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 39
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 40
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Loudspeakers - Best sound in the world
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 42
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Jewellery - Shine bright like a composite
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 44
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Travel - Carbon fibre composites give luggage a leg up
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 46
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Watersports - Closed-loop recycling of epoxy composites
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 48
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 49
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Running shoes - Composites make their own mark in China
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 51
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Sprinting shoes - Future of sprinting: spikeless CFRTP sprinting shoe
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 53
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 54
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Medical - Advanced composite materials for prosthetic sockets in developing countries
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 56
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 57
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 58
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 59
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 60
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 61
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Prostheses - A new way to make prostheses and orthoses
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 63
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - Paralympics - ‘‘The company’s objective is to design a future full of choices”
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 65
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 66
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 67
JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 68
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