MTorres, Airbus Enable Next-Gen Composites via Thin-Ply AFP

Why It Matters

The breakthrough enables lighter, tougher aerospace components and accelerates adoption of thin‑ply composites in high‑value markets such as hydrogen storage, improving performance and sustainability.

Key Takeaways

• Thin‑ply tapes reduce weight and increase toughness.
• Redesigned AFP heads prevent twisting and wrinkling.
• TorFiber CAM now handles closed, self‑intersecting paths.
• AFP offers fiber orientation flexibility beyond filament winding.
• Airbus validation shows feasibility for hydrogen tanks.

Pulse Analysis

Thin‑ply or spread‑tow tapes have emerged as a game‑changer for aerospace composites, offering up to 30% weight savings while boosting impact resistance. Their extreme thinness—often under 0.02 mm—creates handling challenges that traditional AFP equipment cannot overcome, leading to defects that compromise structural integrity. MTorres tackled these issues by re‑engineering the entire material feed line, from spool tension to compaction rollers, and by tightening temperature control to stabilize the delicate fibers. This hardware overhaul eliminates the common problems of twist and wrinkle, making high‑speed layup of ultra‑light tapes practical for production environments.

Equally critical is the software side. MTorres’ TorFiber CAM, now fully integrated with Dassault Systemes’ CATIA, can automatically generate closed‑loop and self‑intersecting tow trajectories—essential for pressure vessels and other complex geometries where fibers must loop or cross. The automation reduces programming time dramatically and improves material utilization by allowing precise tow‑by‑tow control. Engineers can now tailor fiber orientation, layer thickness, and reinforcement zones with unprecedented granularity, unlocking design freedom that surpasses conventional filament winding, which is limited to rotationally symmetric parts.

The partnership with Airbus validates the commercial viability of this technology, with two tank halves successfully laminated for hydrogen storage—a sector poised for rapid growth as the aviation industry decarbonizes. By delivering a scalable AFP solution for thin‑ply composites, MTorres positions itself at the forefront of next‑generation aerospace manufacturing, offering manufacturers a path to lighter, more efficient airframes and energy‑storage systems. As airlines and OEMs pursue stricter fuel‑burn targets, the ability to integrate such high‑performance composites will become a decisive competitive advantage.