A major highlight of the Broetje-Automation exhibition is the new STAXX Flex 8-tow end-effector. It is specially designed for the production of tank structures. The latest member of the STAXX AFP family represents a leap forward in Automated Fibre Placement (AFP) technology by integrating both conventional winding and AFP layup in a single end-effector. This unique capability increases efficiency, improves part quality and enables more precise fibre placement for high-end composite tank structures.

Unlike traditional composite manufacturing methods, where filament winding is primarily used for smaller hydrogen tanks, the combination of winding and AFP processes in a single robotic end-effector addresses critical challenges in large-scale aerospace applications. In industries such as aerospace and space – where structural strength, weight optimisation and durability under varying pressure and temperature conditions are paramount – the ability to manufacture high performance composite tanks with precision is a game changer.

Broetje-Automation’s latest development is particularly relevant to the production of aerospace applications. While effective for small tanks, traditional winding methods often result in higher resin content and inaccuracies in tow placement, leading to potential material weaknesses. In addition, the domed end sections of tanks present a challenge to achieving optimum fibre angles when using standard winding techniques.

The STAXX Flex overcomes these limitations by seamlessly switching between AFP and winding processes. This innovative approach enables optimal fibre orientation in the dome area while utilising the speed and efficiency of filament winding for cylindrical sections. The result is a hydrogen tank with superior mechanical properties, reduced weight and improved long-term durability. Broetje-Automation is the first company to successfully integrate both processes in a single robotic end-effector, setting a new industry benchmark.

Visitors to the Broetje-Automation stand at JEC World 2025 will have the opportunity to see the hydrogen tank demonstrator and the STAXX Flex 8-tow end-effector first hand. Our experts will be on hand to discuss the latest advances in automated composite manufacturing and how Broetje-Automation is shaping the factory of the future.

Join us in Paris to explore the next generation of composite manufacturing technology. For more information or to arrange a meeting at JEC World 2025, please contact Broetje-Automation.

Broetje-Automation is a leading provider of advanced production systems for the aerospace and composite industries. With a strong focus on innovation, automation, and precision engineering, the company delivers cutting-edge solutions to enhance manufacturing efficiency and product quality on a global scale.