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Why Does Composite Manufacturing Require Dust Extraction?

A universal essential across industries, dust extraction systems are of high importance to protect workers, avoid impairment/contamination of goods and prevent/handle combustible dust igniting. Critical for many industries, this article will look at the significance of dust control for composite manufacturing.

Used everywhere in today’s world, the materials that become composites bring their own risks for the manufacturer.

Materials Used in Composites

Referring to the aerospace industry, the two classes of polymer resins most commonly used for aerospace composites are thermoset and thermoplastics. The epoxy resins in thermoset-made components are strong, easy to make and can withstand moderate temperatures.

However, their heat release rate cannot handle high temperatures. For aerospace components that experience high temperatures, other thermoset resins like phenolics with a low heat release would be used.

Due to these properties, different thermoset composites would be used in different areas of the aircraft. The epoxy resin components would commonly be for the interior of the aircraft, while the phenolic components are used in areas under higher heat stress.

How Can Composite Dust Harm a Person?

The dust & fibre that comes from cutting, sanding and machining composites is what can harm operators. Fine enough to affect the lungs, nose, throat, upper respiratory tract, eyes and skin, the dust can generally cause irritation and respiratory issues.

This can be seen in silica dust and carbon fibre dust, as both are associated with lung damage and have ruled limitations of exposure.

Other hazardous dust can include the dust from polyurethane resin as it is toxic to humans. The dust from carbon nanotubes (known for being 20 times stronger than carbon fibre) is considered to be as dangerous to a person’s lungs as asbestos.

What Makes the Composite Dusts Explosive?

A risk of many dusts is they can become combustible and composites are no different. In conditions with enough dust and oxygen, the dust can ignite causing a sudden explosion.

To manage dust and the risk of explosion in the factory environment it needs proper extraction close to the source.

Once extracted from the general environment, there is still a risk of explosion within the dust extraction system. To handle this risk, explosion panels are fitted to dust extraction systems.

How Does Explosion Panel Solve the Combustibility of Dust?

As dust extraction systems suck in air to gather the dust polluting it, the concentrated volume of dust inside the extractor becomes a risk for the dust to explode.

Before it is gathered in a waste bin, typically located at the bottom of the extractor, the volume of dust inside the unit still has a chance of igniting so the construction must be adapted to handle the explosion. If ignited the dust burns rapidly, causing a sudden change in pressure in the extraction system. Once this pressure reaches the explosion panel, the panel will open to absorb some of the energy from the ignition. Preventing damage to the structural integrity and proceeding to exhaust the explosion to a safe exterior area or venting device to diminish the flame.

How Do Manufacturers Control Their Dust Levels?

To control all these risks, dust control systems come in many designs and sizes, catering to the materials and processes.

Having supplied extraction machinery for years, a great example of dust extraction set up from one of our customers is composite specialist Permali. Their extraction system including:

Multiple extractor units for a high extraction rate with fitted explosion panels.
Fettling booth for a direct and localised extraction.

Fettling booths and benches can be connected to the main duct system as it is in these booths that the manual processes such as cutting, sanding and machining take place. Requiring direct extraction to protect the worker.

Another option we’ve supplied to the industry includes portable extractors, perfect for manufacturers that produce less dust.

Dust Extraction for Composite Manufacturing

In conclusion, the dust from handling composites is a risk in many ways but can easily be resolved. By installing dust extraction systems suitable to manage your dust output, you can remove and control the risks of handling composites.

With no shortage of options to customise your extraction system to your requirements, feel free to call us at +44(0)1922 45 8000 for further guidance.

Furthermore, to upgrade, expand or replace your current extraction units/system, check out our Dust & Fume Extraction Range.

Zubler V7000 Dust Collector

Zubler single suction units are highly versatile, used for a wide range of low dust and fume applications, and ideal for use in dental laboratories.

Stock No: EC2038
Category: Dry Dust Filters
Model: Zubler V7000
Year of Manufacture: Unused
Approx Duty CFM / M³/Hr: 53-80 // 90-135 @ 34 in wg // 85mbar
Filter Area ft² / m²: 43 + 75 // .4 + .7
Other Info: Suction of 20-40 L/S
Condition: Excellent Condition, Unused, Current Model
Sold As Seen Price [?]: £ Login or Register for price.

Why Does Composite Manufacturing Require Dust Extraction?

Materials Used in Composites

How Can Composite Dust Harm a Person?

What Makes the Composite Dusts Explosive?

How Does Explosion Panel Solve the Combustibility of Dust?

How Do Manufacturers Control Their Dust Levels?

Dust Extraction for Composite Manufacturing

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