1 / 6

How to Improve Quality Control in Advanced Composites Manufacturing

In todayu2019s fast-paced world, where innovation and precision walk hand in hand, advanced composites manufacturing is at the forefront of industries like aerospace, automotive, defence, and renewable energy. With increasing demand for lighter, stronger, and more durable materials, manufacturers face immense pressure to ensure consistent quality u2014 right from raw materials to the final composite product.

Download Presentation

How to Improve Quality Control in Advanced Composites Manufacturing

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. How to Improve Quality Control in Advanced Composites Manufacturing In today’s fast-paced world, where innovation and precision walk hand in hand, advanced composites manufacturing is at the forefront of industries like aerospace, automotive, defence, and renewable energy. With increasing demand for lighter, stronger, and more durable materials, manufacturers face immense pressure to ensure consistent quality — right from raw materials to the final composite product. But quality in composite manufacturing isn't just about appearance or meeting a few mechanical specs. It involves rigorous control over processes, materials, and environmental conditions to avoid failures that could lead to expensive rework or even catastrophic product failure. Let’s dive into how manufacturers can actually improve quality control in advanced composites manufacturing without breaking the bank or overhauling their entire setup.

  2. Why Quality Control Matters in Advanced Composites Manufacturing Before we talk solutions, let’s understand the why. Composites, by nature, are layered materials made from different components — typically fibres and resin — that must come together in harmony. A small inconsistency during curing, layup, or bonding can compromise structural integrity. Here’s what poor quality control might lead to: Delamination Voids or porosity Uneven curing Low strength-to-weight ratio Shortened product life In critical sectors like aviation or defence, even a minor flaw in the composite part could mean major safety risks. So, getting it right the first time is not a luxury – it's a necessity. 1. Standardise Your Manufacturing Processes One of the most effective ways to maintain quality is through process standardisation. When every technician follows the same detailed process, the risk of human error drops drastically. Tips to Standardise Processes: Develop clear SOPs (Standard Operating Procedures) for each stage Implement digital work instructions to reduce ambiguity Use checklists at every quality gate to avoid missing critical steps Train all operators and supervisors on SOP adherence Consistency breeds quality, especially in composite layups and resin infusion techniques. 2. Invest in Skilled Manpower and Training In a process-driven sector like advanced composites manufacturing, machines may do the heavy lifting, but the role of skilled manpower cannot be overstated.

  3. Human oversight and expertise are often what determine whether a composite part is flawless or flawed. Here’s how to enhance quality through people: Provide regular hands-on training for technicians on new tools and techniques Organise workshops on defect detection and quality assessment Encourage a culture of ownership and responsibility in production teams Train QC staff in non-destructive testing (NDT) methods specific to composites An alert, well-trained operator can spot issues that even sensors might miss. 3. Use Automation Where It Makes Sense Automation is not about replacing people —it’s about reducing the chance of error in repetitive or precision-critical tasks. Advanced composites manufacturing now uses technologies like robotic layup systems, automated fibre placement (AFP), and CNC trimming, which increase both efficiency and repeatability. Automation helps quality control in several ways: Ensures precise resin-to-fibre ratios Reduces manual handling errors Provides uniform compaction and cure cycles Collects real-time production data for later analysis When paired with human supervision, automation can raise your overall quality benchmarks significantly. 4. Perform Real-Time Quality Monitoring Traditional quality checks at the end of a production batch are no longer enough. The focus has now shifted towards real-time quality monitoring using sensors and digital tools during production. Methods of Real-Time Monitoring: Thermal sensors during curing to ensure proper temperature profile

  4. Laser profilometers for dimensional accuracy Moisture sensors in storage to maintain resin integrity Use of IoT-connected systems for tracking environmental conditions By catching deviations as they happen, manufacturers can make immediate corrections, thus reducing scrap rates and rework time. 5. Non-Destructive Testing (NDT) Is a Game Changer In composites, internal defects aren’t always visible to the naked eye. That’s where non-destructive testing plays a key role in maintaining quality without damaging the product. Popular NDT Methods for Composites: Ultrasonic Testing (UT)– detects voids, delaminations X-ray or CT Scanning– finds internal cracks or fibre misalignment Thermography– identifies bonding and curing issues Acoustic Emission Testing– monitors structural integrity under load Investing in proper NDT equipment and training makes a huge difference in delivering consistent, defect-free products. 6. Control Raw Material Quality The quality of your composite product begins before manufacturing — with the raw materials. Poor-quality fibres or expired resins can instantly compromise the outcome. How to ensure raw material consistency: Maintain a qualified supplier list Do batch-wise testing of incoming resin and fibre Store materials in temperature-controlled environments Keep track of shelf life and expiry dates for prepregs Good input materials reduce half the quality risks at the start. 7. Document Everything

  5. Every defect tells a story. If your production and inspection steps are well- documented, you can trace back any failure to its root cause. What to document: Resin mix ratios and batch numbers Ambient temperature and humidity during layup Curing cycle temperatures and durations Operator shift logs and inspection reports This documentation not only helps in troubleshooting but also builds customer confidence— especially in aerospace and defence contracts. 8. Conduct Periodic Audits and Quality Reviews Having systems in place isn’t enough.Periodic audits ensure that your systems are actually being followed. These can be internal or even third-party assessments. Benefits of Regular Quality Audits: Identify process loopholes Validate operator compliance Benchmark your performance Identify areas for process improvement It’s also a great way tokeep your certifications valid, especially if you're operating under AS9100 or ISO standards. 9. Encourage a “Quality First” Culture No matter how robust your systems or how high-tech your tools, the biggest factor in ensuring quality is company culture. From top management to floor staff, everyone must buy into the idea that quality is non-negotiable. How to Build a Quality-First Culture: Celebrate zero-defect days Share success stories from the shop floor Provide incentives for quality improvements

  6. Conduct open discussions about production challenges When quality becomes part of your identity, errors reduce organically. Final Thoughts Improving quality control in advanced composites manufacturing is a continuous journey, not a one-time effort. With the right mix of technology, training, process optimisation, and cultural alignment, manufacturers can consistently produce reliable, high-performance composite parts that meet even the most stringent industry standards. At Datum Advanced Composites, quality is not just a checkpoint —it’s a mindset that shapes every layer, every fibre, and every detail of what we create. By embracing best practices in quality control, your manufacturing process doesn’t just meet the standard — it sets it.

More Related