Energy Material Solution - Services and Products
We help make the creation of new products commercially and technically successful.
Composite & Thermoplastic Composite Formatting
Web Industries continually develops advanced technologies to slit, spool, chop, or pre-form thermoplastics to aerospace-quality levels and scale volumes for automated fabrication processes. We match tape length, winding patterns, liner materials, and spool sizes to meet your specific manufacturing requirements, providing custom-formatted materials that streamline fabrication workflow, increase production rates, and reduce overall waste. We provide the “Right” formats to meet both existing and new technology needs. Formats are based on process optimization and cost targets—not limited to existing sizes/format. Web Industries collaboration with material suppliers, part fabricators, and equipment providers supports next-generation processes.
The range of formats available include:
- Slit tapes for AFP, ATL, AM, and braiding processes (1 mm–2″ in width)
- Quasi-isotropic UD Slit Tape – 45/90 for CCM and ATL processes
- Dried fiber slit tape for AFP/ATL resin infusion processes
- Super roll (edited/spliced for long processing)
Web partners with the world’s leading material manufacturers, major OEMs, and their suppliers to develop formatting processes to support thermoplastic composites manufacturing.
Precision BiasPly™
Our automated process cuts and seams 0-degree 12-inch and 24-inch parent materials to produce quasi-isotropic 50-inch-wide parent rolls that are pre-oriented (at 45 or 90 degrees) and can be pre-formatted materials for custom AFP, ATL, CCM, and hand lay-up manufacturing requirements.
Chopped Flake
Web Industries precision slits and chops TPC material for compression molding. The chopped product is pre-weighed to meet individual part mold requirements. We also recycle and chop virgin TPC materials left over from other formatting operations to reduce or eliminate material waste. Our innovations with these materials continue to promote sustainability.
Ply Cutting and Kitting & Pre-Forming
Our customers rely on our NADCAP-certified automated ply cutting and ply kitting services to provide proven, cost-effective composite, specialty fabric, and film formatting. Web’s customized, automated table cutting processes produce precisely cut plies faster and more consistently than traditional hand-cutting methods. Also, our advanced shape nesting ensures efficient material usage. Easy-to-order, easy-to-install single-SKU supply solutions eliminate non-value-add work for our customers.
Our proprietary PlyScan™ technology labels and sequences the precision-cut plies, providing aerospace-grade quality assurance. Our pre-assembled kits are ready to go from our inventory to your factory floor for final production. Combined with our other process-optimizing solutions, we provide a streamlined supply chain that helps reduces overhead costs.
Precision Ply Kits
To optimize their manufacturing processes, our partners rely on our automated ply cutting and ply kitting services to provide proven, cost-effective outsourced composite, specialty fabric, and film formatting.
Utilizing easy-to-order, easy-to-install single-SKU supply solutions, our customers can eliminate non-value-add make-ready work, freeing up personnel and resources to focus on their core business.
Our expert technicians nest ply shapes to maximize yields and minimize waste from high-value materials. Temperature, humidity, and particulate-controlled environments protect materials during processing. Web’s exclusive PlyScan™ technology labels and sequences the precision-cut plies, providing aerospace-grade quality assurance so that every pre-assembled kit is ready to go from our inventory to your factory floor for final production. In combination with our material and supply chain management solutions, our customers benefit from a streamlined supply chain, simplified cost modeling, and reduced overhead costs.
Precision Slitting, Spooling, and Winding
Companies developing or using challenging flexible materials trust our precision slitting services for reliable, cost-effective, and scalable formatting for nonwoven specialty films, composites, and plastics. Our innovative slitting solutions are customized to get the most out of your high-value flexible materials. Our PrecisionSlit™ tape technologies define aerospace industry standards for slitting, spooling, and winding prepreg composites. With over 50 slitting lines around the world, we provide key market proximity and capacity.
Our experience spans the breadth of composite material slitting: thermosets, thermoplastics, adhesives, dry fiber, BMI, CMC, and pre-laminated materials.
We are the only AS/EN9100C-certified composite formatting company with the proven ability to simultaneously support multiple major aircraft development programs like the 787, 777X, and A350.
Our unique PrecisionSlit™ slitting technology enables us to format prepreg composite tapes as narrow as 0.125″ (3.2 mm) while exceeding aerospace tolerances. We match tape length, winding patterns, liner materials, and spool sizes to meet our customers’ specific fabrication requirements, providing them with custom-formatted material that streamlines workflow, increases production rates, and reduces overall waste.
Benefits of PrecisionSlit™ Technology Include:
Ultra Narrow Slitting for Additive Manufacturing capabilities include:
Prepreg Composite Slit Tapes
Web Industries defines the industry standards for slitting, spooling, and winding prepreg composites.
We are also the only AS/EN9100C-certified composite formatting company with the proven ability to simultaneously support multiple major aircraft development programs.
Qualified on all major AFP and ATL lines, our propriety PrecisionSlit® cutting technology allows us to slit prepreg composite tapes as narrow as 0.125″ (3.2 mm) while exceeding aerospace tolerances. We match tape lengths, winding patterns, liner materials, and spool sizes to meet our customers’ specific fabrication requirements, providing them with custom-formatted material that streamlines workflow, increases production rates, and reduces overall waste.
Lamination: Cross Ply and 2-Ply Lamination
Superbulk® Fibrillated Cable Fillers
Web Industries’ Superbulk® polypropylene cable fillers are lighter, stronger, and safer than traditional alternatives. They can be custom-tailored to meet specific engineering and production requirements, including custom colors, fibrillation levels, fiber diameter, tensile strength, and elongation. Because Superbulk® is formed into yarns and tapes, it is much more flexible than piped-in polypropylene foam or beads. Adaptable to most combinations, Superbulk® polypropylene can be used alone or in combination with other materials.
Our flame-retardant (FR) Superbulk® and zero-halogen flame-retardant (ZHFR) Superbulk® cable fillers were developed to meet strict military, transportation, and energy industry needs. They can be used alone or with other materials to add cost-effective flame-retardant properties to mission-critical cables. Currently used in NAVSEA-approved products, ZHFR Superbulk® offers outstanding flame retardancy with zero-halogen, zero-acid-gas, low-smoke/fuel density performance. Both products are REACH and RoHS compliant, and work to smother fires before they get out of control.
Laminated Shielding Tapes
Developed in response to market demand, our laminated shielding tapes offer superior performance and easier use during end-product production. Featuring polyester or polypropylene tape and aluminum foil construction, they are manufactured to precise tolerances and are available in a variety of configurations. These include continuous and segmented tapes as well as cross web configurations. Designed to address evolving industry requirements, our product shielding performance, product marking, and deliverable formats can all be customized.
Web Industries is compliant with the International Traffic in Arms Regulations (ITAR).
PET Core Wrap Tapes
Our PET Core Wrap is a binding tape with outstanding strength and dielectric properties. It adds mechanical and electrical protection to your products while supporting proper cable assembly and construction.
Sewing & Assembly
Web Industries has a deep understanding of the way soft goods are engineered, formatted, and installed. Computerized cutting, seaming, and finishing are complemented by expert handwork capabilities for all soft goods used in energy applications.
Rotary Die Cutting
- Process materials up to 13” wide
- Die-cut repeat lengths for discrete parts up to 38”
- Longer repeat lengths available for continuous parts with die cut features
- Part to part registration tolerance of .025”
- Depth controlled die cutting
- Slug removal/ part removal