What are the biggest challenges in manufacturing and assembling composite structures?

2 Manufacturing methods

Another challenge in manufacturing and assembling composite structures is selecting and applying the appropriate manufacturing methods that can produce high-quality and consistent products. There are many manufacturing methods available for composite materials, such as lay-up, filament winding, pultrusion, injection molding, and resin transfer molding. Each method has its own advantages and disadvantages, such as the degree of automation, the level of control, the waste generation, and the production rate. Structural engineers need to evaluate the suitability of each method for the type, shape, size, and complexity of the composite structure and ensure that the manufacturing process meets the design specifications and standards.

3 Joining techniques

A third challenge in manufacturing and assembling composite structures is finding and implementing the best joining techniques that can ensure the structural integrity, functionality, and aesthetics of the final product. Joining techniques for composite materials can be divided into two categories: mechanical and adhesive. Mechanical techniques include fasteners, bolts, rivets, and clips, while adhesive techniques include epoxy, polyurethane, and acrylic. Both categories have their pros and cons, such as the strength, stiffness, weight, cost, reliability, and maintenance. Structural engineers need to compare and contrast the different joining techniques and select the most suitable one for the composite structure and its application.

4 Testing and inspection

A fourth challenge in manufacturing and assembling composite structures is performing adequate testing and inspection to verify the quality, performance, and safety of the product. Testing and inspection for composite materials can be done at different stages of the manufacturing and assembly process, such as the raw materials, the intermediate products, and the final product. Testing and inspection methods can be either destructive or non-destructive, depending on the purpose and the scope of the evaluation. Destructive methods include tensile, compression, bending, and fatigue tests, while non-destructive methods include ultrasonic, radiographic, acoustic emission, and thermal imaging. Structural engineers need to choose and apply the most effective and efficient testing and inspection methods for the composite structure and its service conditions.

5 Repair and maintenance

A fifth challenge in manufacturing and assembling composite structures is ensuring the proper repair and maintenance of the product throughout its service life. Repair and maintenance for composite materials can be more complex and challenging than for conventional materials, due to the heterogeneity, anisotropy, and damage tolerance of the composites. Repair and maintenance methods can vary depending on the type, extent, and location of the damage, as well as the availability of the resources and the skills. Repair and maintenance methods can include patching, bonding, stitching, and bolting. Structural engineers need to assess the damage and determine the most appropriate and feasible repair and maintenance method for the composite structure and its functionality.