Syensqo and Bell drive composite industrialisation with DDF innovation

Bell has adopted Syensqo’s double diaphragm forming process to boost its aerospace composite part production efficiency, cut waste and reduce environmental impact.

Syensqo has teamed up with Bell to accelerate the industrialisation of composite manufacturing. Bell has become an early adopter of Syensqo’s patented double diaphragm forming (DDF) manufacturing process, an automatable and efficient technology designed for high-rate, high-volume production of composite parts using fast-cure prepreg materials.

The company is coupling DDF with Syensqo’s aerospace-grade prepreg CYCOM EP2750, developed for rapid production of small to medium primary structures that can be press molded. Bell has qualified and industrialized this process at speed, achieving consistent high-rate production of aerospace composite parts.

"After more than 30 years our Syensqo–Bell relationship continues to bring innovative solutions to benefit the composite industry," says Marc Doyle, Business Executive Vice-President of Syensqo Composite Materials. "Syensqo's customer support model is based on the belief that design, material and manufacturing are all inter-related and key to a successful increase in composites adoption. Our teams are structured to support this model and customer collaborations are fundamental in working towards a more industrialized composites industry."

Implementing DDF has delivered significant benefits, including lower operational costs and measurable environmental improvements through reduced waste, energy use and greenhouse gas emissions. It also relieves autoclave capacity, freeing it for larger structures.