BTMA Members Highlight Advances in Composites Engineering and Manufacturing

Airbond, Cygnet Texkimp and Roaches International, all members of the British Textile Machinery Association (BTMA), have reported recent developments linked to composites engineering and manufacturing. These include award recognition, new technology platforms and expanded communication channels for industry engagement.

Airbond, based in Pontypool, South Wales, has received the Make UK Energy and Sustainability Award for its Lattice 3D Printing project. The recognition relates to the company’s application of industrial 3D printing and advanced design techniques to reduce material consumption and waste in the manufacture of its pneumatic splicers, while maintaining performance standards for industrial use.

Airbond prototyped and tested a number of structures with different cell sizes and thicknesses before deciding on the optimised structure for its latest range of 3D-printed splicers.

The company applied additive manufacturing to redesign internal structures of components, integrating strength and performance while using less material. Maxim Wright, Head of Design and Development at Airbond, said: “We’ve used 3D printing to do something traditional manufacturing can’t – build strength and performance into the inside of the part, using far less material. Winning a national sustainability award is a big moment for a small team in Pontypool and it shows what modern Welsh engineering can deliver.”

Pneumatic splicing was originally developed by Airbond in the 1960s for textile applications and has since been adopted in the production of carbon and aramid-based components for aerospace, automotive and wind power sectors. Using Carbon3D’s Lattice Design Engine, the company evaluated several structural formats, including Voronoi, Tetrahedral and Kagome designs, with varying cell sizes and wall thicknesses, before selecting an optimised structure for its current splicer range.

Testing confirmed zero mechanical failures and a positive customer response. The modular design is reported to be 33% lighter than previous versions and has reduced costs associated with electrical systems, engineering and installation. Airbond continues to develop its manufacturing capabilities in South Wales, focusing on lighter and more resource-efficient industrial tools.

Cygnet Texkimp, another BTMA member, has been shortlisted for a 2026 JEC Innovation Award following its collaboration with McLaren Automotive on the ART rapid tape-deposition system. The system is capable of placing dry fibre tapes at speeds of up to 2.5 metres per second with high precision, enabling reductions in scrap and production cycle times and contributing to structural performance improvements in composite-intensive vehicle platforms.

Cygnet has just launched a new website for its global audience.

Cygnet Texkimp, which manufactures prepreg production machinery and handling and converting systems for the composites sector, has also launched a new website aimed at its international customer base. The platform provides access to technical resources and facilitates contact with product specialists. CEO Luke Vardy stated: “The new site gives us a dynamic platform to share our technologies and expertise with our global audience in a way that reflects the ease and professionalism with which we operate. We hope it will provide a sense of what it’s like to collaborate with us and a clear view of our commitment to innovation and performance in fibre processing.”

A third BTMA member, Roaches International, has marked 15 years of activity in autoclave and thermosetting technology through the launch of a dedicated LinkedIn page. Founded in 2011, Roaches Autoclaves has supported the manufacture of aerospace components and high-performance automotive structures, as well as components for construction, sporting goods and food processing applications.

Roaches International is marking 15 years of manufacturing autoclaves for composites manufacturers.

The company’s first autoclave installation was completed at Crosby Composites in Brackley, Northamptonshire, featuring a diameter of 2.5 metres and a length of three metres. Roaches International Managing Director Sean O’Neil said: “We started big and the industry instantly wanted more, so happily, we carried on and Crosby went on to order three more autoclaves of the same size, all of which are still in operation today and receive reliable and ongoing service from us. In addition to the machines themselves, support, service, calibration and collaboration remain the cornerstones of Roaches Autoclaves and our dedicated new LinkedIn platform will allow for more frequent, higher quality communication with the digital composites community.”

BTMA CEO Jason Kent commented on the developments across member companies: “From additive manufacturing and sustainable product design to high-speed fibre placement and advanced autoclave technologies, our members continue to demonstrate how British machinery and engineering expertise are helping to shape the future of the global composites industry. These achievements underline the depth and diversity of engineering excellence across our membership, and what is particularly encouraging is the way they all deliver real, measurable benefits in efficiency, sustainability and performance, while being rooted in long-term investment, collaboration and skills within the UK.”

Issued on behalf of the BTMA by AWOL Media.