Process Optimization Services
For over 50 years, Web Industries has assisted companies in choosing the right material components, streamlining manufacturing, and planning for profitability throughout the entire product life cycle.
Material Testing & Qualification
Our co-located Development Centers shorten new-product development cycles by answering important early-stage questions such as:
- Will a material meet your performance needs?
- Is it viable for use in commercial-scale manufacturing?
- How do you qualify the material for end-use?
By testing and qualifying new materials early in the product design process, we uncover hidden issues before they become painful problems. This allows you to investigate alternate materials or production-line solutions before you make manufacturing-related capital expenditures.
Product Specification
Precision converting and outsource manufacturing are our core businesses. From composites to plastics, nonwovens to specialized materials, our technical experts help you select materials that best match your product performance goals and specific manufacturing needs.
Process Design & Optimization
Manufacturing process design is about enhancing a product’s potential through the application of solutions tailored to your specific needs. We offer customized design processes that are aligned with your product’s life cycle. Applying our flexible material and formatting knowledge, we integrate manufacturing process design into your product to improve performance, production rates, and margins.
Design For Manufacturability
We Specialize in transitioning our partners’ products from the concept to the factory floor. We’ve helped hundreds of products reach the marketplace over our company’s history. We design for manufacturability to help ensure that you make successful products. Innovative products usually require multiple manufacturing processes; the solutions we create during product development can dramatically reduce time to market while building efficient scalability and price stability into long manufacturing runs.
Material & Supply Chain Management
Web Industries handles all aspects of supply chain management and is experienced at balancing downstream production forecasts with upstream material management. Our customizable packing solution SpoolKit™ provides consolidated sets of formatted materials keyed to match our customers’ manufacturing workflow, ensuring their lines are at peak efficiency.
Product Lifecycle Management
Working with our partners to get your ideas into the market quickly, we leverage our extensive converting and manufacturing experience to recommend materials and production methods that are scalable and commercially viable throughout every phase of your product’s life.
Global Development Center for Composites
Strategically co-located within our state-of-the-art Atlanta manufacturing facility is our Development Center for Composites Materials. It expedites precision-formatted product and process development to reduce time to production, plus maximize production efficiency and material yield for life of the program. The Development Center is fully dedicated to testing new carbon fiber prepreg composites and creating processes to format thermoplastic carbon fiber prepreg materials in both Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) manufacturing equipment. This accelerates end-to-end material development and qualification cycles, reduces capital and labor costs, and speeds products to market.
Our operation features dedicated pilot slitting/spooling lines to assess material processability, an AS9100C-certified material analysis lab to determine the optimum environmental factors for successful composite formatting, and secure visitor conference rooms and workstations for productive onsite visits.
The Center is focused on leading innovation in the areas of thermoplastic composite development and qualification for the purpose of creating processes to format thermoplastic carbon fiber prepreg materials (e.g. PEEK, PEKK, PPS) for use in various fabrication technologies. This facility also proves and qualifies the equipment that will process emerging thermoplastic composite formats. Its features include:
- A 10,000+ square foot development, testing, and qualification facility
- Complete assessment services
for prepreg composites - A thermal analysis lab
- Separate trial processing lines
for TSC and TPC materials - In-house autoclave for coupon testing
- A dedicated team of engineers, technicians, and operators with over 30 years’ experience in precision formatting for commercial-scale production
Lab Testing
- Slit-edge quality
- Contamination levels and FOD ID
- Prepreg curing status
- Optimum processing conditions
- Impregnation levels
- Moisture take-up
- Resin-fiber ratio
Process Testing
- Slitting, spooling, winding
- Web path analysis
- Environmental controls
- Material fit-for-use analysis