A novel manufacturing process to make complex components such as aircraft windows and engine casings has been designed and successfully tested at the Bernal Institute Composite Materials Lab.

This manufacturing technique can

  • eliminate defects in composite components;
  • eliminate the problem with manufacturing complex composite components;
  • enable the production of lighter parts with no reduction in strength.

The process will have a positive impact on the environment and our lifestyles as it will result in lighter aircraft, a reduction in carbon emissions and an increase in the distance aircraft can fly – so less stops for refuelling!

The project is funded by Science Foundation Ireland.    The findings are published in Materials and Design, In-line variable spreading of carbon fibre/thermoplastic pre-preg tapes for application in automatic tape placement