Reinforced Plastics d Volume 64, Number 3 d May/June 2020
com
A closer look at Optima 3D and the 3D
weaving industry
Optima 3D
A revolutionary 3D weaving system that redefines current industry standards – deploying cutting edge
technology both in concept & design.
The OPTIMA 3D Series 500 is primarily a Jacquard Shuttle weav-
ing machine, with various Warp Shedding formats available, cap-
able of producing a comprehensive range of 3D Net Shapes,
Billets, Para Beams and Multi-layer textile architectures. From a
full spectrum of raw materials including Carbon, Glass, Ceramic,
Aramid and Organic fibers. Industries such as Aerospace, Auto-
motive, Military, Bio Medical & Spacecraft will benefit from the
new horizons OPTIMA 3D can offer Design Engineers in the field
of Composite Engineering (Figure 1).
Optima 3D Ltd founded in 2018 is a High-Tech new start
OEM company based in Huddersfield UK. June 2019 saw the
launch of the OPTIMA 3D SERIES 500 at the ITMA19 world tex-
tile machine exhibition in Barcelona, Spain. Throughout this
exhibition Optima 3D received accolades from both Industry &
Academia from a global audience. The winning of a place at
the prestigious “UK Innovations Awards” which was held at
the UK National Exhibition Centre during the Advanced Engi-
neering Expo in the fall of 2019 was a very proud moment for
the team at Optima 3D Ltd.
The concept of 3D Weaving is well documented, many aca-
demic institutions have produced papers and various ideas on
the advantages of 3D Woven Composites over Hand Laid Com-
posites. Composites objects & shapes are traditionally produced
by manually placing layers of material on or into a mold, resin
is added between each layer to a desired level, the whole compos-
ite is then infused with the resin and placed into an autoclave
oven for baking. The result is a 3D polymer laminate which
can be machined and finished as required, this method of Com-
posite production relies solely on resin to bond each layer
together, and is prone to inter-laminar shear stress which can
cause failures such as DELAMINATION where the resin bond fails
and layers of the composite matrix become separated, a further
failure is known as INTERLAMINAR MATRIX DAMAGE due to
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the resin bond failing but in this case the resin damages the
matrix upon separation either of these events can lead to catas-
trophic failure.
The application of 3D Composite weaving avoids delamina-
tion by the interlacing of each “X + Y” woven layer with a bind-
ing yarn “Z” resulting in a structurally integrated weave
architecture, which forms the architectural reinforcement before
adding the resin and is known as “RTM” resin transfer molding.
A further advantage that Optima 3D offers is the deployment of
Shuttle weft/filling yarn insertion which carries the weft/filling
yarn package through the interlacing point resulting in continu-
ous binding on each side of the fabric maintaining structural
integrity on 3 dimensions.
Industry has recognized the need for 3D weaving with the use
of adapted 2D weaving machines & equipment, which in most
cases have proved to be either very complicated or very expen-
sive or both! The use of adapted equipment inevitably has con-
straints and often requires human intervention within the
weave process in order to achieve the required results. This
method whilst being acceptable for “One Off” production is
not acceptable for volume production in industries such as Aero-
space where product certification and conformity are key require-
ments. Repeatability of a woven architecture is paramount,
Optima 3D can produce woven architectures without human
intervention within the weave construction process, moreover,
the Optima 3D digital drive and control system allow the exter-
nal archiving of all machine settings, weave design and produc-
tion data, which can be uploaded digitally when required,
ensuring the repeatability of the original weave architecture.
Optima 3D Ltd was originally formed as an R&D operation,
with its sole purpose of designing a Digital driven & controlled,
high-tech machine which would interface with real time produc-
tion monitoring systems and fit the visual expectations of high-
0034-3617/Ó 2020 Published by Elsevier Ltd. https://doi.org/10.1016/j.repl.2020.04.070
Reinforced Plastics d Volume 64, Number 3 d May/June 2020
FIGURE 1
The OPTIMA 3D Series 500 range.
tech industries. Being able to apply our wealth of knowledge &
experience coupled with uninhibited design scope we have cre-
ated an extremely flexible 3D weaving system, driven and con-
trolled by cutting edge digital technology.
The machine design rationale is of a modular format, each
module being a primary weaving function allowing optional
choices for various weave applications within each module.
The Optima 3D proprietary software package accessed via the
onboard touchscreen allows optional settings within each mod-
ule without the need for software change. The digital system con-
tains a remote access portal for online upgrades & maintenance
giving the user a rapid response service anywhere in the world.
The revolutionary Optima 3D weaving system has the capac-
ity to create weave architectures within a fabric width up to 2000
(500 mm) wide, and fabric thickness of up to 600 (150 mm), Weft/
Filling insertion is primarily by Shuttle, with an option of utiliz-
ing Rapier weft/filling insertion. The shedding function is nor-
mally by electronic Jacquard, but the use of Dobby shedding
FEATURE
FEATURE
equipment is available. Warp delivery is by Creel which is essen-
tial for weave architectures requiring variable yarn length,
Fabric take off utilizes a linear draw down table for thick fabrics
which cannot be rolled and a more conventional option with
Center Wind roller take off system.
Optima 3d Ltd have established a dedicated demonstration
machine within its facility base in Huddersfield UK, with the
prime objective of promoting 3D weaving technology and ulti-
mately the sale of Optima 3D weaving machines. Production of
the Series 500 machine will commence in the second quarter
of 2020, with anticipated delivery of machines at the end of third
quarter 2020. Optima 3D strongly believe the availability of a
dedicated 3D weaving machine will help stimulate the growth
of Composites Component manufacturing on a global scale.
Our dedicated demonstration facility is a key component of this
stimuli, we encourage Industrial companies and Academic insti-
tutions from around the world to view this innovative and excit-
ing technology.
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 FEATURE Reinforced Plastics d Volume 64, Number 3 d May/June 2020

The OPTIMA 3D Series 500 Jacquard Shuttle weaving machine
has the capability of producing a comprehensive range of 3D Net
Shapes, Billets, Para Beams and Multi-layer textile architectures.
From a full spectrum of raw materials including Carbon, Glass,
Ceramic, and Organic fibers. Industries such as Aerospace, Auto-
FEATURE
motive, Military, Bio Medical & Spacecraft will benefit from the
new horizons OPTIMA 3D can offer Design Engineers in the field
of Composite Engineering.
Press@optima3d.co.uk

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