Part 3
Carbon Fiber Applications
Carbon Fiber Trusses and Beams
Carbon fiber composites provide an alternative to conventional materials, such as steel or aluminum, for the construction of lightweight trusses and frame structures.
Element 6 Composites has developed three systems for designing and fabricating carbon fiber tubular structures: two optimized for high strength, robustness, and customization, and one for reduced weight and lower cost.
Square Carbon Fiber Tubes and Gussets
The first high strength, robust construction system utilizes rectangular and square tubes and gussets to connect them. The tubes range from as small as 3/4”x3/4” to 2”x4” and larger. In addition to overall dimensions, wall thicknesses, gusset geometries, and layup schedules can be customized to meet the needs of each application.
For example, uni-direction carbon fiber can be added to individual members to increase bending/axial stiffness and strength. Likewise, gusset thickness and geometry can be adjusted to ensure proper load transfer through the joints. NeiNastran composite FEA calculations can be used to optimize structures for minimum weight while maintaining the specified strength and stiffness requirements.
Modular Connectors and Roll Wrapped Carbon Fiber Tubes
DragonPlate now offers a full line of patented Modular Carbon Fiber Tube Connectors that make it very easy to build strong, robust structures with roll wrapped carbon fiber tubes.
The Modular connectors are typically bonded inside the end of tubes and connected to each other with bolts. Multiple tubes can be connected with a single bolt that can easily be removed for quick disassembly and reinstalled later.
Simple pinned joints allow infinite choices in attachment angles. Tubes can be attached to plates or other mounting brackets. Modular connectors with end threads allow easy attachment of hardware, sensors, cameras, etc. The connector is easily bonded into the tube with a patented joint design that is exceptionally strong.
Pultruded Round Tubes and Connectors Truss
An alternative lightweight, and cost-effective, carbon fiber construction method utilizes our patented connectors and pultruded carbon fiber tubes. This system provides a great deal of versatility to the structural designer, with infinite combinations of lengths and angles, and a wide array of attachment components.
In addition, the skills necessary for the construction of this type of structure are very easy to master. Element 6 Composites specializes in both design and fabrication; however, many of our customers have the in-house capability to assemble the final carbon fiber truss structures once we have worked together through the design and prototyping phases of development.
The Ultimate Guide to Carbon Fiber Design and Application
Carbon Fiber Structural Beams
Many applications from robots to load-bearing structures require customized carbon fiber structural beams. Element 6 Composites specializes in designing and fabricating custom carbon fiber structural beams for a wide array of industries and users.
Although these beams are typically more expensive than a similar metal component, the substantial weight savings that can be achieved through advanced composites often outweighs this upfront investment.
Carbon Fiber Truss Applications
The applications for lightweight carbon fiber trusses and beams are endless. Some examples include robotic support structures and end-effectors, replacements for cantilevered beams in high-speed or portable applications, scientific and meteorology applications, and unmanned vehicle frames.
If the application requires minimum weight, yet high stiffness and strength, carbon fiber trusses or beams may be a solution worth investigating.
Carbon Fiber Tactical Bridges and Ladders
Carbon fiber composites provide substantial advantages over conventional materials in the construction of advanced tactical carbon fiber ladders and bridges.
Element 6 Composites has worked with both the military and law enforcement to develop a wide range of patented lightweight tactical carbon fiber ladders, platforms, and bridges, ranging from extremely lightweight ladders to heavy-duty segmented ladder/bridges.
Carbon Fiber in Musical Instruments
In addition to industrial and military applications, the people at Element 6 Composites also have a strong interest in the application of carbon fiber composites to the field of music and acoustic resonance.
Element 6 has been privileged to work with some of the preeminent instrument builders and researchers, leading to the development of many unique applications for carbon fiber stringed instrument building.
Unmanned Vehicles
Element 6 Composites has worked with multiple companies to help develop and manufacture a variety of unmanned ground and air vehicles. Combining decades of experience in composites, structural design, and aerodynamics, Element 6 Composites supports customers in basic configuration design and analysis, component optimization, prototyping, and production manufacture.
With a history of projects ranging from military ground robotics to lighter than air vehicles to rigid wing and vertical takeoff and landing carbon fiber UAVs, we have both the expertise and facilities to support your project. Below are a few examples of unmanned vehicles and components Element 6 Composites has helped design and/or produce.
Automation and Robotics
Facilities incorporating industrial automation into their manufacturing processes continually strive to improve efficiency through increased speed and greater precision.
Often the most direct means to achieve these goals is reduced weight and increased stiffness of the robotics and in particular the robotic end effectors. Lightweight end effectors translate directly to increased speed on the production line, higher precision, reduced motor and actuator loads, and improved reliability.
Part 1Carbon Fiber
LEARN MOREPart 2Engineering
LEARN MORECarbon Fiber Specialists
