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  1. A Closer Look at the Types of Coating Materials

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    A Closer Look at the Types of Coating Materials

    Tex Tech Industries is a leading textile coating manufacturer that works with advanced polymer systems to customize different coating options. Our coatings enhance the properties of all types of fabric, improving their weldability, thermal protection, abrasion resistance, water resistance, air holding, antimicrobial protection, and more. We develop and patent high-tech coating technology—such as thermal protection systems for space vehicles at our cutting-edge research lab.

    Here we’ll review the different types of coating materials available from Tex Tech, along with their benefits and potential applications.

     

    Types of Coating Materials

    Textile coatings come in a variety of materials depending on what each application requires. The materials we offer at Tex Tech include:

    Silicone

    Silicone coatings add resistance to heat, flame, chemicals, abrasion, UV, and weather. Many products use silicone coatings, including thermal insulation, gaskets, automotive airbags, parachutes and protection from slag and weld spatter.

    Polyurethane

    Polyurethane coatings enhance abrasion resistance and durability. For this reason, it is often the final protective layer over other industrial primers. Polyurethane coatings often enable the materials to be welded using IR, RF and heat systems.

    PVC

    Polyvinyl chloride (PVC) is a versatile polymer coating that enhances the fabric’s resistance to chemicals, corrosion, pressure, and abrasion. Many industries utilize PVC-coated materials, including wastewater treatment, food processing, oil and gas, and pharmaceuticals.

    Acrylic

    Acrylic coatings dry quickly and have a high-gloss finish. They are especially ideal as primers promoting adhesion. Acrylic also offers superior corrosion resistance for textiles and fabrics.

    Phenolic

    Phenolic epoxy coatings improve corrosion resistance. However, it does not perform well with UV exposure, so most applications for epoxy are located in indoor facilities.

    Rubber

    Rubber coatings resist mechanical wear and tear as well as generally harsh environments. Coatings may consist of natural or synthetic rubbers, including nitrile, chloroprene, EPDM, and fluoroelastomer rubbers. The electronics, automotive, military, and medical industries rely on these types of coatings.

     

    Fabric Coatings and Lamination by Tex Tech

    Tex Tech provides advanced textile coating and lamination services for a variety of industries. Using our polymer coating systems, we enhance customer specific needs. Our coating equipment can apply aqueous, solvent, and 100% solid polymer coatings. In addition, we offer both single- and double-sided textile coatings for materials.

    To ensure the secure application of each coating, we utilize methods such as direct coating, reverse roll coating, immersion coating, and heat lamination. We also provide several analytical services, including differential scanning calorimetry and thermogravimetric analysis.

    With years of combined experience and resources, our team has a deep understanding of every fabric coating need. If you would like to learn more about our coating technologies and solutions, contact us today. To get started on a custom coating solution for your application, request a quote.

  2. Thermal Protection Systems and Materials

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    The term thermal protection system (TPS) refers to various materials applied externally to the outer structural skin on an orbiter to maintain acceptable temperatures, especially for the reentry phase of a mission. Materials used for a TPS are selected for their high-temperature stability and weight efficiency.

    Space vehicles that enter the earth’s atmosphere require thermal protection systems to protect them from aerodynamic heating. The TPS system used by space vehicles inhibits the conduction of heat on the interior of the vehicle by combining an underlying layer of thermal insulation with high-temperature resistant surface materials.

    Thermal Protection System Materials

    Friction with the atmosphere during re-entry produces extreme temperatures that require specialized shielding systems to protect space vehicles. In addition to heat, space vehicle thermal protection systems also shield systems and the airframe from the extremely cold conditions that occur during parts of orbit. A TPS is produced using the following materials:

    Reinforced Carbon Carbon (RCC)

    RCC is a strong all-carbon composite. It is light gray and able to withstand the aerodynamic forces of launch and re-entry, which reach up to 800 lbs per sq. ft.

    Felt Reusable Surface Insulation (FRSI)

    Felt Reusable Surface Insulation (FRSI) is a type of protective blanket material that shields orbiter surfaces from high temperatures. It protects surfaces from heat between 350 °F to 700 °F.

    Reusable Surface Insulation Tiles

    Space vehicle tiles come in two types: white for low-temperature applications, and black for high temperatures. High-temperature reusable surface insulation tiles utilize a black borosilicate glass coating that has an emittance value higher than 0.8. They protect areas of the vehicle which reach temperatures up to 2,300 °F.

    Low-temperature reusable insulation tiles are coated in a white substance that contains the necessary optical properties to maintain on-orbit temperatures. These low-temperature reusable insulation tiles are placed on vehicle areas that have the potential to reach a maximum of 1,200 °F.

    Tile Bonding

    The bonding agent that attaches tiles to the vehicle surface is a type of silicone adhesive. Silicones are an ideal bonding agent for these types of applications. They retain excellent bond strength during the high temperatures of re-entry and are also flexible at the low temperatures experienced during orbit.

    Legacy TPS Products

    Legacy materials are often difficult to source due to low volumes, and lack of demand for years, or even decades. Tex Tech is the only US company that has re-created these types of products to NASA specs to provide exceedingly well characterized materials that orbital vehicle designers can utilize with confidence.

    Infused Stabilized Ablative Insulation Felt

    Our system replaces a traditional single use cork TPS with a higher performance multi-use composite system that relies on a fiber reinforcing structure to increase the erosion resistance. Tex Tech produces low temperature ablative systems using felts that have been stabilized with a high char yield silicone. This silicone can also be customized further to meet low out-gas requirements when needed.

    Multi-layered Felt Hybrids (MLF)

    MLF takes the concept of MLI (Multi-Layered Insulation) and adapts it for use with needle-punched hybrid structures rather than laminated films. Carbonizing Assembly may be used to fabricate unique precursor structures for C/C or C/SiC. Within this assembly a non-woven felt is sandwiched between two or more woven fabric layers. Once converted to C/C or C/SiC, the assembly becomes a highly insulating composite with high thermal stability.

    Requirements of a Thermal Protection System

    The amount of pressure and aerodynamic heating that occurs during launch and re-entry varies according to vehicle type, shape, and trajectory. To provide adequate protection, the following requirements must be met for all thermal protection systems.

    • Heat load. Regulating the flow of heat into and out of the vehicle is the main role of thermal protection systems. In most situations, a TPS is designed around the aerodynamic heating during a vehicle’s re-entry into the Earth’s atmosphere. The TPS system must be able to withstand high temperatures without excessive degradation of material properties.
    • Mechanic loads. Extreme aerodynamic pressure, as well as in-plane inertial, dynamic, and acoustic loads, are all mechanical loads on the TPS. The TPS must withstand these loads without failure.
    • Deflection limits. The TPS shapes the vehicle’s aerodynamic profile. Surface deflections of the TPS need to be below a certain limit to maintain this aerodynamic profile and prevent local overheating and system failure.
    • Impact loads. The TPS can be subjected to many types of impact during installation, launch, flight, and landing. Having adequate impact resistance is an important requirement of a TPS.
    • Chemical deterioration. High surface temperatures during re-entry make the TPS susceptible to oxidation. It may also be altered during maintenance.
    • Low-cost operability. A TPS will require maintenance throughout its life, in addition to the initial fabrication and installation costs. A TPS should be easily replaceable or repairable as well as designed to withstand a certain amount of damage without requiring immediate repair.
    • Lightweight. Due to the large amount of space that a TPS occupies, it makes up a majority of the launch weight. To prevent the need for increased fuel requirements, a TPS must be as lightweight as possible.

    TPS Solutions from Tex Tech

    Tex Tech Industries is proud to be an industry leader in high-performance textile manufacturing. Since 1904, we have been delivering the highest quality products available for the most challenging applications. Our expert research and development team and state-of-the-art facilities allow us to provide the high-performance textile solutions the aerospace industry demands. For more information about our advanced TPS solutions or our other textile products and services, please contact us or request a quote today.

  3. CarbonX Breathable Aluminized: A Comfortable Solution for Superior Protection

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    Working in Extreme Environments

    Aluminum and copper furnaces run between 1500-1700 °F, and steel furnaces run at temperatures above 3000 °F! In these extreme conditions, the Personal Protective Equipment (PPE) used must shield workers from the potential metal splash of these insanely hot materials, and they must also protect against the staggering amount of radiant heat that is generated by the metal and furnaces. Ideally, you would also like to keep those same workers comfortable, allowing them to safely complete their strenuous tasks while working in such extreme conditions.

    How to Protect Against Molten Metal

    The most widely used fabrics for protection against molten metal utilize a thin aluminum laminate on their surfaces. The aluminum exterior reflects much of the radiant heat generated by the metal and/or furnace, allowing personnel to work in close proximity to these industrial heat sources. Aluminized fabrics are the standard components for this type of exposure.

    Our CarbonX FL-100A has been used for this very purpose for some time. CarbonX FL-100A is an aluminized fleeced knit that is lightweight and flexible, and therefore it is a relatively comfortable option for protection against metal splash. However, as with almost all other aluminized fabrics, the aluminum film used in laminating the outside of these fabrics is a solid layer, and therefore non-breathable.

    What Is CarbonX Breathable Aluminized?

    To create a more comfortable Aluminized Fabric, CarbonX Breathable Aluminized combines the level of protection one would expect in a CarbonX fabric while elevating the comfort aspects of the garment using two key factors: Moisture Wicking and Breathability.

    To create a moisture wicking substrate, we’ve combined a multi-layer non-woven felt as the base fabric used in this fabric. One layer includes a layer of hydrophobic fibers, the other layer includes a layer of hydrophilic fibers. The hydrophobic fibers do not like moisture, while the hydrophilic fibers love moisture. The hydrophilic fibers are placed in the layer away from the skin, and because of their orientation in relation to the hydrophobic fibers and the wearer, they pull the sweat and moisture away from the body and to the outside of the garment. (side note…we’ve even added a strengthening scrim layer between those two layers of fibers to keep the fabric strong and durable!)

    To give the garment breathability, we have used Tex Tech’s vast experience in needling technology to perforate the aluminum to create a breathability aspect to the aluminized surface. In simple terms, we’ve poked thousands of tiny holes in the surface of the fabric! When the moisture is wicked away from the body via the hydrophilic fibers it can then escape the holes on the surface of the aluminum. The airflow and the water evaporating after seeping through the holes as a dramatic cooling effect. The outdoor apparel industry has utilized this cooling process in soft-shell technology for jackets and coats for some time now, and now we are using the same method to keep our steel workers cool!

    With All Those Holes, Does it Still Protect?

    Of course it does!While the holes are small enough to allow air permeation, those holes are not large enough to significantly affect the level of radiant heat protection that the outer layer of aluminum provides.Likewise, when exposed to molten splash, the holes are small enough and the metal splash hot enough that the holes seal when hit with molten metal.The perforated fabrics still meet the ASTM F 955 standard, which is the “Standard Test Method for Evaluating Heat Transfer for Protective Clothing Upon Contact with Molten Substances.”

    The CarbonX Breathable Aluminized fabric provides an unmatched level of comfort in an aluminized garment using breathability and moisture wicking to add to CarbonX level protection!

  5. CarbonX® Launches Defender Masks to Address Industrial PPE Shortage

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    For workers who require protection from COVID-19 while working in dangerous areas with threats of fire or arc flash, the CarbonX® Defender Masks provide a safe solution for both.

    At Tex Tech Industries, we’ve added CarbonX® Defender Masks to our line of flame-resistant (FR) PPE to provide the protection industrial workers need. These masks are reusable, comfortable, washable, and offer superior protection against most common industrial hazards.

    The CarbonX® Defender Mask

    At CarbonX®, we strive to do our part to provide protection in applications where safety is of the utmost importance. Our FR Defender Masks are created from breathable, non-flammable CarbonX® fabric front covering backed with a non-woven filter made from polyester. All masks are customizable with your company logo. We offer two different mask varieties:

    CarbonX® Defender Mask 1

    The CarbonX® Defender Mask 1 offers the following features:

    • High breathability at 50 cfm
    • Captures 65% of particulates larger than 0.3 microns (±10%)
    • Three-layer construction: Two layers of non-flammable CarbonX® TK-60 knit (front and back covering) and a single layer of 6 oz polyester non-woven filter media (middle layer)
    • Machine washable, hand washing recommended with 3% hydrogen peroxide solution
    • Air drying recommended

    CarbonX® Defender Mask 2

    The CarbonX® Defender Mask 2 provides the following:

    • Breathability at 37 cfm
    • Captures 75% of particulates larger than 0.3 microns (±10%)
    • Three-layer construction: Single layer of non-flammable CarbonX® 6 oz non-woven (front covering), single layer of 6 oz polyester non-woven filter media (middle layer), single layer of 3.5 oz 100% hypoallergenic cotton (back covering)
    • NAFTA/USMCA compliant
    • Hand washable with 3% hydrogen peroxide solution
    • Air drying recommended

    For comparison purposes, the N95 mask offers 95% particulate filtration and breathability of 32 cfm. Of note, the Defender masks are designed for industrial and commercial use and are non-medical grade. The above statistics are the result of in-house testing by Tex Tech and have not yet been verified by an independent third-party.

    Wear and Care Instructions for CarbonX®
    FR Defender Masks

    While wearing a face mask may feel uncomfortable, your own health and the safety of others paramount. In an effort to ensure the proper and safe use of our protective masks, we’ve provided the following wear and care guidelines below.

    Wear Instructions:

    1. Make sure the mask covers your nose almost to the bridge. There is a moldable nosebar. Press it into shape over the bridge of your nose. This will be very helpful for glasses wearers, as it helps to prevent fogging of your lenses.
    2. Place the top elastic near the crown of your head and then tighten the toggle of the bottom elastic behind your neck. This should create a good amount of snugness. If you have long hair, a ponytail will also help with fit.
    3. Keep your mask on! This is important as it prevents contamination of your mask. Excessive handling of your mask increases risk of germ spread.

    Washing Instructions:

    1. Thoroughly spray both sides of the mask with a 3% hydrogen peroxide solution and hang to dry, OR
    2. Soak your mask in warm water and antibacterial soap or dish soap. Rinse well. Place between layers of a clean towel to remove excess water (DO NOT twist or wring), and hang to air dry.
    3. Store mask in an airtight resealable bag between uses. For best performance, limit hand washing of a mask to no more than 10 times, then discard and replace.

    Your mask has been carefully packed and does not need to be washed prior to wearing. The CarbonX® Defender Mask 1 is machine washable, but hand washing is recommended. DO NOT machine dry. DO NOT machine wash or dry the CarbonX® Defender Mask 2.

    Flame-Resistant Personal Protective Equipment From CarbonX® by Tex Tech

    At CarbonX®, we specialize in the fabrication of high-performance, flame-resistant PPE for use in even the harshest environments. CarbonX® products are designed not only for maximum protection, but maximum comfort. Our lightweight, flexible fabrics dry quickly and are soft to the touch, which is highly important for masks intended to be worn for long periods. We hope that our line of FR Defender Masks will help to keep industrial workers safe during this trying time.

    For more information about CarbonX® Defender Masks, please contact Adam Mitchell at amitchell@textechindustries.com. For more information about CarbonX® or our products and services, please contact us.

    Thomas Supplier

  6. Protecting Spacecraft Against Re-Entry Heating

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    As the aerospace industry evolves with a renewed focus on space travel, there is a growing need for innovation in the area of thermal protective systems (TPS). Even as older systems are refined for viability, new systems must be carefully designed to meet the demands of new atmospheres and multi-launch vehicles.

    Developing such new technologies is far from easy given that aerospace requirements are necessarily stringent. Complying with industry regulations often means identifying new manufacturing techniques that push beyond current capabilities to find solutions that are safer and more practical.

    As interest in space travel grows once more, Tex Tech is leading the push for customized hybrid TPS systems to protect vessels from re-entry heating.

    How to Prevent the Dangers of Re-Entry Heating

    Re-entry has always been one of the most challenging aspects of space flight. As an object falls through the earth’s atmosphere, it experiences intense friction. Compound that friction with a fast re-entry speed and a spacecraft can experience temperatures of >3,000° F as the air around it compresses into plasma. A TPS protects astronauts and internal equipment from these extreme temperatures.

    There is no single thermal protective system design that accounts for all flight variables, but all systems will include a lightweight heat shield that dissipates the heat while insulating the occupants. A well-designed TPS reflects most of the heat back into the atmosphere or sheds it away from the vehicle, preventing any damage to the interior of the craft.

    Advances in material science have led to the development of many different synthetic materials to perform this job, each varying in weight and temperature resistance capabilities. Selecting the best materials for a heat shield or TPS requires a careful evaluation of applicable heat zones, heat fluxes, and mechanical forces that will be present during re-entry.

    In most cases, a curated selection of multiple materials will be necessary since the forces experienced during re-entry are not uniform. The nose of the craft, for instance, experiences substantially more heat and pressure, so the material selected for that region must withstand higher temperatures.

    Types of TPS Materials

    Tex Tech specializes in the manufacture of flexible, graded TPS structures. For each project, we assess the performance requirements carefully to select an appropriate combination of TPS materials from the following:

    • Needle-punched felt
    • Woven fabrics
    • 3D woven/braided fabrics
    • 5D assemblies
    • Unidirectional tows reinforcement
    • Coatings
    • Lamination
    • Hybrid fabrics

    Custom Thermal Protective Systems by Tex Tech

    Tex Tech serves high quality coated and laminated products to a wide range of industries, including not only aerospace and defense clients, but also industrial and medical customers. Our expertise lies in performance coatings, applied in solvent, aqueous, or solid form using a variety of techniques:

    • Direct application (including knife-over-roll, knife-over-table, and knife-over-air)
    • Immersion (dip coating)
    • Reverse roll coating
    • Heat lamination
    • Adhesive lamination
    • Transfer coating

    Our diverse industry experience and broad manufacturing capabilities allow us to supply all varieties of cutting-edge materials, including those that align with rigorous aerospace requirements.

    For more comprehensive information about Tex Tech’s hybrid TPS technologies, download our “Aerospace and Thermal Protective Systems” eBook, or contact us with specific questions.

    Download the Aerospace and
    Thermal Protective Systems eBook

  7. How to Properly Transport Lithium Batteries

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    Laptops, smartphones, tablets, and many other electronic devices rely on lithium-ion batteries to as a power source. They’re one of the most popular choices for batteries because they’re lightweight compared to other same-size rechargeable batteries, they last longer than other competitive batteries, and they can be recharged many times.

    For all their benefits, however, lithium-ion batteries pose a major risk—they sometimes burst into flames. This only happens occasionally, with estimates averaging about three packs per million. Their sensitivity to heat also causes these batteries to degrade more quickly than other types. Degraded batteries are more likely to cause short-circuiting or fire. Though rare, these qualities make it very important to take extra consideration when transporting lithium batteries.

    Why Are Lithium Batteries Regulated in Transportation?

    Though incidents are rare, they’re quite dangerous when they do occur. Even more rare is thermal runaway, where high heat contributes to a chain reaction of chemical breakdowns in the battery that result in additional rapid temperature increases. Lithium batteries have a higher energy density than other types of batteries, so a thermal runaway can become very intense as that energy is released.

    As such, careful packaging and handling of lithium-ion batteries is essential. This is especially in transportation, where fires in confined spaces pose a higher risk to equipment, other cargo, or passengers.

    Air & Ground Transportation of Lithium Batteries

    Due to the high energy potential and fire hazard, the transportation of lithium batteries requires additional precautions. Like other hazardous materials, they may require special labeling or additional documentation that indicates they are compliant with regulations.

    These regulations are designed to help prevent a short-circuit or overheating event while the batteries are en route to their destination. The appropriate means of packaging batteries depends upon the type of battery, how much lithium it contains, and whether it’s already inside a piece of equipment.

    Here are some of the guidelines regarding the transportation of lithium-ion batteries:

    • Isolate batteries—don’t let them touch each other or metal surfaces.
    • Packaging should be made of plastic or another non-conductive material.
    • Maintain a cool environment.
    • Use layers for leak and fire protection, as well as durable outer packing.
    • Terminals and connectors should be capped or otherwise covered.
    • Pack and cushion securely to prevent bumping and jostling.

    Specific Requirements for Air Travel

    It’s permitted to put both non-rechargeable and rechargeable lithium batteries in your carry-on—as long as they contain less than the recommended amount of lithium. The lithium content in lithium metal and lithium-alloy batteries may be up to two grams; for lithium-ion batteries, that limit is eight grams. Batteries with up to 25 grams of lithium must be individually packed to be allowed in a carry-on, and you can carry no more than two of them.

    Specific Requirements for Shipping

    Whether you’re shipping lithium-ion batteries across the state or around the world, there are requirements for the transportation of lithium batteries by air, sea, or ground. A lithium content over eight grams per battery pack is considered a Class 9 miscellaneous hazardous material and must be labeled as such. If the pack contains less than that, no label is required unless the shipment contains more than 12 such packs.

    It is possible to consolidate several battery packs into one overpack—a strong outer box—but the outer packaging must be labeled. Within that overpack, each individual pack is required to carry the appropriate labeling, as well.

    These considerations are made with the assumption that the batteries are in ideal condition. A damaged, leaking or otherwise flawed battery is even more dangerous, which is why it’s essential to avoid shipping or traveling with damaged batteries. To that end, lithium-ion batteries are tested according to UN 3090 to ensure they’re in proper working condition before travel.

    Fire and thermal protection within the battery packaging offers another way to protect against battery-related fires. Fireproof materials like silica or Oxidized PAN provide an additional layer of fire protection.

    Fire and Thermal Protection Fabrics for Lithium Batteries

    At Tex Tech, we design non-woven Oxidized PAN felts that withstand temperatures around 2000° F. Our non-woven silica felts resist even higher temperatures. We manufacture these fibers specifically to block flame propagation and resist burn-through at temperatures much higher than what is typically generated by a standard thermal runaway. The weight of these materials begins at four ounces per square yard and goes up from there based on specific application needs and material combinations.

    Since 1904, Tex Tech has been manufacturing high-quality technical textiles. We operate at the cutting edge of the industry, where our dedicated team, constant innovation, and more than 7,000 products have made us a global leader in high-performance fabrics. From aerospace and automotive to protective apparel, we proudly serve a variety of industries.

    We’re happy to help you determine your flame resistant needs pertaining to lithium-ion batteries or other high temperature applications. For more information about our flame resistant materials or other products, please contact us.

  8. Advances in 3D Composite Fabrics

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    The need for strong, lightweight materials to fabricate parts and components in critical industries has led to rapid advancements in 3D weaving technology. This has enabled manufacturers to increasingly use composites in place of traditional metals and plastics.

    Composites based on 3D woven fabrics can often be used as lightweight alternatives to steel and aluminum without sacrificing strength or durability, making them ideal for aerospace, heavy industrial, marine, transportation, and myriad other applications.

    A wide variety of fibers can be used in 3D woven fabrics to produce advanced composites. Some of the fiber types commonly used in composites include:

    • Carbon
    • Glass
    • Polymers
    • Ceramics
    • Metals

    Industry Applications

    Numerous industries utilize advanced composites manufactured via 3D weaving, such as:

    Aerospace

    At Tex Tech, we are exploring a variety of solutions for the aerospace sector, including hybrid materials such as fabrics that include Kevlar, S-glass, or carbon. We’re also exploring the possibility of fabricating common preforms, such as I-shaped, H-shaped, and T-shaped preforms.

    Composites have also become integral in the fabrication of aerospace tooling. This tooling often has to undergo repetitive autoclaving, so it must be able to withstand repeated cycles of high temperatures. Composite tooling offers a more affordable means to produce tooling for high-volume production of aerospace parts and components when compared to more traditional metal tooling. Using the thicker, fast infusing 3D woven fabrics and preforms can both speed the manufacture of the tooling and make it tougher, more durable.

    Construction

    The construction sector has turned to composites as a means to provide strong structural support without the heavy weights or high corrosion risk of metals. Architects and designers, in particular, appreciate the versatility and reduced costs associated with composites for construction.

    Tex Tech offers pilings and 3D composite mats for use in the commercial construction market. We’re also working on developing composite I-beams, as well as C-shapes and various angles.

    Industrial

    The innate corrosion resistance of composites makes them an ideal material choice for many industries with harsh operating environments, such as chemical production, power generation, and oil and gas. These sectors and many others have turned to composite fibers for their longevity and superior performance under conditions that other materials simply can’t handle.

    Tex Tech currently offers composite solutions used in electric power generation, chemical tanks, water tanks, and fracking, among others. We’re always investigating new ways to use 3D fabric-based composites to replace steel or other metals in harsh operating environments, such as in cooling towers used in power generation.

    Infrastructure

    The United States is facing an infrastructure crisis, leading to demand for innovative and affordable new material options for components. Composites have gained particular traction in bridges, where composite wraps are frequently used for repair and refurbishment of existing structures. While the applications for 3D composite fabrics are still in development for infrastructure, there is much room for growth in this area.

    Transportation

    Across transportation vehicles and modes, one fact remains true: Lighter vehicles use less fuel. 3D composites have made their way into automobiles, buses, trains, and more as a means to decrease the weight of vehicles and improve fuel efficiency. For example, Tex Tech is currently exploring the possibility of creating 3D composite railcars and truck trailers to significantly reduce weight for commercial transportation applications.

    Marine

    The boat manufacturing sector relies on 3D composites as a means to fabricate marine components that can resist the corrosive effects of constant water exposure. The fast lay-up, higher strength, and toughness of composites based on 3D woven fabrics also makes them ideal for marine applications.

    At Tex Tech, we’ve served the marine industry with the development of a glass Z yarn/carbon hybrid ideal for tooling carbon boat hulls and other carbon parts.

    Benefits of 3D Weaving

    3D weaving technology enables manufacturers to produce materials and components that have:

    • Improved durability
    • Increased strength
    • Superior joining capabilities
    • No risk of delamination
    • Lower labor costs
    • Customizable thickness

    These fabrics are created using specially designed 3D looms. The resulting un-crimped yarn paths eliminate potential weaknesses in the 3D material, as tensile and compressive strengths may be compromised if the fibers are bent or damaged. Additionally, Z-fibers reinforce the fabric by binding it from top to bottom, increasing the ultimate toughness of the material.

    Multiple features may be implemented as required, as 3D fabric designs are highly customizable. For example, an item fabricated from 3D composites may offer increased shear strength in one section and axial stiffness elsewhere as required by the application.

    The Future of 3D Weaving Technology

    Material scientists continue to explore ways to develop 3D weaving technology and produce more advanced composites that can successfully replace traditional materials with stronger, lighter alternatives. 3D woven fabric has already found a permanent place as a lightweight alternative to metal in many critical industries.

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  9. New Research in 3D Woven Fabrics Reveals the Potential for Higher Performance Textiles

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    For over 100 years, Tex Tech Industries has committed itself to continuously developing and providing high-performance textiles that meet the requirements of complex and demanding industrial applications. As one of the world’s leading needle and woven fabric manufacturers, our research and development department is well-equipped with an advanced development facility, a drive for innovation, and a thirst for knowledge, which, combined, often result in breakthroughs in the technical textiles sector. For our expert team, the latter two qualities extend beyond the walls of our facility and confines of our products into broader research and development ventures, including international research collaborations focused on high-performance textiles.

    The Positive Potential of Through-thickness Fiber Orientation on Through-thickness Permeability

    3D Woven Fabrics

    In late October 2019, one of our Product Development Specialists—Keith Sharp, Ph.D.— co-authored research article[1] on the potential advantages of 3D woven fabrics (3D-WFs) with high through-thickness fiber content for structural applications. Completed with research partners David May, Björn Willenbacher, Jan Semar, and Peter Mitschang from the Institute for Composite Materials (IVW) in Germany, the study tackled the issues of high lay-up requirements and sensitivity to delamination when using 2D textile fabrics and the difficulty impregnating when using thicker traditional 3D woven fabrics. The team believed that by integrating through-thickness oriented fibers in 3D woven fabrics, they could achieve more promising results from through-thickness permeability tests.

    Testing the Theory

    To test their theory, they measured the permeability of several glass fiber textiles, four of which were 3D woven fabrics and two of which—a 2D non-crimp fabric and 2D woven fabric—served as benchmarks. These tests focused on calculating the relationship, if any, between the particular textile’s areal weight and number of layers to its permeability.

    Research Conclusions

    From their tests, the team came to a few key conclusions, including:

    • Across the board, all 3D woven fabrics tested demonstrated higher through-thickness permeability than both of the 2D benchmarks. Increases were on the order of 10 times as high.
    • An increase in the areal weight of the 3D woven fabrics results in an increase in the fabric’s through-thickness permeability.
    • The amount of through-thickness oriented fibers significantly influences areal weight and, consequently, through-thickness permeability.
    • There was no significant difference in permeability between the 3 layer and the 8 layer 3D woven fabric.
    • The above correlations remain true at increasing pressures.

    Altogether, these conclusions highlight the potential advantages of 3D woven fabrics and lay the framework for the future development of even higher performance textiles.

    To learn more about the potential advantages of using 3D woven fabrics with through-thickness oriented fibers, read the full article here.

     

    [1] D. May, B. Willenbach, J.Semar, K.Sharp, P. Mitschang, “Out-of-plane permeability of 3D-fabrics for composite structures”, The Journal of The Textile Institute pp 1-7; doi:10.1080/00405000.2019.1682759

  10. Improving Aviation Safety With High Performance Materials

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    Aviation safety has always been and will remain a top priority within the industry. Training programs for pilots and crew continue to evolve to ensure they can properly utilize the technology and safety features available to them. Technology has even improved air traffic control practices.

    As a result of these advancements in materials, technology, and training, crashes have steadily decreased since the 1950s, even with the increase in air traffic. As innovations continue, we expect to see a continued decline in fatal aircraft accidents, especially with planes getting faster and becoming more fuel efficient.

    Flying is generally considered the safest way to travel. The Civil Aviation Authority reports that the fatality rate per billion kilometers traveled is 0.003 for airplanes; meanwhile, it’s 2.57 for automobiles. Even train accidents, at 0.27 deaths per billion kilometers, are more dangerous. In fact, statistics show you’re more likely to die while riding a bicycle than while flying.

    Advanced Aerospace Technology at Tex Tech

    Rightfully so, aviation safety regulations are rigid and demanding. At Tex Tech, we rise to meet those demands with customized, high-performance fabrics. We offer more than 7,000 products that appear in industrial applications and the aerospace industry: military planes, commercial aircraft, business jets, and even space travel. As a leader in the industry, we’re committed to developing the highest-quality materials to improve aircraft safety and efficiency and continuing to innovate to meet ever-changing trends and demands.

    We have a wide variety of products that meet FAR 25.853 or FAR 25.856, including:

    • Burnthrough Insulation
    • Cabin-Divider Linings
    • Carbonized Rayon
    • Carpet Underlayments
    • Fire-Blocking Layers for Seating
    • High-Temperature Ducting Insulation
    • Moisture-Absorbing Felts
    • Over-the-Frame Blankets
    • Thermal Ablatives
    • Thermal Acoustic Insulation

    You’ll find products like these in the fuselage and the cabin as well as in seats, safety vests, and more. We design our products for the highest level of durability, abrasion resistance, thermal resistance, and overall product integrity to meet international standards. We’re proud to lead the way in an industry where there is no room for error.

    New Materials to Improve Aviation Safety

    The drive to create more fuel-efficient airplanes has encouraged the development of lightweight yet strong and durable materials. These materials need to withstand extreme environments: heat, cold, wind, pressure, and more, without adding unnecessary weight to the aircraft. Thermal acoustic materials, for example, insulate the cabin and the cockpit from temperatures on the skin of the plane that may range from -60°F to 160°F. At the same time, it blocks excess noise to ensure comfort for the passengers and crew. This insulation must also feature fire protection in the event of an accident, and it must not absorb moisture or conduct electricity. Bringing all those features together is a tall order, but it’s what is required for safety.

    Eventually, there may be a shift toward hybrid or solar-powered aircraft, new aircraft designs, and advanced techniques for takeoff and landing. Until then, innovative electronics—such as improved cockpit instrumentation display—and composite materials are improving aviation safety one flight at a time.

    You can learn more about our advanced aerospace technology by downloading our Aerospace Solutions Data Sheet. If you have any questions about what we offer, feel free to contact us.

    Download the Data Sheet

Tex Tech Experts

Tex Tech Industries Inc. is a leading developer and supplier of high-performance materials globally, and we are committed to providing innovative solutions for each of our customers. We serve wide-ranging industries, including aerospace, protective apparel, automotive, law enforcement, coatings, filtration, 3D weaving, and high-performance materials. Contact us today to learn more about our offerings, or request a quote to get started.

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