In this article by Steve Barbour, Managing Director at Composite Braiding, he explains how the company’s unique braiding process can manufacture cheaper, lighter and more sustainable components for the rail industry.
At Composite Braiding, we pride ourselves on challenging traditional methods in composite manufacturing.
Our unique braiding process, which can produce up to a mile of material per shift, is revolutionising industries, including rail.
Our innovation is not only about speed but also about delivering tangible benefits: reduced costs, higher efficiency, and sustainable solutions that address real-world challenges. Through the Clean Futures Accelerator programme, we are working closely with organisations in the rail industry to showcase how our technology can make a significant impact.
A unique manufacturing process
Our braiding process starts with a material we call “commingled fibre”—a combination of a reinforcement fibre like carbon or glass and a thermoplastic like nylon or polypropylene. This integration simplifies production, reduces waste, and enables us to create preforms with unparalleled speed and efficiency.
Using our patented heating and moulding techniques, we convert these preforms into structural components in just 5 to 10 minutes. Compared to the traditional two-to-three-hour process, this is a staggering 97% reduction in production time. Moreover, our energy consumption is cut by up to 99%, meaning we can support the rail industry’s sustainability goals by manufacturing components at a fraction of the traditional energy output.
Real-world benefits for contractors
As part of the Clean Futures Accelerator programme, we are developing an innovative solution for overhead line equipment (OLE). The structural components, an 8-metre vertical column and a 4-metre horizontal arm, serve as a lighter, more sustainable alternative to traditional steel.
While these components maintain the same functional capabilities as their steel counterparts, they offer significant advantages:
- Reduced weight: With a weight reduction of up to 85%, these vastly lighter components mean smaller foundations and less concrete, which not only lowers costs but also reduces carbon footprints.
- Simplified installation: Our solution eases transport and logistics and allows Tier 1 contractors to use smaller installation plant, avoiding the need for expensive access roads to be created and heavy kit used. This increases installation speed and decreases overall project costs.
- Sustainability: Our materials are recyclable, offering cost recovery opportunities and supporting the rail industry’s circular economy principles. The weight reduction also reduces emissions during delivery and installation.
- High volume, low Cost: Our highly automated process ensures consistent quality while enabling scalability and affordability.
Overcoming adoption barriers
When innovation is involved in construction, there can be questions raised. We understand the hesitations contractors might have when adopting new technologies. The rail industry has long relied on proven solutions, and introducing alternatives can be a major change for organisations with tried and trusted methodologies.
That’s why we’re working closely with rail organisations to validate our technology. Through the Clean Futures Accelerator, we have unique access to BCIMO’s Rail Development & Test Site, where we’re rigorously testing our OLE components against strict industry standards.
Our approach is to ensure that when contractors reach GRIP 3 (option selection) under Network Rail’s new PACE framework, they have the data and confidence to consider our solution as a proven, low-risk alternative. By showcasing the tangible benefits, from reduced installation costs to faster project timelines, we aim to empower contractors to embrace this change in technology.
Broader applications and future potential
While our current focus is on overhead line equipment, the potential applications of our composite braiding technology extend far beyond rail. From 5G masts to highway infrastructure, our process can deliver lightweight, high-performance components for many diverse industries. With our processing technology we can produce complex shapes with minimal waste, offering a versatile solution for the challenges of modern manufacturing. This approach could deliver exciting results for rail vehicles and infrastructure but also has scope for many other industries such as highways, telecoms and more.
Clean Futures Accelerator and BCIMO Demo Day
Participation in the Clean Futures Accelerator has been instrumental in advancing our innovation. The funding, technical expertise, and commercial support provided by the programme have enabled us to fast-track development and testing. In February 2025, we’ll showcase our solution at BCIMO’s exclusive Demo Day, presenting our achievements to industry leaders and stakeholders.
This event is a great opportunity for us to demonstrate how our braiding technology aligns with the rail industry’s goals for sustainability, efficiency, and cost reduction. We’re eager to highlight the collaborative work we’ve done so far with Tier 1 contractors and show the real-world impact of our innovation.
Transforming industries
At Composite Braiding, we’re not just transforming materials; we’re transforming industries. By combining lightweight design, high-volume production, lower costs, and sustainability, our braiding process offers a compelling alternative to traditional manufacturing methods. For the rail industry, the benefits are clear: faster, more cost-effective projects with a reduced environmental impact.
We’re excited to be at the forefront of this change and to continue working with partners who share our vision for a cleaner, smarter future. Join us at the BCIMO Demo Day in February 2025 to see how our innovation is driving progress for the rail industry and beyond.
For more information on Composites Braiding please visit: https://compositebraiding.com/
