Innovative Additive Manufacturing Using Carbon Fiber Tow and UV-Cured Epoxy via Modified Sewing Systems

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additive manufacturing technique that combines carbon fiber tow, UV-cured epoxy, and modified sewing technology to create ultra-lightweight, high-strength structures in real time

Just-in-Time Manufacturing with Carbon Fiber UV-Cured Composite Deposition

The innovative system developed by Infinity Turbine LLC exemplifies a just-in-time (JIT) manufacturing approach by enabling on-demand production of reinforced composite structures using carbon fiber tow and UV-cured epoxy. Unlike traditional batch-based composite fabrication, this method stitches reinforcement material directly into a substrate and cures it immediately, layer by layer, with no need for intermediate storage or thermal processing.

Because the fiber, resin, and reinforcement pattern are applied only where and when needed—driven by a programmable system—material waste is minimized, energy use is drastically reduced, and inventory overhead is virtually eliminated. This makes the technology ideal for custom parts, rapid prototyping, and scalable small-batch production, aligning perfectly with the principles of JIT manufacturing: efficiency, responsiveness, and minimal excess.

Programmable Additive Manufacturing with Carbon Fiber Tow and UV-Cured Epoxy A Textile-Driven Composite Fabrication Method by Infinity Turbine LLC

Executive Summary

Infinity Turbine LLC introduces a groundbreaking additive manufacturing system that integrates continuous carbon fiber reinforcement with textile-based fabrication, combined with real-time UV-cured epoxy application. This innovation transforms traditional sewing machines into programmable composite deposition systems capable of producing strong, lightweight structures with minimal energy input, no autoclave requirements, and broad application potential across multiple industries.

Problem Statement

Conventional composite manufacturing processes are:

• Labor-intensive and time-consuming

• Dependent on high-energy thermal curing (autoclaves, ovens)

• Geared toward large-scale or batch fabrication

• Lacking in fine-grained, programmable fiber placement for small-scale or localized reinforcement

There is a clear demand for modular, scalable, and energy-efficient composite fabrication—especially for prototyping, localized repairs, and lightweight embedded structures.

Technology Overview

Infinity Turbine’s solution repurposes a sewing machine platform to:

• Feed and align carbon fiber tow from a spool

• Stitch the tow into or onto a substrate material

• Immediately spray UV-curable epoxy resin onto the sewn fibers

• Cure the epoxy in real-time using high-intensity UV LEDs

• Optionally deposit pigments or functional additives (such as ceramics or polymers)

This process allows simultaneous mechanical reinforcement and surface finishing—all within a closed-loop, programmable workflow.

System Components

• Carbon Fiber Feed Mechanism

Tension-controlled spindle for continuous tow feeding

• Tow Alignment and Flattening Guide

Optional rollers to convert round tow into ribbon format

• Modified Sewing Head

Reinforced needle and programmable motion for tailored stitch paths

• Epoxy Spray Nozzle Array

Low-pressure precision resin application immediately after stitching

• UV Curing Module

Adjustable intensity and wavelength light source to rapidly solidify the epoxy

• Conveyor or Platform Output

Supports post-process cooling, inspection, or bonding

Key Benefits

• No Autoclave Needed: Low-energy UV curing eliminates bulky, expensive thermal curing equipment

• Highly Programmable: Customize reinforcement geometry on demand

• In-Situ Functionalization: Ability to embed color, sensors, or conductivity in-line

• Rapid Prototyping and Repair: Ideal for short runs, R\&D, and field repair applications

• Sustainable and Efficient: Reduces material waste and processing time

Use Cases and Applications

• Aerospace: Wing edge repairs, fairings, drone skins

• Automotive: Interior panel reinforcement, seat frames

• Defense: Tactical gear, soft armor augmentation

• Architecture: Composite fabric tension structures

• Consumer Products: Smart textiles, wearables, flexible casings

• Research and Development: Labs requiring on-demand prototyping of composite forms

Market Opportunity

With rising demand for lightweight, sustainable, and highly customizable material systems, this technology positions Infinity Turbine LLC to serve fast-growing markets in:

• Advanced manufacturing

• Defense and aerospace

• Clean energy

• Robotics and UAVs

• Smart textiles

The total addressable market for programmable composites and functional textile structures is projected to exceed $20 billion globally by 2030.

Conclusion

Infinity Turbine LLC’s carbon fiber tow + UV epoxy sewing platform represents a powerful innovation at the intersection of composites, automation, and textiles. With broad applicability, low infrastructure requirements, and real-time curing, this system enables a new class of efficient, customizable, and modular additive manufacturing.

Revolutionizing Additive Manufacturing with Carbon Fiber and UV-Cured Epoxy

As industries seek faster, more flexible methods to produce high-strength, lightweight materials, a novel approach has emerged that merges textile engineering with advanced composites. By adapting a sewing machine to feed carbon fiber tow, apply UV-curable epoxy, and cure the material in real time, a new form of additive manufacturing becomes possible—one that is scalable, programmable, and highly adaptable.

The Process Explained

This system uses a continuous spool of carbon fiber tow as the raw material, which is guided through a modified sewing machine. The process flow is as follows:

1. Tow Feeding and Alignment

Carbon fiber tow is drawn from a spool and passed through rollers or a light weave system to align and flatten the material into a thread-like ribbon.

2. Stitching into Substrate

The tow is stitched directly into or onto a material substrate using a reinforced sewing head. The pattern can be programmed to create custom reinforcement layouts.

3. Epoxy Spray Application

Immediately following the stitching process, a fine mist of UV-curable epoxy resin is sprayed over the carbon fiber and surrounding material.

4. UV Light Curing

High-intensity UV LEDs cure the resin in place within seconds, bonding the fiber to the base material and hardening the composite structure.

5. Optional Additives and Finishes

Pigments, functional coatings, or ceramic particles can be added to the epoxy stream to enhance color, strength, conductivity, or environmental resistance.

6. Output and Cooling

The finished material exits onto a cooled conveyor for inspection, trimming, or further integration.

Advantages of This Method

• Real-Time Reinforcement

Adds structural strength where needed without laminating or laying full sheets of composite.

• Low Energy Consumption

UV-cured resins eliminate the need for ovens or autoclaves, drastically reducing power requirements.

• Scalable and Modular

Systems can be designed for desktop prototyping or scaled for industrial production lines.

• Design Flexibility

The programmable stitching head allows for tailored reinforcement, embedded circuits, or multi-material hybrid layers.

• Reduced Waste

Precise material usage and on-the-fly customization reduce offcuts and excess resin waste.

Potential Applications

This innovative method of additive manufacturing holds promise across a variety of industries:

• Aerospace: Lightweight reinforcement panels, structural skin layering, and patch repair systems for composites.

• Automotive: Integration of structural carbon fiber ribs in door panels, seats, and dashboards.

• Wearable Technology: Embedding conductive or reinforced fiber paths in flexible textiles for sensors or exoskeletons.

• Architecture: Fabric-reinforced membranes and tension structures with embedded carbon lattice.

• Defense and Tactical Gear: Rapid fabrication of ballistic or impact-resistant panels and soft armor.

• Prototyping and Research: Functional models that combine strength, conductivity, and form in a single pass.

Looking Ahead

This hybrid of sewing and composites introduces a new paradigm in additive manufacturing—one that favors speed, programmability, and material performance. As UV-curable resin chemistries evolve and automation systems become more advanced, the potential for this system will only grow.

The fusion of traditional textile processes with cutting-edge materials and curing techniques offers a flexible, efficient, and scalable solution for producing next-generation components in both commercial and industrial settings.