January 2025 Composites Blog
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January 16, 2025
Turning Carbon Dioxide into Carbon Nanotube 3D Printer Ink
A groundbreaking process developed by researchers at the University of Delaware and Washington University transforms carbon dioxide into high-performance composite materials using carbon nanotube-based 3D printer ink. This innovative method not only addresses rising demand for lightweight, durable materials but also significantly reduces carbon emissions.
The process, led by Kelvin Fu and Feng Jiao, begins by using electrolysis to convert carbon dioxide into carbon monoxide. The carbon monoxide is then fed into a thermochemical reactor, where a steel wool catalyst transforms it into carbon nanotubes. These nanotubes form the basis of a 3D printing ink used to produce thermoset carbon nanocomposites, materials known for their exceptional strength, thermal stability, and lightweight properties.
One of the most impressive aspects of the process is its efficiency: the final nanocomposite contains 38% carbon nanotubes by weight, maximizing carbon dioxide utilization. This innovation also slashes carbon nanotube production costs by 90% compared to traditional fossil fuel-based methods, making the technology economically viable at scale.
Carbon nanocomposites hold immense promise as a superior alternative to metals like aluminum and titanium in transportation and construction applications. Their strength and lightweight nature make them ideal for reducing energy consumption in vehicles and enhancing durability in building materials.
“With the growing demand for carbon nanocomposites, this process can play a critical role in global carbon emission reduction efforts,” the researchers emphasized. By converting a greenhouse gas into cutting-edge materials, this technology exemplifies a sustainable approach to innovation and industrial development. Learn more here.
The process, led by Kelvin Fu and Feng Jiao, begins by using electrolysis to convert carbon dioxide into carbon monoxide. The carbon monoxide is then fed into a thermochemical reactor, where a steel wool catalyst transforms it into carbon nanotubes. These nanotubes form the basis of a 3D printing ink used to produce thermoset carbon nanocomposites, materials known for their exceptional strength, thermal stability, and lightweight properties.
One of the most impressive aspects of the process is its efficiency: the final nanocomposite contains 38% carbon nanotubes by weight, maximizing carbon dioxide utilization. This innovation also slashes carbon nanotube production costs by 90% compared to traditional fossil fuel-based methods, making the technology economically viable at scale.
Carbon nanocomposites hold immense promise as a superior alternative to metals like aluminum and titanium in transportation and construction applications. Their strength and lightweight nature make them ideal for reducing energy consumption in vehicles and enhancing durability in building materials.
“With the growing demand for carbon nanocomposites, this process can play a critical role in global carbon emission reduction efforts,” the researchers emphasized. By converting a greenhouse gas into cutting-edge materials, this technology exemplifies a sustainable approach to innovation and industrial development. Learn more here.
January 31, 2024
Breakthrough: Fully Automated Deposition System for Composites Preforming
Breakthrough: Fully Automated Deposition System for Composites Preforming
Loop Technology, based in Dorchester, U.K., has introduced the FibreLine system, a groundbreaking automation solution for composite aerostructures manufacturing. Designed to streamline the preforming process, FibreLine significantly increases material deposition rates, making it ideal for producing components like aircraft wings and fuselage sections.
This innovation was recognized at the prestigious JEC Composites Innovation Awards 2025, where FibreLine won in the “Aerospace – Process” category. Managing Director Alun Reece, joined by Marketing Director Samantha Reece and Technical Sales Manager Matt Hardman, accepted the award in Paris. Reflecting on the achievement, Alun Reece remarked, “It’s been quite a journey. We’re conscious that any development starts as an acorn and aims to be an oak.”
The FibreLine system integrates cutting-edge technology developed with partners Gudel, Zünd, FANUC, and the National Composites Centre (NCC). Its suite of end effectors automates every stage of preforming: cutting, sorting, sequencing, and depositing carbon fiber or other materials with precision and speed. Key components, such as FibreForm and FibreRoll, handle large plies with unparalleled efficiency—achieving deposition rates up to 350 kg/hr during trials. Advanced scanning via FibreEye ensures defect-free results.
Beyond high deposition rates, FibreLine reduces factory footprints and enhances assembly efficiency, offering transformative benefits to manufacturers. Learn more about this topic here.
This innovation was recognized at the prestigious JEC Composites Innovation Awards 2025, where FibreLine won in the “Aerospace – Process” category. Managing Director Alun Reece, joined by Marketing Director Samantha Reece and Technical Sales Manager Matt Hardman, accepted the award in Paris. Reflecting on the achievement, Alun Reece remarked, “It’s been quite a journey. We’re conscious that any development starts as an acorn and aims to be an oak.”
The FibreLine system integrates cutting-edge technology developed with partners Gudel, Zünd, FANUC, and the National Composites Centre (NCC). Its suite of end effectors automates every stage of preforming: cutting, sorting, sequencing, and depositing carbon fiber or other materials with precision and speed. Key components, such as FibreForm and FibreRoll, handle large plies with unparalleled efficiency—achieving deposition rates up to 350 kg/hr during trials. Advanced scanning via FibreEye ensures defect-free results.
Beyond high deposition rates, FibreLine reduces factory footprints and enhances assembly efficiency, offering transformative benefits to manufacturers. Learn more about this topic here.