Filament Winding of CFRP shafts - AVANCO composites

The manufacturing process

Resin-soaked fibers form a strong bond

Filament winding is a process in which continuous fibers (usually glass or carbon fibers, but also aramid or kevlar fibers) are wound around a rotating core to create a structural part. The core can be as well rotationally symmetrical as rectangular or polygonal. The fibers are impregnated with resin to create a strong bonding between the fibers. As the core rotates, the filaments are deposited onto it. The combination of feed (feed eye) and rotation speed (core) describes the later winding angle and as well as the rigidity and strength of the structure created in this way in the three room axes. As soon as the filaments are completely applied to the core, the component produced is cured and then demolded.

Fibers

What material can be used?

A wide range of reinforcing fibers can be used in filament winding, depending on the specific requirements of the end product.
These requirements may include mechanical strength, stiffness, temperature resistance, and chemical resistance.

Carbon Fiber: Carbon fibers are known for their exceptional mechanical properties, including high tensile strength, stiffness, and low weight. These characteristics make them suitable for high-performance applications, particularly in: Aviation and Space, Defense, mobility and Marine. Various grades of carbon fiber are available, covering a broad spectrum of performance.
Glass Fiber: Glass fiber is the most commonly used material worldwide in filament winding due to its good strength and stiffness, low cost, ease of handling and processing. It is ideal for a wide range of general-purpose applications where, weight is not the decisive factor.
Aramid, Basalt, and Natural Fibers: These fibers are less commonly used but can be employed for specific applications: Aramid fibers (e.g. Kevlar) offer high impact resistance and are used where toughness is crucial. Basalt fibers provide good thermal and chemical resistance. Natural fibers are considered for sustainable and eco-friendly applications.

These materials can be processed along with many other semi-finished fiber products.
Additional or specialized fibers can be used upon request, tailored to meet unique performance or environmental requirements.

Resins

Mechanical strength and chemical resistance

The specific requirements of the end product are decisive for the choice of the resin system. Basically, resin systems are used that have good adhesion to the fibers and have high mechanical strength and chemical resistance.

The most common resin systems used in filament winding are:

Epoxy resin: Epoxy resins are one of the most common resin types for fiber composites. They offer high strength, rigidity and chemical resistance. However, epoxy resins can be brittle and are not as temperature resistant as other resin systems.
Polyurethane resin: Polyurethane resins offer high impact resistance and are more flexible than other resin systems. However, they are more susceptible to moisture ingress and have lower chemical resistance.
Polyester, polyvinylester and phenolic resins: are other resin systems that we work with and which can provide inherent benefits.

The choice of resin system depends on the end product requirements, including strength, stiffness, chemical resistance and temperature resistance.

AVANCO Composites can look back on decades of experience in the field of fiber winding. The majority of fiber composite products manufactured today and shipped to our customers are manufactured using the filament winding process. Like all other processes, the products manufactured in this way benefit from the high level of vertical integration and the possibility of customizing the products and adapting them to the application of our customers.

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