Czech-based composites innovator CompoTech is reshaping the future of carbon fibre-reinforced polymer (CFRP) components through its proprietary zero-degree axial fibre placement technology, a departure from conventional filament winding. The breakthrough enables manufacturers to achieve unmatched strength-to-weight ratios, higher stiffness, and improved material efficiency across demanding applications, from high-speed automation and machine tools to bike frames and race yachts.

At the core of this innovation is CompoTech s Automated Fibre Laying (AFL) system, integrated with a 6-axis Fanuc robotic arm. Unlike traditional filament winding, which typically places axial fibres at angles no lower than 10 , CompoTech s system achieves true 0 fibre orientation using both PAN and ultra-high modulus pitch carbon fibres, significantly increasing bending stiffness and overall performance.

"Our automated system delivers production flexibility and the ability to precisely place delicate pitch fibres axially without damage," says Dr. Humphrey Carter, Head of Business Development at CompoTech. This enables the creation of stiffer, lighter, and higher-performance CFRP components than are achievable with standard winding methods.

Proven through multiple case studies, the technology yields measurable gains:

• Wind blade tip shafts show up to 50% higher bending strength when optimized for axial fibre placement.
• Pitch fibre tubes for automation exhibit 20% greater stiffness in bending compared to equivalent 10 axial configurations.

This performance leap has enabled the replacement of steel structural components with CFRP alternatives offering equivalent stiffness at only 25% of the weight, while also improving damping properties and reducing lifetime operational costs for machinery and equipment.

CompoTech s standard square beam range, featuring integrated design elements like foam cores and threaded inserts, highlights the power of this technology. The smallest profile (60mm x 60mm x 5mm) weighs 1.7 kg/m and achieves an axial modulus of 196 GPa. The largest beam (200mm x 200mm x 8mm) weighs just 4.19 kg/m yet matches tool steel s modulus of 210 GPa. The company s stiffest beam design reaches a modulus of 327 GPa, making it 69% stiffer than stainless steel (193 GPa) and 56% stiffer than tool steel (210 GPa).

All beams are produced using a robot-assisted wet layup and press moulding process, followed by a dual-stage curing method for dimensional precision and surface accuracy.

Industry leaders such as Bilsing Automation, EAGLE LASERS, and Kongsberg Precision Cutting Systems have adopted CompoTech's CFRP beams in place of aluminium or steel. The switch has yielded significant gains in efficiency, faster throughput, and energy savings across production lines.

Source: compotech.com