LINGE Composite Consulting

Resilient 3D printing with composite material

Michael_Bondzio — Mon, 14 Nov 2022 16:02:39 +0000

3D printing opens up exciting new applications for us. Especially when composite materials are printed, whole new dimensions in stability, stiffness, heat resistance and durability emerge. There are many areas where such 3D printing is the solution we are looking for: A technology that is dynamically evolving We still consider 3D printing with composite material …

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(Metal) Lightweight Construction meets Aerospace

Michael_Bondzio — Fri, 22 Oct 2021 17:30:00 +0000

Leading aerospace engineers met at Schönhagen airfield in October 2021 for the conference “(Metal) Lightweight Construction Meets Aerospace”. In addition to numerous top-class speakers, I was also invited as a presenter – which immediately raises the question: Why actually? It’s about lightweight metal construction and not composites. The clear distinction between lightweight metal construction and …

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Mould making for composites: Difficulties solved systematically

Michael_Bondzio — Mon, 17 May 2021 16:56:17 +0000

Mould making for composite components is a fundamental field that is absolutely crucial for the success of projects. In mould making, problems are solved before they arise – or, on the contrary, numerous problems arise that show up in later production phases and often cost the company dearly. In the case I would like to …

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Avoidance of errors with manual rework processed

Martin Linge — Wed, 10 Mar 2021 19:15:00 +0000

It happens again and again that composite components in series production have to be reworked manually. In this case, it was a question of recesses in the core material for inserts for the subsequent screw connection of the components. Unfortunately, depending on the shape of the inserts, this cannot always be done during the layer …

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Faulty curvature and displacement of the core material in composite materials

Michael_Bondzio — Thu, 03 Dec 2020 07:49:02 +0000

One customer repeatedly experienced an increase in scrap during the production of components made of composite materials. The causes were bulges, displacements and gaps in the core material (see figure above). (The visible small wrinkles are not the subject of this article, I have already dealt with these in an earlier blog post on the …

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Why the precise cutting of the peel ply is so crucial for a successful component back

Martin Linge — Thu, 08 Oct 2020 06:46:05 +0000

Even if we are talking about the backs or B-sides of components – in many cases the optical demands are still high in practice. Difficulties are often caused by the development. The illustrated component was designed on CAD and there it had a perfect back side (Class A Surface) in the 3D model. Thickness tolerances …

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The different ways of thinking of departments when it comes to technical problems and solutions

Martin Linge — Fri, 04 Sep 2020 12:52:56 +0000

Do you know it? There are problems in production and the different departments involved, such as production, quality and development, are not getting the issue solved. In addition to the personal distance of the people involved, there is often also the physical distance. The consequence: responsibility is passed on in the circle of departments. I …

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Successful development of series components in composite

Martin Linge — Mon, 10 Aug 2020 11:54:50 +0000

If you want to bring a composite component to series production, some problems can arise. A good example of this is a component with Nomex® Honeycomb as core material, which is produced using autoclave technology. Nomex® Honeycomb is a wonderful core material with many advantages, but like all composite materials and processes, it requires practical …

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Avoidance of problems in the development and production of series components in composite

Martin Linge — Wed, 08 Jul 2020 06:17:19 +0000

A topic that I encounter again and again in my consulting work is the development of composite components and their subsequent production in series. Already during development, the course is set for possible problems in production, which then result in expensive reworking or rejects. An example is shown in the picture above: In this component, …

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Carbon Composite Optimization: Example of a quality improvement of visible carbon components

Martin Linge — Tue, 16 Jun 2020 13:52:16 +0000

A component with visible carbon optics had an optical problem due to unsightly distortion of the fabric. As a result, the fibre flow did not meet the customer’s high aesthetic requirements for a visible carbon surface. The task was to optimize the component and get it approved by the OEM. This was done in close …

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