Advanced Composites
Filament Winding

Filament winding is a highly automated process in which fiber roving (Carbon Fiber, Fiberglass, Kevlar®, etc.) is pulled from large spools through a resinous polymeric material, such as epoxy, and wound upon specially designed mandrels. For tubular structures, the mandrel is a cylinder made from either steel or aluminum and has a carefully machined outer diameter with a precision ground and polished surface to ensure easy extraction. The mandrel is then placed under tension in one of our filament winding machines. While the mandrel is spun, a carriage containing the fiber spools and resin matrix travels back and forth down the length of the mandrel. The epoxy fiber matrix is applied while the mandrel is spun at a precise rate to ensure proper winding. This process is automated and monitored by specifically designed computer winding programs which ensure that the composite material, now a series of laminate plies, is applied accurately in regards to fiber orientation and precise fiber to resin volume.

Once the composite material is applied, a special non-stick plastic film is wrapped under tension around the part. This film is applied to provide additional compaction to the composite, and is easily removed following the curing process. The mandrel is then placed in a computer-controlled oven in which special heating profiles harden the polymeric resin, solidifying the composite material. The mandrel is then pulled from the composite part using an extracting machine. A release agent applied to mandrels prior to winding aids in extraction. The part can then be machined, finished, and painted into its’ final form per customer specification.

Advanced Composites, Inc. has four long winding machines that can wind up to 30 feet in length and 48 inches in diameter. Filament wound composite tubes can reach ID tolerances of +/- 0.002” dependent on diameter and customer requirements. Additionally, ACI has a 4-axis fifth winding machine that is ideally suited for quick turnaround prototype runs up to 12 feet in length. All machines have state of the art computer controls to properly apply laminate layers to meet specific design criteria.

Please use the links below to see filament winding processes at ACI.