CAMX 2021 exhibit preview: Helicoid

Helicoid Industries Inc. (Indio, Calif., U.S.) reveals the Helicoid architecture for composites, and is showcasing a few of the many development projects currently undergoing at almost 20 different industrial partners. Inspired by the “smasher” Mantis shrimp, Helicoid consists of layers of aligned fibers which are stacked up with a progressive change in fiber orientation which leads to a helicoidal distribution of fiber orientation. Under impact, the company says the architecture steers and controls crack growth leading to highly diffused sub-critical damage. This allows the structure to dissipate energy while preventing catastrophic failure, resulting in high damage resistance and structural integrity.

For example, Helicoid rain erosion-resistant substrates for wind blade applications — such as a fiber-reinforced substrate made of non-crimp fabrics (NCF) E-glass fabrics, infused with epoxy resin and developed in collaboration with SAERTEX GmbH (Saerbeck, Germany) — have reportedly shown a 34% erosion reduction compared to conventional NCF BX45 substrates (ASTM G73-10). Further development to optimize the Helicoid fiber architecture to delay leading-edge protection (LEP) coating erosion is currently underway at the University of California Irvine. Overall, this collaboration targets the development of innovative multi-axial Helicoid NCF fabrics for the fast and cost-effective manufacture of large Helicoid NCF structural components. Helicoid Industries says the development project will ultimately lead to an LEP solution for longer maintenance interval and higher blade durability.

Similarly, aerospace structures with high structural integrity — Helicoid  aerospace-grade carbon fiber/epoxy composite structures manufactured via automated fiber placement (AFP) with conventional 200 gsm carbon fiber-reinforced polymer (CFRP) towpreg — have been developed in collaboration with Carbon Axis (Perigny, France). A detailed study, part of the presentation to be given by Dr. Lorenzo Mencattelli, Helicoid’s director of research and development, reveals that Helicoid CFRP structures can achieve at least a 17% structural weight reduction at equal maximum load compared to conventional quasi-isotropic structures. The company says this is achieved with unprecedented resistance to full perforation and structural integrity.

The Helicoid technology has also been applied to protective helmet equipment for the sporting goods industries, including the construction of motorcycle helmets. Embedded in the shells of E-glass NCF fiber-reinforced composites, with fabrics co-developed in collaboration with SAERTEX GmbH, the application reportedly led to a 25% weight reduction in local areas reinforced to resist impact, compared to conventional helmets. Tests have been performed following ECE22.05 safety standards on different areas of the helmet, Helicoid Industries says, at cold/hot temperature and against various impact surfaces, including flat and kerb anvil.

During Dr. Lorenzo Mencattelli’s technical presentation, helmet applications manufactured via AFP and thin-ply technology are being presented to provide an insight to automated manufacturing for mass production of sporting goods. 

Helicoid Industries licenses its Helicoid technology to composite producers, as well as produces preform solutions. The company is committed to developing solutions that reduce the environmental impacts of composite products from their initial manufacturing to their end of useable life.