sensXPERT’s innovative system that utilizes real-time process monitoring combines decades of materials science expertise with AI-driven technology to deliver a next-generation process control solution. Our system goes beyond traditional monitoring tools by integrating real-time in-mold dielectric sensor technology to analyze material behavior directly during production. This allows manufacturers to visualize critical parameters such as the degree of cure, glass transition temperature, and viscosity, ensuring optimal process performance at every stage.
The Challenge of Precision in Composites Manufacturing
In composites manufacturing, ensuring that resins are fully cured before removing parts from RTM molds or autoclaves is critical. Yet, the challenge lies in pinpointing the exact moment when the cure cycle is complete. Relying solely on time as a measurement variable often leads to conservative estimates, resulting in unnecessarily extended cycle times, increased energy consumption, and reduced throughput. For manufacturers facing tight order deadlines, this inefficiency can hinder overall equipment effectiveness (OEE), delay production schedules, and limit the ability to take on new business opportunities.
The sensXPERT Solution
sensXPERT’s real-time process monitoring technology offers a groundbreaking solution. By integrating AI and dielectric sensor technology directly into manufacturing processes like vacuum-assisted resin transfer molding (VARTM), reaction injection molding (RIM), and autoclave curing, we empower manufacturers to visualize material behavior in real time. This enables precise adjustments, optimized cycle times, and enhanced sustainability.
The Science Behind sensXPERT
Dielectric Sensor Technology Meets AI
Our dielectric sensors monitor the material’s electrical properties during the curing process, providing insights into critical parameters such as degree of cure (DoC), glass transition temperature (Tg), and viscosity.
These data points are analyzed by AI algorithms in real time, predicting process outcomes and allowing for adaptive process control to maximize efficiency. By combining these technologies, sensXPERT helps manufacturers reduce waste, minimize energy usage, and ensure that every component meets stringent quality standards.
Key Features of Our Technology
Real-World Impact: Composites in Aerospace
One aerospace leader recently transformed its production process using sensXPERT technology. By implementing real-time material monitoring, they:
- Reduced VARTM cycle times by up to 20%.
- Improved energy efficiency by 23%.
- Achieved unparalleled process transparency, enabling faster decision-making and enhanced component quality.
This success story is just one example of how sensXPERT is revolutionizing composites manufacturing in high-stakes industries like aerospace. Read the full success story here.
Ready to Transform Your Composites Manufacturing?
Experience the power of real-time process control and advanced material insights with sensXPERT. Let’s collaborate to optimize your production cycles, reduce waste, and elevate your business to new heights.