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Since 1923, Bally Ribbon Mills (BRM) has designed, developed and manufactured woven webbing, tapes and specialty fabrics for the aerospace, defense, medical and automotive industries. In 1991, to meet growing demand in the composites industry, the Bally, Pa.-based company began accelerating its work with carbon fiber, creating woven preforms and 2D and 3D structural fabrics made from or incorporating this material. Fueled by its “superior strength-to-weight ratio,” demand for carbon fiber has only increased since its introduction to the composites industry, says Mark Harries, president of BRM.
Carbon fiber has several other characteristics that make it appealing to manufacturers and consumers. For example, its high stiffness makes it less likely to bend or distort, better maintaining its shape or form. It is extremely lightweight yet durable and resistant to environmental stressors, corrosion and fatigue, resulting in longer-lasting products and cost savings. Its versatility is also valued; the fiber can be woven into textiles, molded into shapes or coated/combined with resins to create composites.
“Two main carbon fiber properties are the tow size and modulus,” Harries explains. “The modulus is a property of strength, and tow size is a measure of how big the fiber is related to filament count. Because of its weight and strength, aerospace applications are an ideal fit. However, we continuously seek out new areas where we think carbon fiber will be beneficial, including defense, space, industrial, medical and recreational.”
While carbon fiber excels in certain applications and projects, it also has its cons.
“But it is costly and can be challenging to weave,” Harries continues. “Carbon fiber is also brittle and requires careful handling in order not to damage the fibers. Like all fibers, there is a learning curve on how to work with and weave carbon fiber.”
Expanding the frontiers
The University of Maine Advanced Structures and Composites Center (ASCC) has also been working with carbon fiber for several years. The center’s research areas include additive manufacturing, material development, civil infrastructure
and national security.
The center has conducted research in partnership with the U.S. Army several times. The ASCC and the U.S. Army Natick Soldier Systems Center have been collaborating since 2006 to develop war fighter protection systems, including the modular ballistic protection system (MBPS). In 2020, the ASCC was awarded $3.2 million from Natick to enhance the system, and it has since been renamed to the Expeditionary Shelter Protection System.
The ASCC recently opened the Fiber and Specialty Textile Research (FASTR) lab, which also works with Natick. The lab has received funding from the U.S. Department of Defense to research and develop complex fibers and 2D and 3D knit and woven goods designed to enhance soldier safety.
“[The lab] focuses on advancing the field by integrating cutting-edge fibers and textiles with advanced manufacturing,” says Lynn Wagner, senior textile research manager at ASCC. “Its goal is to drive innovation across critical sectors such as aerospace, national security and high-performance industries. At its core, the lab is committed to expanding the frontiers of specialty textile research and manufacturing.”
This research includes incorporating electromagnetic interference properties into smart textiles; novel resins such as those with bio-based or biosynthetic fibers offering “unique performance characteristics” either on their own or in combination; and 3D jacquard woven carbon fiber products that can be used in place of steel for building joints or for various aerospace components, among other applications, says Wagner.
“The ASCC’s mission is pushing the boundaries of composite materials and manufacturing technologies, delivering innovative solutions for infrastructure, affordable housing, process automation and national security,” says Rolando Luna, engineer and project manager at ASCC.
The ASCC has also been working with the Maine Department of Transportation since 2007, testing the performance of carbon fiber composite strands on the Penobscot Narrows Bridge. The six carbon fiber composite strands replaced steel ones, and more composite strands are expected to be added in the future.
“The center plays a leading role in developing new industries that are reshaping the national innovation landscape,” says Luna. “These innovations position the center to drive technological advancement and support the state’s long-term goals for economic growth and industrial leadership.”
New possibilities
Carbon fiber’s versatility has led to increased interest in its possible applications, with customers seeking new ways to use the material.
According to Harries, BRM customers are exploring its use for “new resins, fiber replacement, robotics and additive manufacturing.”
Two of BRM’s carbon fiber products are the 3D woven composite structures and the woven thermal protection systems (TPS). The former is a multilayer textile fashioned using a continuous multidimensional technique. It can be fabricated into a “near-net shape,” enabling it, in some cases, to be directly inserted into a mold or tool, reducing post-processing steps, labor and materials, says Harries.
“The woven thermal protection systems protect aviation systems during flight, especially space exploration vehicles,” Harries says. “We have the ability to vary yarn type, density, thickness, width and resin type. Customers can tailor the [TPS] to each specific mission need.
“Both product types offer weight savings over traditional metals,” he continues. “In the aerospace market, this is a game-changer and allows for large savings in fuel where every ounce matters.”
Wagner says multiple industries, including construction and aerospace, have reached out to the FASTR lab, expressing interest in exploring new ways to integrate carbon fiber into 3D woven structures using the lab’s Optima 3D jacquard shuttle weaving loom.
At BRM, working with any new fiber has always expanded the company’s knowledge and expertise.
“Carbon fiber was no different,” Harries says. “Learning to weave with the fiber taught us skills that are still in use today and across more than just the composites market. We also added another processing step in our production and started to infuse our parts with resin.”
Pamela Mills-Senn is a freelance writer based in Seal Beach, Calif.
SIDEBAR: Advancing warfighting technology
Research at the University of Maine Advanced Structures and Composites Center (ASCC) focuses on “advancing next-generation materials and manufacturing technologies” through various research efforts and projects, says Rolando Luna, engineer and project manager. Included among these was the modular ballistic protection system (MBPS), designed in partnership with the U.S. Army Natick Soldier Systems Center in 2006.
The MBPS consists of panels fabricated from ceramic and high-performance fiber-reinforced composite materials, says Luna. Lightweight, reusable and rapidly deployable, it protects troops, structures and equipment, offering an alternative to heavier materials such as sandbags and concrete barriers.
“Requiring no tools for installation, the system can up-armor a standard 20-by-32-foot tent in under 30 minutes with a four-person team,” Luna explains. “Each panel includes mounting and carrying holes at the ends, allowing them to be connected to one another or secured
to the structure or asset being protected.”
Following the development of the protection system, two companies were created—Compotech Inc., a defense technology company, and Advanced Infrastructure Technologies (AIT). Compotech manufactures ballistic panels and shelters developed at the ASCC, and AIT manufactures composite bridges developed by the center. Compotech and the ASCC later rebranded the MBPS to the Expeditionary Shelter Protection System.
“This innovation has been deployed across multiple military installations and is now recognized as a program of record with the U.S. military,” Luna says. “The research conducted at the ASCC led to a groundbreaking technological advancement and spin-off company that was successfully transitioned towards defense applications.”