Syensqo and Bell Join Forces to Accelerate the Industrialization of Aerospace Composites

Advanced materials supplier Syensqo has partnered with aerospace and defense company Bell Textron to accelerate the industrialization process of composite materials. Bell is an early adopter of Syensqo's patented Double Diaphragm Forming (DDF) manufacturing process, which utilizes Syensqo's fast-curing aerospace prepreg Cycom EP 2750. This material is designed based on a toughened epoxy resin system specifically for high-speed, cost-effective composite manufacturing, suitable for compression molding of medium to small parts.

The Double Diaphragm Forming (DDF) method integrates the automation of dry fiber preforming, prepreg preforming, or compression molding into a single-step process. Image provided by Sika.

Single-step process

The Double Diaphragm Forming (DDF) method integrates the automation of dry fiber preforming, prepreg preforming, or compression molding into a single-step process, reducing the cycle time for part manufacturing. This technology also lowers labor costs and processing time because the two layers of diaphragms eliminate the need for tool preparation and cooling steps during the forming process. Furthermore, the diaphragm itself can serve as a protective layer for painting and bonding operations.

Accelerated Certification and Commercialization

Bell quickly completed the certification and industrial application of Double Diaphragm Forming (DDF) technology, achieving high-speed production of aerospace composite material parts. The application of this new process has brought numerous significant benefits, such as reducing operating costs, while also having a positive environmental impact by reducing waste, energy consumption, and greenhouse gas emissions. Additionally, the DDF technology eliminates the need for autoclave curing for small to medium-sized parts, making it applicable for the production of large parts. This technology supports the production of up to 50,000 structural components per year on a single production line.

Thirty years of partnership.

"For over thirty years, the collaboration between Hexcel and Bell has continuously brought innovative solutions, benefiting the composite materials industry," said Marc Doyle, Executive Vice President of Hexcel's Composite Materials business. "Hexcel's customer support model is based on a core belief: design, materials, and manufacturing are interconnected and are key to driving the widespread adoption of composite materials. Our team structure is designed to support this model, and collaboration with customers is the foundation for achieving a higher degree of industrialization in the composite materials industry."