JEC COMPOSITES MAGAZINE - Special Issue Composites for Sports, Health & Leisure - November 2020 - 25

lntegrated loop technology provides new high strength joints for carbon fibre composites

Fig. 4: CompoTech's CDURO development
mountain bike frame sub-assembly ILT parts
Fig. 2: Integrated
loop technology (ILT)
production dog bone
test coupon

Fig. 3 (a) and (b): ILT
epoxy carbon tactical
ladder

of ILT parts is that fewer assembly
parts and production operations are
needed. Sub-assembly components
can be positioned and rapidly bonded
together by applying a suitable twopart epoxy structural adhesive to the
integrated loop contact area. The final
bonded ILT joint provides superior
performance.
Oval, round and tapered epoxy carbon composite tubes in one piece up
to 12m long and with a diameter of
up to 2m can be produced with integrated loop joints at one or both ends
as required. The 3D-printed custom
tooling and process programming
used by CompoTech can create beam
end junction designs with a specified
length, diameter and laminate wall
length thickness. Currently, angle capabilities for integrated loop joints of between 60°- 90° can be produced. Trials
are ongoing to achieve more acute angles down to 45°.
Production benefits
The production benefits of the ILT
process are significant when compared
with the standard process steps and
methodology typically used to join
tubular FRP composite sub-assembly

components. Instead of machining
and adding fixings, ILT components
are simply bonded into place. By using
ILT-designed parts, bills of materials
(BOMs) can be reduced and costly,
time-consuming CNC machining and
assembly steps can be avoided, which
boosts productivity and lowers direct
production costs.
This was clearly demonstrated by
CompoTech in the comparative production trials to manufacture a very
lightweight carbon epoxy high-performance tactical ladder used by emergency services, law enforcement or
military personnel. The company's
integrated loop technology is ideal for
producing "dog bone" design rungs for
the modular ladder with an ILT joint
at both ends. For a three-rung ladder
section, they were able to eliminate the
need for a reinforcer and insert part at
each end, halving the number of assembly parts needed and saving both
cost and weight. Critically, the automated ILT process reduced the total
production time by 39% to only eight
hours by making it possible to cut out
a turning, second milling and third assembly operation (see Figure 1).

The epoxy carbon fibre tactical ladder with ILT rung joints is a modular
design. Essential specification features for the military ladder included
needing to be as light as possible, very
high strength, transportable in short
sections and quick to assemble and
dismantle in the field. Dog bone design
ILT coupons, tested during the development phase in conjunction with the
Czech Technical University (CTU),
were produced by CompoTech as
part of the new product development
process. An indicative test of the
load-bearing capabilities and end-use
performance was rigorously carried
out by military personnel in extreme
conditions.
Another ongoing in-house ILT project
also showing significant production
benefits is the "enduro" mountain
bike prototype designed by Compo
Tech, providing a 50% reduction in
comparative assembly times, plus reducing overall frame weight and cost.
The project has demonstrated that
the same epoxy carbon bike frame
manufactured using ILT joints can be
assembled in about half the time compared to conventionally producing the
frame using standard-design sub-frame
joints.
ILT enduro bike frame
Mountain biking is very popular in the
area, being so close to the beautiful, but
challenging, Šumava mountain range,
also the venue in the Czech Republic
where European Enduro Series (EES)
international race events are held.
CompoTech's co-founder and R&D
director Ondřej Uher has a personal mission to use design engineering

SPECIAL ISSUE Sports, Health & Leisure / November 2020 /

jec composites magazine

25



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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