Australian manufacturer Sydney Composites is developing a rapid-cycle heat transfer moulding process designed to reduce composite production times and increase manufacturing output. Supported by the Australian Composites Manufacturing Cooperative Research Centre (ACM CRC), the 12-month project brings together Sydney Composites, aerodynamics specialist JKF Consultants, and machinery builder McMillan Engineering Group.
The proposed process could reduce production cycles from approximately four hours to 10 minutes, according to ACM CRC. The shorter cycle time could lower labour and energy requirements while reducing costs associated with production equipment and asset depreciation. ACM CRC CEO Luke Preston said the technology could increase Sydney Composites’ output by 400% to 650%.
The process combines multiple curing methods to accelerate the manufacture of composite components. For manufacturers working with carbon fibre-reinforced materials, reducing curing time can improve equipment utilisation and increase the number of components produced within a given period. It could also help address the labour demands associated with manual layup and the high operating costs faced by Australian manufacturers.
The project will begin with theoretical validation before moving to implementation and testing. The team aims to advance the technology from Technology Readiness Level 3 to TRL 7, progressing from proof of concept toward demonstration in an operational environment.
Initial testing will use a batch of 10 composite aerofoil car mirrors produced by Sydney Composites. The components will be evaluated against parts manufactured using conventional oven or autoclave curing, including comparisons of mechanical strength. This will help assess whether the accelerated process can deliver the required component performance alongside shorter production cycles.
Based in Wetherill Park, New South Wales, Sydney Composites manufactures carbon fibre components for motorsport, renewable energy, medical, and industrial applications. Founder and CEO Greg Kerba said the process could provide a new manufacturing capability for the Australian composites sector and help the company expand into additional markets.
Beyond automotive components, the technology could eventually support production in medical technology and renewable energy. Its commercial potential will depend on validation results, component performance, and the ability to transfer the process to different product geometries and production requirements.
The project targets a key constraint in composite manufacturing: balancing material performance with production speed and cost. If testing confirms the expected cycle-time reductions and mechanical properties, rapid-cycle heat transfer moulding could help Sydney Composites scale production while broadening the range of applications it can serve.
Source: Australian Manufacturing | News
