FILAMENT WOUND TUBES
Filament winding is a fabrication technique for creating composite material structures. The process involves winding filaments under varying amounts of tension over a male mould or mandrel. The mandrel rotates while a carriage moves horizontally, laying down fibers in the desired pattern. The most common filaments are carbon or glass fiber and are coated with synthetic resin as they are wound. Once the mandrel is completely covered to the desired thickness, the mandrel is placed in an oven to solidify (set) the resin. Once the resin has cured, the mandrel is removed, leaving the hollow final product.
Filament winding is well suited to automation, where the tension on the filaments can be carefully controlled. Filaments that are applied with high tension results in a final product with higher rigidity and strength; lower tension results in more flexibility. The orientation of the filaments can also be carefully controlled so that successive layers are plied or oriented differently from the previous layer. The angle at which the fiber is laid down will determine the properties of the final product. A high angle "hoop" will provide crush strength, while a lower angle pattern (known as a closed or helical) will provide greater tensile strength.
Advantages of Filament Winding Filament winding has many advantages in the process of creating hollow composite products.
- Weight – A key advantage to the filament winding process is that since all products are hollow and can be made without a permanent internal system, they are extremely light without sacrificing strength. Light products translate to lower costs to produce, transport, and ship.
- Design – Changes in the design and engineering process using different techniques in winding, curing, and material options allow for variations in flexibility, strength, and pressure holding capacities (hoop strength).
- Automation – Filament winding can be done in a high speed process using machines to quickly and accurately reproduce identical components. This process can include sophisticated machinery and software to create complex engineered non-circular composite materials. Since the process can be automated to a high degree, it is scalable and can allow for the precise mass production of highly complex components.
- Cost Effective – By using low cost materials and automation the cost to produce components is substantially reduced. The process involves less material, less labor, and less transportation costs than many other forms of component manufacturing methods.
The process of filament winding is widely used in composite manufacturing to create highly customized hollow core structures that have unique flexibility and strength characteristics. The process allows for the creation of these structures in a scalable, automated, and cost effective format.
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