Optima 3D demonstrates new 3D weaving technology for ASCC

Optima 3D (Holmfirth, U.K.) is delivering weaving technology it demonstrated to the U.S. for installation at the University of Maine’s (Orono) Advanced Structures and Composites Center (ASCC) for the processing of carbon fiber yarns. The 3D weaving system consists of an Optima 3D Series 600 shuttle weaving machine with an integrated 2,688-hook Stäubli (Pfäffikon, Switzerland) SX jacquard and harness. It is also complemented by Optima’s compact warp delivery creel and an associated pirn winder for shuttle bobbins and a spool winder for creel spools.

Optima 3D notes that its looms offer many advanced features over conventional weaving machines, particularly in terms of versatility — comprehensive use of digital control systems enable rapid parameter and sequence changes, coupled with an innovative shuttle system.

“Our aim from the start was to look at 3D weaving machine technology with a fresh pair of eyes and produce a machine that is simply better by design and delivers real benefits to our customers,” says managing director Steve Cooper. “The key interest in this technology has been in producing new structures from expensive fibers such as carbon [fiber] into workable structures, as the essential reinforcements for composites.”

ASCC engineer Professor James Stahl notes that the “new Optima 3D weaving system will be a cornerstone of a new textile lab we are developing here. We chose the loom to take advantage of the design flexibility the shuttle-based weft/fill insertion will provide for fabrics that will be used in soft and hard composite structures and materials.”

The ASCC is no stranger to advanced technology, or composite projects — in 2019 it received no less than three Guinness World Records, for the world’s largest prototype polymer 3D printer, the largest solid, 3D-printed object and the largest 3D-printed boat. In its latest project, it has introduced BioHome3D — a 3D-printed house made entirely with bio-based materials developed in a partnership with Oak Ridge National Laboratory (ORNL, Oak Ridge, Tenn., U.S.). The 182-square-meter prototype features 3D-printed floors, walls and roof which are fully recyclable and highly insulated with 100% wood insulation and customizable R-values. Construction waste was nearly eliminated due to the precision of the printing process.

“With its 3D system, Optima is really taking weaving back to first principles — it’s technology that embodies true innovation in both design and process possibilities,” adds Jason Kent, CEO of the British Textile Machinery Association (BTMA). “It’s great that it will contribute to the development of some forward-looking projects for tomorrow’s sustainable living at the ASCC, and represents another solid example of innovation from the U.K.”