The quality of composites is assured through state-of-the-art testing methods, strict production controls and ongoing process improvements. For instance, Boeing inspects its carbon fiber composite wings for the 787 Dreamliner using ultrasonic testing to check for imperfections. Testing in this manner validates structural integrity, so no internal issues — such as separation between layers or cracks that would be detrimental to safety — exist. 53% of the company’s Dreamliner consists of composite materials and the company uses quality checks to reinforce industry standards as aerospace products must demonstrate a failure rating of 0.1% or less.
For example, in the automobile sector, Automaker Tesla uses reciprocal systems to improve quality control and minimize production time by 25%. Tesla’s application of composite materials in electric vehicles — where reducing weight is chronological — demands loftier bar.” By doing its production in a highly automated way, Tesla guarantees that each composite component — such as its lightweight body panels — are produced with specifications of durability and performance matching the efficiency of the cars and their ensured long service life.
SPC in composite industry Composite manufacturers also most likely implement SPC each time they have produced to keep producing the same. For instance, General Electric (GE) uses SPC to keep watch over its turbine blade manufacturing, spurring a 10% reduction in defects and an efficiency boost. Real-time tracking of this data means that no case is allowed for quality deviations, which is particularly essential for high-stress applications such as wind turbines.
Quality management systems (QMS), like ISO 9001, are crucial in ensuring high standards as well. For instance, Hexcel, one of the largest global suppliers of carbon fiber for industries such as aerospace, places great importance on these certifications, ensuring that all of its composite products conform to the strictest safety and performance specifications.
Also, their start of the line ingredients are paramount. Tier one manufacturers such as Toray Industries work closely with suppliers to ensure every batch of carbon fiber used is created to precise tensile strength and durability specifications. This focus on material quality guarantees reliable performance of the end composite product in the field, even in demanding situations.
One of the recent trends is sustainability in composite manufacturing. Composite manufacturer and others are experimenting with products made from recycled materials, but new and old materials need to have the same fiber strength and durability (and still allow soy or resins to work as they should). Not just be up to environmental standards, this method still keeps the end-result high-quality.
“The quality of a product is directly related to the quality of the process” — Ray Kroc, founder of McDonald’s Vendors within the composite space perform extensive testing, require stringent process controls and adapt to improvements in technology all in the name of quality and performance — all aspects of this principle in action.