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Utilising 3D woven composite structures in place of traditional metal or 2D laminated composites can
provide cost savings through both the manufacturing process and a product’s operational lifetime,
according to Bally Ribbon Mills, an industry leader in the design, development, and manufacture of
highly specialised engineered woven fabrics.
“3D weaving of composite fabrics can produce complex, single-piece structures that are strong and
lightweight. Compared to traditional 2D fabrics, 3D weaving reduces weight, eliminates the
delamination often experienced with 2D fabrics, reduces crack risks, and lowers production time. 3D
fabrics also offer direct and indirect manufacturing and operational cost reductions,” said Mark
Harries, Marketing Executive, Bally Ribbon Mills.
In 1991, Bally Ribbon Mills (BRM) received a research contract from the United States Air Force
Research Laboratory that started the company on the path to developing the requisite technology for
3D weaving. The experience gained from researching and building the first fully automated 3D bias
loom, gave BRM the knowledge and experience to develop other 3D woven composites for the
aerospace, automotive, construction, military, and safety industries.
Benefits
“3D woven composites are drastically lighter than metal structures. This is particularly relevant to the
aerospace industry. Every pound of weight saved from an aircraft is estimated to save the aircraft’s
operator roughly US$ 1 million in operating expenses, primarily fuel, over that aircraft’s lifetime.
Smart utilisation of 3D woven composite structures in aircraft design can reduce the weight of an
aircraft by up to 30 percent, resulting in considerable operational cost savings,” continued Harries.
Delamination occurs when two or more layers of a 2D woven composite come apart, or delaminate,
from each other. “3D weaving can produce near-net-shape composite structures that are fully
interconnected by their yarn, as opposed to 2D composites which include a number of different
layers of materials artificially bonded together. This means there is no risk of delamination in 3D
woven composites,” added Harries.
“Utilising 3D woven composite structures in place of traditional metal or 2D laminated composites
can provide cost savings through both the manufacturing process and the product’s operational
lifetime. Automated 3D weaving technology and near net shape capabilities reduce direct labour and
secondary machining costs,” commented Harries. “Indirect cost savings result from operational cost
savings, for example reduced fuel.”
https://www.insidecomposites.com/saving-costs-with-3d-woven-composites/
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