Composite and thermoplastic joining, inspection, and processing technologies

TWI provides integrated expertise in composite and thermoplastic processing, joining, and inspection, supporting the design, manufacture, and qualification of lightweight, high-performance structures for space, aerospace, automotive, and energy sectors.

Our multidisciplinary teams develop, optimise, and validate fusion and solid-state joining techniques tailored for fibre-reinforced polymers, thermoplastics, and hybrid metal–polymer assemblies. In parallel, we design advanced inspection and NDT approaches that ensure quality and structural integrity across all stages of production and repair.

Key capabilities

• Thermoplastic welding: resistance, ultrasonic, laser, and induction methods for aerospace- and space-grade composites.

• Composite–metal joining: solid-state and adhesive techniques for hybrid and multi-material structures.

• Forming and repair: thermoforming, consolidation, and in-situ repair of structural thermoplastics and fibre composites.

• Inspection and NDT: laser shearography, thermography, phased array ultrasonics, and digital radiography for defect detection and quality assurance in thick or complex laminates.

• Embedded sensing and digital twins: integration of in-process monitoring and simulation for weld and bond quality prediction.

• Material characterisation: mechanical, thermal, and environmental testing to verify performance and durability.

• Process modelling: simulation of heat flow, bonding behaviour, and residual stress in composite and thermoplastic structures.

Applications

These technologies enable lightweight, reliable, and repairable structures for satellites, launch vehicles, cryogenic tanks, and in-orbit manufacturing systems. TWI’s combined joining and inspection expertise supports mass reduction, reusability, and sustainability—key requirements for next-generation space systems.

Collaboration invitation

TWI invites industrial and academic partners to collaborate on composite and thermoplastic processing, joining, and inspection innovations. With extensive laboratory and pilot-scale facilities, we can support development, validation, and qualification of new materials and manufacturing methods for mission-critical space applications.