Mikrosam, Qarbon Aerospace and Toray join forces to advance aircraft composite

 
Mikrosam’s automated fibre placement machine

This innovative system is specifically designed to elevate Qarbon Aerospace’s R&T capabilities, enabling the production of high-performance thermoplastic composite parts with exceptional precision and efficiency. This technological advancement is poised to meet the evolving demands of the aircraft industry for faster rate of manufacturing lightweight and strong parts.

 

Key features of the AFP work cell

The Libra-series AFP machine offers a comprehensive solution for automated fibre placement, including:

• Multi-material AFP head: capable of processing thermoset, thermoplastic and dry-fibre UD prepreg tapes, ensuring versatility and flexibility in production.
• Advanced heating systems: integrated laser heating with multiple pyrometers and fast thermal camera for thermoplastic, and IR heating for thermoset prepregs, ensuring optimal material consolidation and quality.
• Quality Control System (QCS): real-time monitoring and reporting of production parameters for traceability and quality assurance, aligning with the aerospace industry’s stringent standards.
• MikroPlace software: offline programming and simulation tools for seamless part design and production planning, enhancing efficiency and reducing production time.
• Flexible upgrades: options for automated head exchange, tool rotation axis and compatibility with wider tapes (½”) for future scalability, ensuring the system remains adaptable to evolving R&D and manufacturing needs.
• Automatic head exchange system: allowing Qarbon to upgrade the AFP work cell in the future with additional AFP heads or end-effectors.

Meeting Qarbon Aerospace’s high standards

The AFP work cell was tailored to Qarbon Aerospace’s specific requirements, combining Mikrosam’s engineering expertise with industry-leading technology. Its scope of supply includes a multi-material AFP head, equipped with laser heating and compaction during the placement of the tows while maintaining constant tow tension to ensure precise material placement. The system’s ability to handle complex geometries, coupled with its closed-loop thermal control, ensures consistent quality and reduces material waste – critical factors for aerospace applications.

“We are thrilled to support Qarbon Aerospace with this advanced and versatile AFP solution to accommodate different manufacturing processes and materials,” said Vele Samak, vice president at Mikrosam. “Combined with Qarbon’s know-how in producing thermoplastic parts, we believe this addition will speed up parts development and open new markets.”

The installation of Mikrosam’s AFP work cell at Qarbon Aerospace marks a major milestone in the company’s effort to advance its composite manufacturing capabilities – particularly for thermoplastic technologies like induction welding and Helios™ ice protection.

The new system supports active R&T projects while positioning Qarbon to transition advanced thermoplastic processes into future production programs. It enables the fabrication of complex, high-performance composite structures and is a key part of Qarbon’s strategy to support evolving needs across both commercial and Department of Defence applications.

The AFP machine enhances precision and repeatability in thermoplastic processing, making it ideal for subcomponent fabrication and scaling new technologies. By pairing Mikrosam’s automation capabilities with Toray’s industry-leading thermoplastic materials, Qarbon is equipped to accelerate development timelines and reduce risk in future qualification efforts.

“This system is a strategic investment in our future,” said John Hannappel, research & technology manager at Qarbon Aerospace. “It not only advances our ability to develop and validate thermoplastic technologies but also strengthens our position to support future defence and commercial programs with scalable, high-performance solutions.”

Qarbon’s expanded capability reflects its commitment to innovation and collaboration with strategic partners, opening the door for new program opportunities across the aerospace sector.

Collaboration with Toray

Qarbon Aerospace has partnered with Toray, leveraging its high-quality composite materials to further enhance the performance and reliability of the aerospace components produced. This collaboration underscores the commitment to using the finest materials and advanced manufacturing technology to achieve superior mechanical properties and durability in thermoplastic aircraft parts.

Toray Cetex® thermoplastic prepregs and UD tapes feature unique resin distribution and highly consistent fibre alignment, making the material well-suited for large structural components while eliminating processing steps and minimising overall costs. It is offered in a wide range of fibre-resin combinations and meets aerospace OEM’s strict specifications.

 “We’re proud to continue supporting Qarbon Aerospace as their strategic material partner. The addition of the new AFP work cell marks an exciting step forward – enhancing Qarbon’s capabilities and positioning them for significant growth in the market,” says Steve Mead, chief operating officer of Toray. “We’re honoured that Toray’s advanced materials will contribute to the success of this pivotal program.”

Commitment to development of innovative thermoplastic aircraft parts

The successful integration of Mikrosam’s AFP work cell at Qarbon Aerospace, combined with Toray’s advanced materials, represents a significant step forward in the development of innovative thermoplastic aircraft parts. By combining cutting-edge AFP technology with high-quality materials, these companies are poised to revolutionise the aerospace industry’s manufacturing processes, ensuring faster production times, reduced waste and enhanced component performance.