Roll Wrapping

Roll wrapping is a process commonly used to produce composite tubes. With this process, layers of reinforcing fibers or fabrics are wrapped around a mandrel or core. It allows for precise control over the orientation and thickness of the layers, resulting in composite products with tailored mechanical properties.

At Goodwinds Composites, we specialize in customizing composite materials, all sourced and manufactured in the United States. We are located in Mount Vernon, Washington, and our facilities employ advanced techniques to ensure that our products exhibit strength and durability. We also leverage our extensive knowledge and engineering proficiency in every project we handle.

How Does Roll Wrapping Work?

Roll wrapping reinforces and forms composite materials widely employed in producing rods and tubes. This process is performed in a spiral pattern, allowing for optimal layer orientation and thickness control. The mechanical qualities of the final composite product are greatly influenced by the materials used and an accurate wrapping technique.

The process begins with selecting a mandrel, which serves as the inner core of the structure. Layers of reinforcing material are then applied in a continuous spiral motion around the mandrel. The orientation of these layers can be adjusted to meet specific design requirements, influencing the final product’s strength and other mechanical properties. This entire assembly is cured or set in place through heat.

Technical Advantages of Roll Wrapping

This technique offers the following advantages in creating composite structures, making it a preferred choice for industries requiring strength, durability, and customization:

Customization and Tailoring Properties

The roll-wrapping process allows for extensive customization, letting manufacturers customize the qualities of composite items based on their individual needs. It also enables the production of structures with specific mechanical properties by altering the orientation, thickness, and type of reinforcing materials.

Optimized Strength-to-Weight Ratio

The controlled layering inherent in this roll-wrapping process contributes to an optimized strength-to-weight ratio in the final composite product. Manufacturers can enhance structural integrity without unnecessarily increasing the weight by strategically placing reinforcing materials in the layup.

white paper rolled carbon tubes

custom branded wrapped carbon

Cost-Effectiveness and Material Efficiency

The roll-wrapping technique is a cost-effective manufacturing method due to its efficiency in material usage. It minimizes waste by precisely applying reinforcing materials in the desired orientation, reducing the need for excess resources.

Versatility Across Industries

The versatility of roll-wrapped structures makes them suitable for various industries and applications. The technique can be adapted to meet the specific needs of diverse sectors, whether to produce basic tubes or intricate high-tech structures.

Consistency and Repeatability of Results

The roll-wrapping method allows for the creation of composite products with consistent and repeatable results. Its controlled and automated process ensures uniform layering and application, reducing variability in the final product.

Best Applications of Roll Wrapping

Roll wrapping is a technique employed in composite manufacturing that offers advantages in specific applications. One scenario where choosing it is advantageous is when precise control over the fiber orientation is crucial for the structural integrity of the final product. This method allows for meticulous customization, ensuring the composite materials are layered according to the design specifications.

Furthermore, roll wrapping is preferred when dealing with components requiring a seamless and continuous surface. The process allows for the creation of a smooth and uniform exterior, enhancing the composite structure’s aesthetics and functionality. This benefits applications where aerodynamics, surface finish, and contact with other components are critical.

Additionally, the technique is often chosen when dealing with parts and components of varying lengths and complex geometries. Its adaptability makes it suitable for creating composite structures with diverse shapes and dimensions. Whether a long tube or a piece with intricate curves, roll wrapping allows for the seamless integration of composite materials.

Why Choose Goodwinds Composites for Roll Wrapping

When choosing a partner for roll wrapping, Goodwinds Composites stands out as the go-to option, and here’s why. Our roll-wrapped carbon tubes offer unparalleled customization, making them perfect for applications where weight and stiffness are critical factors. From UAVs and hiking sticks to pool cues, gun barrel sleeves, scientific instruments, and even contributing to NASA’s Ingenuity Helicopter on Mars, the versatility of our tubes speaks volumes about their engineering prowess.

Moreover, roll wrapping is a meticulous journey, starting with a mandrel and pre-preg fabric cut into flags. This pre-preg fabric — pre-impregnated with resin — ensures a precise and uniform application around the mandrel. The incorporation of cellophane tape aids in compacting the tube, and the curing process in a specialized oven ensures that the resin liquifies and disperses evenly throughout the composite layers and solidifies to perfection.

Choose Goodwinds Composites for High-Quality Composite Manufacturing Solutions

Goodwinds Composites is a well-known American company specializing in creating unique composite materials. We have the knowledge and engineering experience to offer helpful advice and design practical, cost-effective solutions for your specific needs. We also strive to meet your requirements, whether for a simple tube or a sophisticated, high-tech construction.

Contact us today to learn more about our comprehensive products and services or submit an RFQ here!