This Article is published in Composites in Manufacturing Magazine | September – October 2025

When evaluating the capacity of a filament winding line, it’s essential to consider more than just spindle speed or mandrel size. Key performance indicators include:

• Cycle time per part – How long it takes to produce a finished product from start to finish. Which process step is the bottleneck neck can drive different solution outcomes? For example, are we replacing the mandrels first, or are we splicing fibers, or controlling for resin, or curing times?
  
• Number of parts per day/month – Actual throughput based on real-world production conditions. Not just parts, but part variations and batch sizes need to be considered to understand the bottlenecks, layout and flexibility of the line.
  
• Material efficiency – Automated systems minimize waste with precise control over fiber placement and resin usage. Measuring fiber, resin, and energy consumption can lead to understanding where operators need to focus during the automated production process.
  
• Uptime – Fewer manual interventions mean fewer stoppages and higher operational continuity. This is key to deciding what you can and should automate vs what you should leave to a trained operator.
  
• Product and Mandrel flow – are we moving mandrels or are we moving products? This key question drives the overall design of the automated line. For example, type 4 vessels are completed with curing, but pipes and other products need extraction, cutting, and mandrel treatment.

One of the most compelling aspects of automation is how it unlocks economies of scale. A single high-capacity automated line can often replace two or more conventional or manually-operated filament winding machines, especially when combined with parallel curing, automated loading/unloading, and optimized cycle times.

Steps in an Automated Filament Winding Line

Every Mikrosam filament winding line is custom-configured to match the customer’s unique product and production goals, but the core process flow and technical features remain consistent across our solutions. A typical automated line integrates the following key modules and capabilities:

• Mandrel Loading: The process begins with the automatic loading of the metallic or polymer liner (mandrel) onto the winding station. This can be accomplished using robotic arms or advanced composite automation handling systems such as area gantry systems, ensuring efficient and precise positioning regardless of part size or weight.
  
• Fiber Delivery & Resin Impregnation: Depending on the application, the line either utilizes pre-impregnated towpreg or features an exchangeable resin bath for wet winding with minimal downtime. Mikrosam’s patented, expanded and automated fiber cut and restart system has been in production for over 15 years. Also, by precisely programmatically adjusting the resin pick-up, the resin is delivered to the fibers in a controlled manner with each layer, thus saves a significant amount of money through not only resin conservation but also equipment preparation and maintenance.

• Multi-spindle Winding: The heart of the process is the multi-axis controlled filament winding machine—typically equipped with 5 or 6 spindles for high-volume production. These machines follow precise pathing algorithms to create complex, repeatable winding patterns. Our patented automatic cut and restart technology further boosts throughput by eliminating downtime between cycles.
  
• Curing: After winding, parts are thermally cured in ovens. Multiple parts can be cured in parallel, significantly reducing production bottlenecks and supporting annual outputs from 30,000 up to 1,000,000 units. Curing ovens can be equipped with gas or electric heaters, and are designed based on the resin systems that the customer wishes to use. Higher temperatures may be able to cure the tanks more quickly, but their liners would be unable to withstand the high temperatures.
  
• Cooling & Unloading: Once cured, finished parts are cooled and unloaded from the line. This is managed by either robotic handlers or area gantry systems, which transfer the products to racks, conveyors, or buffer zones for downstream processing.
  
• Inspection & Finishing: Depending on customer requirements and product types, final steps may involve extraction, cutting, mandrel treatment, burst testing or other finishing steps. This ensures each part meets strict quality standards before leaving the factory.

Throughout every stage, Mikrosam’s proprietary top-level control system digitally coordinates all operations. This advanced software platform enables real-time monitoring, recipe management, automatic line re-adjustment for different vessel sizes or parts, and comprehensive error diagnostics—delivering full traceability and operational control. We sit between the customer’s MES and the turn-key line, orchestrating production and maintaining traceability records for all steps.

The Role of Operators in a Smart Line

One common misconception is that automation eliminates the need for skilled operators. In reality, it transforms their role. Instead of physically handling mandrels or materials, operators focus on quality control, software supervision, minor adjustments, and maintenance. This reduces fatigue, improves safety, and elevates the human contribution to process optimization and innovation.

Whether you’re a start-up entering the hydrogen economy or an established manufacturer expanding your portfolio, an automated FW line provides a clear path to scale. By increasing throughput and reducing per-part labor costs, companies can achieve faster return on investment and remain competitive in high-demand sectors.

Some of Mikrosam’s customers began with a single winding machine for prototyping and later evolved into fully automated multi-station lines to meet commercial production demands. By offering modularity and upgrade options, we ensure our systems grow with the business – rather than becoming obsolete.

A Global Perspective

Mikrosam’s track record spans four continents and multiple industries. Our customers rely on us not only for equipment, but also for application development, process optimization, and technical training. Each automated line is backed by our dedicated support team, ensuring a successful start-up and ongoing performance.

As global demand rises for lightweight, high-pressure composite parts – especially in clean energy and transportation – automated filament winding lines will be at the heart of the transformation.