February 2025 Composites Blog
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February 22, 2025
Pull-Wound Carbon Fiber Tubes Advance Vertical Takeoff Airship Technology
Exel Composites has partnered with FLYING WHALES to supply approximately 75 kilometers of pull-wound carbon fiber tubes for the LCA60T, the world’s largest airship. This innovative aircraft is designed to transport heavy cargo to remote areas while minimizing environmental impact.
Produced at Exel’s Joensuu facility in Finland, the tubes will be crafted from aeronautical-grade carbon fiber and epoxy resin using cutting-edge pull-winding technology. This method enhances structural integrity while maintaining a lightweight design—essential for aerospace applications. The precision of pull-winding ensures uniform quality, making it ideal for high-volume production in aviation.
This partnership builds on an R&D collaboration launched in 2024, where Exel helped develop and prototype the carbon fiber tubes. With this new agreement, the company will undergo rigorous qualification testing to meet strict aerospace standards before beginning deliveries in Q3 2025.
The LCA60T, a 200-meter-long helium-powered airship, is engineered to transport up to 60 tons of cargo while reducing reliance on traditional logistics infrastructure. The use of advanced carbon fiber composites strengthens the airship’s frame without adding unnecessary weight, improving both performance and efficiency.
“This project demonstrates our leadership in pull-winding technology and our ability to meet aerospace industry demands,” said Paul Sohlberg, CEO of Exel Composites. “We’re proud to support the future of sustainable air transport.”
By leveraging high-performance composites, Exel and FLYING WHALES are reshaping the future of aviation with a focus on efficiency, durability, and environmental responsibility. Learn more about this topic here.
Produced at Exel’s Joensuu facility in Finland, the tubes will be crafted from aeronautical-grade carbon fiber and epoxy resin using cutting-edge pull-winding technology. This method enhances structural integrity while maintaining a lightweight design—essential for aerospace applications. The precision of pull-winding ensures uniform quality, making it ideal for high-volume production in aviation.
This partnership builds on an R&D collaboration launched in 2024, where Exel helped develop and prototype the carbon fiber tubes. With this new agreement, the company will undergo rigorous qualification testing to meet strict aerospace standards before beginning deliveries in Q3 2025.
The LCA60T, a 200-meter-long helium-powered airship, is engineered to transport up to 60 tons of cargo while reducing reliance on traditional logistics infrastructure. The use of advanced carbon fiber composites strengthens the airship’s frame without adding unnecessary weight, improving both performance and efficiency.
“This project demonstrates our leadership in pull-winding technology and our ability to meet aerospace industry demands,” said Paul Sohlberg, CEO of Exel Composites. “We’re proud to support the future of sustainable air transport.”
By leveraging high-performance composites, Exel and FLYING WHALES are reshaping the future of aviation with a focus on efficiency, durability, and environmental responsibility. Learn more about this topic here.
