Testia has presented its In-line Infusion Monitoring technology at JEC World 2025: It helps users to revolutionize their manufacturing of composite parts through real-time insights into their processes. This is achieved through in-line sensors which allow an early detection of process deviations. Therefore, In-line Infusion Monitoring helps ensure high quality parts, shortens process development time and enables automated process control.
Testia’s solution for In-line Infusion Monitoring exceeds the capabilities of competitive products as it does not use point sensors, but evaluates the flow progress with line sensors, which allow for a space-resolved data interpretation. There are two off-the-shelf versions available: A portable device (PF-16) for process development and an embedded system (SF-16) for industrial process integration. This enables customers to address a multitude of scenarios within research and development, process industrialization or in serial manufacturing.
“Our sensor components are designed to be operational in combination with all standard fiber, resin, and tooling materials and withstand temperatures up to 200 °C, which makes them applicable in a variety of industries such as aerospace, wind energy, marine, transport and automotive,” notes Dr. Christopher Buchmann, product owner of In-line Infusion Monitoring. “The available line sensors are as thin as 0.1 mm, reducing the effect on the infusion process to a minimum.”
A customizable solution that enables digitalization in production
The technology package of In-line Infusion Monitoring combines the monitoring device as well as a software framework to allow an intuitive interpretation of the recorded data. This setup provides the operator with real-time info on the flow front position, which is easy to interpret and helps to adapt the process according to the measured data.
Customers may choose from different sensor geometries depending on the targeted application. For different use cases, specially designed components will be available: vacuum-tight connectors for LRI processes and feedthroughs for RTM with additional pressure resistance. A strong focus is also put on tooling integrated sensors, which are especially interesting for industrial applications due to very low recurring costs. Cables of different lengths will complete the product portfolio ensuring a highly versatile application.
Should a customer nonetheless require a customized solution, our engineering team is ready to support all along the way from the design to the implementation into the serial process. “We see our technology as an enabler of digitalization in production, as the digital interfaces can also be customized,” adds Christopher Buchmann, “This means the system can be easily integrated into our customers’ production lines.”
Testimonials from early adopters
“In RTM processes small deviations can have a big impact. With In-line Infusion Monitoring we can track online if the process runs as planned and optimize the infusion strategy accordingly.”
– Prof. Dr.-Ing. Axel Herrmann (CEO, CTC GmbH)
“Monitoring the flow front in infusion and injection processes is a key enabler for mature industrial processes. In-line Infusion Monitoring has proven its capability that helps Airbus to accelerate our development at lower cost.”
– Jelle Bloemhof (Head of Composite Technology, Airbus Operations GmbH)