Filament winding is an automated composite process where resin-impregnated continuous fibers are precisely wound over a rotating mandrel to form high-strength hollow structures. Rooted in technical textiles, it transforms yarns and rovings into engineered composites, enabling controlled fiber orientation and superior performance in pressure, structural, and corrosion-resistant applications.
Step by Step Guide
- Continuous fibers are supplied from creels
- Fibers are impregnated with resin (wet or prepreg)
- Fibers are wound on a rotating mandrel at controlled angles
- Layers are built to required thickness
- Composite is cured (ambient/oven/autoclave)
- Mandrel is removed to obtain hollow structure
Material Used
Fibers
- Glass Fiber (E-glass, S-glass)
- Carbon Fiber
- Aramid Fiber (Kevlar)
- Basalt Fiber
Fabrics / Forms
- Continuous rovings / tows
- UD tapes
- Narrow tapes / hybrid tapes
Resins
- Epoxy (high performance)
- Polyester (cost-effective)
- Vinyl Ester (chemical resistance)
- Phenolic (fire resistance)
Advantages
- High strength-to-weight ratio
- Precise fiber orientation (design flexibility)
- Automated process → consistent quality
- Low material wastage
- Excellent pressure & corrosion resistance
Limitations
- Limited to cylindrical or axi-symmetric shapes
- High initial equipment cost
- Complex geometries need hybrid processes
- Skilled process control required
Applications & End Products
- Pressure vessels (CNG, hydrogen cylinders)
- FRP tanks & storage vessels
- Pipes & pipelines
- Drive shafts
- Rocket motor casings
- Wind energy components
- Industrial rollers & poles
Selection Criteria
- Product is cylindrical or hollow
- Requires high internal pressure strength
- Needs directional mechanical properties
- Demands corrosion resistance & lightweight design
- Suitable for medium to high production volumes
- Fiber alignment is critical for performance