Composites
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Airtech 3D-printed resins deliver composite tooling for competitive motorsport vehicles
BBi Autosport joins with Airtech Advanced Materials Group to develop high-performance carbon fiber body panels for its Porsche race cars using Dahltram resins and Print-Tech services.
BBi Autosport (Huntington Beach, Calif., U.S.) is returning to Pikes Peak, Colorado, for the 99th running of the Pikes Peak International Hillclimb on June 27, 2021. Known as “The Race to the Clouds,” the automobile hill climb is regarded as one of the most famous and arduous racing events globally. For this year’s 2021 effort, BBi says it is bringing three Porsche race cars, all of which make extensive use of carbon fiber composites and 3D-printing technologies.
The high-performance vehicles’ carbon fiber composite body panels were produced using 3D-printed mold tooling manufactured by BBi technical partner, Airtech Advanced Materials Group (Huntington Beach, Calif., U.S.), as well as Airtech’s Dahltram range of resins and Print-Tech in-house tooling 3D print service. Motorsports programs require rapid development cycles, BBi Autosport says, and with Print-Tech, molds are able to be produced much more quickly. This advantage further enables aerodynamic development and part manufacturing to be completed in weeks, rather than months.
Airtech’s Dahltram range of resins have been made distinctly suitable for multiple print platforms, providing production flexibility with end use material approvals. Continuous thermal cycle testing, pressure leak testing, laser surface scanning and contact material testing have generated data supporting more than 250 autoclave cycles, Airtech says, without degradation of the Dahltram manufactured tooling.
Airtech’s retains Dahltram additive manufacturing resins and Print-Tech large-scale 3D-printed tool manufacturing capabilities in the U.S. and Europe.
#Airtech #composites #MotorsportVehicles
> source
BBi Autosport joins with Airtech Advanced Materials Group to develop high-performance carbon fiber body panels for its Porsche race cars using Dahltram resins and Print-Tech services.
BBi Autosport (Huntington Beach, Calif., U.S.) is returning to Pikes Peak, Colorado, for the 99th running of the Pikes Peak International Hillclimb on June 27, 2021. Known as “The Race to the Clouds,” the automobile hill climb is regarded as one of the most famous and arduous racing events globally. For this year’s 2021 effort, BBi says it is bringing three Porsche race cars, all of which make extensive use of carbon fiber composites and 3D-printing technologies.
The high-performance vehicles’ carbon fiber composite body panels were produced using 3D-printed mold tooling manufactured by BBi technical partner, Airtech Advanced Materials Group (Huntington Beach, Calif., U.S.), as well as Airtech’s Dahltram range of resins and Print-Tech in-house tooling 3D print service. Motorsports programs require rapid development cycles, BBi Autosport says, and with Print-Tech, molds are able to be produced much more quickly. This advantage further enables aerodynamic development and part manufacturing to be completed in weeks, rather than months.
Airtech’s Dahltram range of resins have been made distinctly suitable for multiple print platforms, providing production flexibility with end use material approvals. Continuous thermal cycle testing, pressure leak testing, laser surface scanning and contact material testing have generated data supporting more than 250 autoclave cycles, Airtech says, without degradation of the Dahltram manufactured tooling.
Airtech’s retains Dahltram additive manufacturing resins and Print-Tech large-scale 3D-printed tool manufacturing capabilities in the U.S. and Europe.
#Airtech #composites #MotorsportVehicles
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Composites
Qarbon Aerospace’s leading edge structure technology, developed to demonstrate the efficiency and weight savings potential of the company’s Helios Ice Protection system compared to legacy anti-icing technology. Photo: Qarbon Aerospace
Qarbon Aerospace launches composite aircraft icing protection system
The thermoplastic composite Helios system will be distributed by AIR Group for use on the leading edges of turboprop aircraft wings and other components.
On July 14, Qarbon Aerospace Inc. (Red Oak, Texas, U.S.) launched its Helios Ice Protection system, an all-composite electrothermal system designed as an alternative to legacy ice protection technology such as pneumatic boots and bleed air.
According to Qarbon Aerospace, Helios consists of a thermoplastic/carbon fiber heating element with a layer of graphite, embedded within a thermoplastic composite leading edge structure for use on an aircraft wing, nacelle or empennage. The system has achieved icing protection certification requirements in numerous icing tunnel tests, and uses a zoned thermal profile to optimize power usage.
Qarbon Aerospace has partnered with AIR Group, a vertically integrated regional and turboprop aviation organization, for worldwide distribution of Helios. Together, Qarbon Aerospace and AIR Group will target airlines operating turboprop aircraft where there would be value in reducing the maintenance costs, replacement expenses and operational limits imposed by pneumatic boots.
Evan Young, head of engineering at Qarbon Aerospace, says, “Significant technology and manufacturing development have positioned Helios Ice Protection to be a leap forward in safety when flying into known icing conditions. Extensive icing tunnel and operational evaluation tests have proven Helios is an efficient, low power and reliable solution for icing protection.”
Morgan Whitehead, VP of operations for AIR Group, says, “AIR has been supporting turboprop operators around the world for over 20 years. Our team of highly experienced professionals offer class leading around the clock AOG service from our distribution facility near DFW Airport in Texas. We believe Helios brings our customers a whole new level of value and safety, and we are proud to have been selected as Qarbon Aerospace’s partner for the supply of Helios and look forward to stocking and supporting this advanced technology system.”
#composites #aircraft
> source
The thermoplastic composite Helios system will be distributed by AIR Group for use on the leading edges of turboprop aircraft wings and other components.
On July 14, Qarbon Aerospace Inc. (Red Oak, Texas, U.S.) launched its Helios Ice Protection system, an all-composite electrothermal system designed as an alternative to legacy ice protection technology such as pneumatic boots and bleed air.
According to Qarbon Aerospace, Helios consists of a thermoplastic/carbon fiber heating element with a layer of graphite, embedded within a thermoplastic composite leading edge structure for use on an aircraft wing, nacelle or empennage. The system has achieved icing protection certification requirements in numerous icing tunnel tests, and uses a zoned thermal profile to optimize power usage.
Qarbon Aerospace has partnered with AIR Group, a vertically integrated regional and turboprop aviation organization, for worldwide distribution of Helios. Together, Qarbon Aerospace and AIR Group will target airlines operating turboprop aircraft where there would be value in reducing the maintenance costs, replacement expenses and operational limits imposed by pneumatic boots.
Evan Young, head of engineering at Qarbon Aerospace, says, “Significant technology and manufacturing development have positioned Helios Ice Protection to be a leap forward in safety when flying into known icing conditions. Extensive icing tunnel and operational evaluation tests have proven Helios is an efficient, low power and reliable solution for icing protection.”
Morgan Whitehead, VP of operations for AIR Group, says, “AIR has been supporting turboprop operators around the world for over 20 years. Our team of highly experienced professionals offer class leading around the clock AOG service from our distribution facility near DFW Airport in Texas. We believe Helios brings our customers a whole new level of value and safety, and we are proud to have been selected as Qarbon Aerospace’s partner for the supply of Helios and look forward to stocking and supporting this advanced technology system.”
#composites #aircraft
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Composites
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Composites Evolution, Bcomp launch Evopreg ampliTex flax-epoxy prepregs
Compatible with Bcomp’s powerRibs reinforcement grid, the family of natural fiber materials drives enhanced stiffness, lightweight and a reduced footprint for motorsports and high-performance automotive applications.
Composites Evolution Ltd. (Chesterfield, U.K.) has teamed up with natural fiber reinforcement specialists Bcomp (Fribourg, Switzerland) to launch a new range of flax-epoxy prepreg materials, designed to offer enhanced sustainability without compromising on performance. Evopreg ampliTex prepregs are said to combine Composites Evolution’s high-performance Evopreg epoxy resin systems with Bcomp’s award-winning ampliTex flax reinforcements, to deliver a family of materials that offer outstanding performance for component applications.
To reach the full performance of natural fibers, says the company, Evopreg ampliTex prepregs have been tailored to be compatible with Bcomp’s powerRibs reinforcement grid, enabling the same stiffness and weight as thin-walled monolithic carbon fiber parts while decreasing the CO2
footprint by 85%. Composites Evolution also notes that the family of materials improves safety, as it blunts braking behavior without the dangerous debris or sharp edges.
“Sustainability is an increasingly important factor for many of our customers — particularly those involved in motorsports and high-performance automotive applications,” says Composites Evolution’s Sales and Marketing Director, Ben Hargreaves. The company itself has more than 10 years of experience in the development and production of natural fiber prepregs “As you’d expect in these sectors though, sustainability can’t come at the expense of performance — the two must go hand-in-hand. This is something that other prepregs can struggle with, as natural fiber behave very differently to carbon or glass fiber, for example.”
He continues, “Working together with Bcomp, we can offer an unrivaled package of technical expertise and application know-how. We draw upon this to help customers understand the strengths and weaknesses of natural fiber composites, and to show where and how they can be adopted without the need for significant changes to existing composite component production processes.”
One such customer is U.K.-based Retrac Group, which houses a composites division that Composites Evolution claims is one of the U.K.’s most
experienced composites engineering companies across motorsports, automotive and aerospace. It recently used Evopreg ampliTex + powerRibs to produce a demonstrator bonnet panel for a race-bred supercar.
“We’re seeing a growing interest in flax fiber composites, particularly in the motorsports and niche vehicle sectors,” notes Retrac Group Project Manager Alan Purves. “It is therefore essential that we have developed an in-depth understanding of the processing requirements and performance capabilities of these materials, and are ready to respond to our customers' requirements. Being able to tap into the combined expertise and experience of both Composites Evolution and Bcomp is proving invaluable.”
Purves says Retrac’s laminators found the Evopreg ampliTex materials easy to use, with good drape and tack to the molds. “The finished part looks great, and we shall showcase it later in the year,” he says.
The bonnet demonstrator is a two-part molding, with both inner and outer produced using Evopreg ampliTex EPC300-F300T 2x2 twill prepreg, backed with powerRibs. The air duct components were 3D-printed at Retrac, using the company’s Stratasys (Eden Prairie, Minn., U.S.) Fortus 450MC machine.
Bonded using polyurethane adhesive to minimize A-surface witnessing, the whole assembly weighs only four kilograms.
Johann Wacht, motorsports manager at Bcomp Ltd concludes: “We share the view that sustainability and performance need to go hand in hand and are proud that already during the development phase of Evopreg ampliTex several OEMs and parts manufacturers have fully validated the prepregs.”
#composites #FlaxFiberComposites #FlaxEpoxyPrepregs
Compatible with Bcomp’s powerRibs reinforcement grid, the family of natural fiber materials drives enhanced stiffness, lightweight and a reduced footprint for motorsports and high-performance automotive applications.
Composites Evolution Ltd. (Chesterfield, U.K.) has teamed up with natural fiber reinforcement specialists Bcomp (Fribourg, Switzerland) to launch a new range of flax-epoxy prepreg materials, designed to offer enhanced sustainability without compromising on performance. Evopreg ampliTex prepregs are said to combine Composites Evolution’s high-performance Evopreg epoxy resin systems with Bcomp’s award-winning ampliTex flax reinforcements, to deliver a family of materials that offer outstanding performance for component applications.
To reach the full performance of natural fibers, says the company, Evopreg ampliTex prepregs have been tailored to be compatible with Bcomp’s powerRibs reinforcement grid, enabling the same stiffness and weight as thin-walled monolithic carbon fiber parts while decreasing the CO2
footprint by 85%. Composites Evolution also notes that the family of materials improves safety, as it blunts braking behavior without the dangerous debris or sharp edges.
“Sustainability is an increasingly important factor for many of our customers — particularly those involved in motorsports and high-performance automotive applications,” says Composites Evolution’s Sales and Marketing Director, Ben Hargreaves. The company itself has more than 10 years of experience in the development and production of natural fiber prepregs “As you’d expect in these sectors though, sustainability can’t come at the expense of performance — the two must go hand-in-hand. This is something that other prepregs can struggle with, as natural fiber behave very differently to carbon or glass fiber, for example.”
He continues, “Working together with Bcomp, we can offer an unrivaled package of technical expertise and application know-how. We draw upon this to help customers understand the strengths and weaknesses of natural fiber composites, and to show where and how they can be adopted without the need for significant changes to existing composite component production processes.”
One such customer is U.K.-based Retrac Group, which houses a composites division that Composites Evolution claims is one of the U.K.’s most
experienced composites engineering companies across motorsports, automotive and aerospace. It recently used Evopreg ampliTex + powerRibs to produce a demonstrator bonnet panel for a race-bred supercar.
“We’re seeing a growing interest in flax fiber composites, particularly in the motorsports and niche vehicle sectors,” notes Retrac Group Project Manager Alan Purves. “It is therefore essential that we have developed an in-depth understanding of the processing requirements and performance capabilities of these materials, and are ready to respond to our customers' requirements. Being able to tap into the combined expertise and experience of both Composites Evolution and Bcomp is proving invaluable.”
Purves says Retrac’s laminators found the Evopreg ampliTex materials easy to use, with good drape and tack to the molds. “The finished part looks great, and we shall showcase it later in the year,” he says.
The bonnet demonstrator is a two-part molding, with both inner and outer produced using Evopreg ampliTex EPC300-F300T 2x2 twill prepreg, backed with powerRibs. The air duct components were 3D-printed at Retrac, using the company’s Stratasys (Eden Prairie, Minn., U.S.) Fortus 450MC machine.
Bonded using polyurethane adhesive to minimize A-surface witnessing, the whole assembly weighs only four kilograms.
Johann Wacht, motorsports manager at Bcomp Ltd concludes: “We share the view that sustainability and performance need to go hand in hand and are proud that already during the development phase of Evopreg ampliTex several OEMs and parts manufacturers have fully validated the prepregs.”
#composites #FlaxFiberComposites #FlaxEpoxyPrepregs
Composites
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Breton unveils new large-scale Genesi 3D printer
Breton has launched its Genesi 3D printer for the large-scale production of thermoplastic materials. Genesi uses machine learning algorithms and advanced artificial intelligence systems to achieve high-level mechanical and aesthetic properties.
Genesi is said to be one of the world's largest 3D printers for prototyping - 3m in height, up to 5m in width and length on request - with a deposition capacity up to 200kg per hour of reinforced thermoplastic materials.
The intense R&D of new 3D printing systems on which the Breton Institute of Technology has focused in recent years is part of the project co-financed by Mise ‘True 3D printer’. The innovative solution with which Breton opens up a new path for businesses is the result of a process rich in synergies, exploiting the machine learning and artificial intelligence skills of the Canadian company Augmenta, but also all the printing process experience of the MUSP, a research institute in Piacenza.
The development process was carried out in close cooperation with the best material manufacturers in this sector, such as SABIC, and by forming partnerships with strategic companies, such as Siemens in the field of software.
"For a company like Breton, which has always been committed to research and development, it is a pleasure to launch our solution in the extremely innovative and growing sector of 'Large Additive Manufacturing'," said Breton’s business development manager, Gabriele Corletto. "While additive printing is a process that still requires a rather artisanal approach from the user, the goal of 'Breton Genesi', thanks to the development of a complex AI and machine learning system, is to let the machine 'learn' while making the parts in order to shorten the process."
Genesi can operate either in a purely additive version or in combination with a subtractive system. This second solution overcomes the limits of the pure additive method, which allows the production of near net shape parts that are close to the final shape but not completely finished. With Genesi, finishing and optimisation are ensured by the high-speed subtractive capability installed in the same machine, thus making the part not only near net shape but also ready to use.
"For Breton, the partnership with companies is fundamental, as they can re-evaluate the production processes together with our technicians and try out the version available at the Castello di Godego site, which has a printing size of 2,000 x 3,200 x 8,400mm," added Corletto.
The Genesi proposal can be configured with modules of different sizes, with solutions that are adapted to the needs of our current and potential customers.
A partnership has already been established with an innovative start-up, Northern Light Composites, which is using the advantages of Genesi to manufacture the moulds for the prototype of ‘Ecofoiler’, the first sailing boat with a completely recyclable foil on the market. Ecofoiler is a 3.80m hull designed by Matteo Polli with the collaboration of foiling experts such as Matteo Ledri, who has already been involved in three America's Cup campaigns.
Breton invites companies wishing to try out this new solution to visit the company and see Genesi and its advantages first-hand.
#composites #Breton #3Dprinter
> source
Breton has launched its Genesi 3D printer for the large-scale production of thermoplastic materials. Genesi uses machine learning algorithms and advanced artificial intelligence systems to achieve high-level mechanical and aesthetic properties.
Genesi is said to be one of the world's largest 3D printers for prototyping - 3m in height, up to 5m in width and length on request - with a deposition capacity up to 200kg per hour of reinforced thermoplastic materials.
The intense R&D of new 3D printing systems on which the Breton Institute of Technology has focused in recent years is part of the project co-financed by Mise ‘True 3D printer’. The innovative solution with which Breton opens up a new path for businesses is the result of a process rich in synergies, exploiting the machine learning and artificial intelligence skills of the Canadian company Augmenta, but also all the printing process experience of the MUSP, a research institute in Piacenza.
The development process was carried out in close cooperation with the best material manufacturers in this sector, such as SABIC, and by forming partnerships with strategic companies, such as Siemens in the field of software.
"For a company like Breton, which has always been committed to research and development, it is a pleasure to launch our solution in the extremely innovative and growing sector of 'Large Additive Manufacturing'," said Breton’s business development manager, Gabriele Corletto. "While additive printing is a process that still requires a rather artisanal approach from the user, the goal of 'Breton Genesi', thanks to the development of a complex AI and machine learning system, is to let the machine 'learn' while making the parts in order to shorten the process."
Genesi can operate either in a purely additive version or in combination with a subtractive system. This second solution overcomes the limits of the pure additive method, which allows the production of near net shape parts that are close to the final shape but not completely finished. With Genesi, finishing and optimisation are ensured by the high-speed subtractive capability installed in the same machine, thus making the part not only near net shape but also ready to use.
"For Breton, the partnership with companies is fundamental, as they can re-evaluate the production processes together with our technicians and try out the version available at the Castello di Godego site, which has a printing size of 2,000 x 3,200 x 8,400mm," added Corletto.
The Genesi proposal can be configured with modules of different sizes, with solutions that are adapted to the needs of our current and potential customers.
A partnership has already been established with an innovative start-up, Northern Light Composites, which is using the advantages of Genesi to manufacture the moulds for the prototype of ‘Ecofoiler’, the first sailing boat with a completely recyclable foil on the market. Ecofoiler is a 3.80m hull designed by Matteo Polli with the collaboration of foiling experts such as Matteo Ledri, who has already been involved in three America's Cup campaigns.
Breton invites companies wishing to try out this new solution to visit the company and see Genesi and its advantages first-hand.
#composites #Breton #3Dprinter
> source
Composites
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Rize XRIZE composite printer now compatible with Synopsys platform for 3D medical printing
Platform combination enables the creation of affordable, full-color and functional 3D physical replicas from medical imaging for orthopedic, maxillofacial and cardiovascular application fields.
Next-generation additive manufacturing company Rize Inc. (Concord, Mass., U.S.) has announced that its XRIZE full-color industrial desktop composite 3D printing platform is compatible with Synopsys’ (Mountain View, Calif., U.S.) FDA 510(k)-cleared Simpleware software. More specifically, Simpleware software is cleared for creating models from medical imaging that can be exported to compatible printers such as XRIZE to produce physical replicas used for diagnostic purposes in the field of orthopedic, maxillofacial and cardiovascular applications. As part of its clearance process, Synopsys is able to use the XRIZE platform to validate an end-to-end DICOM to 3D print workflow, enabling a 3D point-of-care (POC) solution for end-users.
According to a June 2019 Allied Market Research report, 3D-printed healthcare applications are projected to reach $3.6 billion by 2026. “3D printing is becoming increasingly important in surgery, and the use of 3D-printed models has been shown to increase our understanding of musculoskeletal diseases,” says Professor Alister Hart MD, orthopedic surgeon, Royal National Orthopaedic Hospital, U.K. “We’re excited to work with RIZE’s 3D printing platform along with the Simpleware software solutions for image segmentation. Many aspects of surgical planning can benefit from 3D models — for example, to illustrate the distribution of bone density at various depths in the bone and to assist in positioning and screw placement.”
Complementing the Simpleware, XRIZE will aid creating highly durable anatomical models, surgical guides and implants with minimal effort, with vibrant color highlights on anatomical regions, bone densities and landmarking, according to Rize. Further, the printer’s UL GREENGUARD certification and minimal post-processing reportedly delivers a safety advantage while empowering clinicians and innovators with intelligent workflows that dramatically compress time and costs by 80-90%.
“Our technology has a proven track record for processing 3D images and creating models for a wide variety of applications,” says Terry Ma, VP of engineering at Synopsys. “Adding regulatory clearance for point-of-care 3D printing enables our growth in the point-of-care clinical space, where Simpleware software and our team’s technical expertise will allow for better patient care and a faster workflow for medical professionals.”
#composites #CompositePrinter
> source
Platform combination enables the creation of affordable, full-color and functional 3D physical replicas from medical imaging for orthopedic, maxillofacial and cardiovascular application fields.
Next-generation additive manufacturing company Rize Inc. (Concord, Mass., U.S.) has announced that its XRIZE full-color industrial desktop composite 3D printing platform is compatible with Synopsys’ (Mountain View, Calif., U.S.) FDA 510(k)-cleared Simpleware software. More specifically, Simpleware software is cleared for creating models from medical imaging that can be exported to compatible printers such as XRIZE to produce physical replicas used for diagnostic purposes in the field of orthopedic, maxillofacial and cardiovascular applications. As part of its clearance process, Synopsys is able to use the XRIZE platform to validate an end-to-end DICOM to 3D print workflow, enabling a 3D point-of-care (POC) solution for end-users.
According to a June 2019 Allied Market Research report, 3D-printed healthcare applications are projected to reach $3.6 billion by 2026. “3D printing is becoming increasingly important in surgery, and the use of 3D-printed models has been shown to increase our understanding of musculoskeletal diseases,” says Professor Alister Hart MD, orthopedic surgeon, Royal National Orthopaedic Hospital, U.K. “We’re excited to work with RIZE’s 3D printing platform along with the Simpleware software solutions for image segmentation. Many aspects of surgical planning can benefit from 3D models — for example, to illustrate the distribution of bone density at various depths in the bone and to assist in positioning and screw placement.”
Complementing the Simpleware, XRIZE will aid creating highly durable anatomical models, surgical guides and implants with minimal effort, with vibrant color highlights on anatomical regions, bone densities and landmarking, according to Rize. Further, the printer’s UL GREENGUARD certification and minimal post-processing reportedly delivers a safety advantage while empowering clinicians and innovators with intelligent workflows that dramatically compress time and costs by 80-90%.
“Our technology has a proven track record for processing 3D images and creating models for a wide variety of applications,” says Terry Ma, VP of engineering at Synopsys. “Adding regulatory clearance for point-of-care 3D printing enables our growth in the point-of-care clinical space, where Simpleware software and our team’s technical expertise will allow for better patient care and a faster workflow for medical professionals.”
#composites #CompositePrinter
> source
Composites
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PRF Composite Materials opens fourth manufacturing facility
The completed £6 million investment and expansion program increases the company’s R&D, capacity expansion and sustainability.
PRF Composite Materials (Poole, U.K.) announces the opening of its fourth manufacturing facility, completing an investment and expansion program approaching £6 million, and significantly increasing manufacturing and R&D capacity and capability. This state-of-the-art, purpose-built 14,700-square-foot manufacturing site brings material processing for kitting into a single, controlled environment, the company notes, increasing manufacturing efficiency and helping PRF to minimize the impact of excessive price increases seen across the industry.
In total, this new facility increases PRF’s total factory space to 40,000 square feet, and will make space in its other sites for further R&D and manufacturing expansion. Throughout 2020 and 2021, the team have reportedly been busy investing and improving in R&D, with a complete upgrade of test equipment in both chemical and material testing laboratories, thereby opening the door for new product development and technologies. The team has also increased freezer storage space to 735 cubic meters and installed an additional CNC machine and a third impregnation line. With sustainability in mind, the new site has been built with eco-efficient fixtures and fittings, including a PV system which generates 29,965 kilowatts of electricity a year, saving 16,676 kilograms of carbon dioxide.
“Completing this significant expansion and investment into both capacity and technology will ensure that PRF can meet and exceed market and customer needs for the future, with industry-leading, innovative product development and efficient manufacturing,” says Head of Operations, Dave Ellson. “PRF will continue to invest in R&D, capacity expansion and sustainability; working with our customers and supply chain with environmental needs in mind to contribute to a better future.”
#composites #PRFCompositeMaterials
> photo Credit: PRF Composite Materials
> source
The completed £6 million investment and expansion program increases the company’s R&D, capacity expansion and sustainability.
PRF Composite Materials (Poole, U.K.) announces the opening of its fourth manufacturing facility, completing an investment and expansion program approaching £6 million, and significantly increasing manufacturing and R&D capacity and capability. This state-of-the-art, purpose-built 14,700-square-foot manufacturing site brings material processing for kitting into a single, controlled environment, the company notes, increasing manufacturing efficiency and helping PRF to minimize the impact of excessive price increases seen across the industry.
In total, this new facility increases PRF’s total factory space to 40,000 square feet, and will make space in its other sites for further R&D and manufacturing expansion. Throughout 2020 and 2021, the team have reportedly been busy investing and improving in R&D, with a complete upgrade of test equipment in both chemical and material testing laboratories, thereby opening the door for new product development and technologies. The team has also increased freezer storage space to 735 cubic meters and installed an additional CNC machine and a third impregnation line. With sustainability in mind, the new site has been built with eco-efficient fixtures and fittings, including a PV system which generates 29,965 kilowatts of electricity a year, saving 16,676 kilograms of carbon dioxide.
“Completing this significant expansion and investment into both capacity and technology will ensure that PRF can meet and exceed market and customer needs for the future, with industry-leading, innovative product development and efficient manufacturing,” says Head of Operations, Dave Ellson. “PRF will continue to invest in R&D, capacity expansion and sustainability; working with our customers and supply chain with environmental needs in mind to contribute to a better future.”
#composites #PRFCompositeMaterials
> photo Credit: PRF Composite Materials
> source
Composites
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Lanxess, INFAC develop composite battery module housing
The halogen-free, flame-retardant and glass fiber-reinforced polyamide 6 (PA6) part lowers battery module assembly weight, improves insulation and flame resistance and retains a high level of functional integration.
Specialty chemicals company Lanxess (Cologne, Germany) and Korean auto parts specialist INFAC (Seoul), which specializes in automotive control cables, actuators, antennas, and battery packs, have together developed a battery module housing for electric vehicles (EVs).
The battery housing uses Durethan BKV30FN04 from Lanxess to satisfy stringent mechanical and chemical property requirements for latest EV components. The halogen-free, flame-retardant and glass fiber-reinforced polyamide 6 (PA6) is characterized by its optimized flame-retardant and electrical properties. Lanxess notes that the material is highly processable and enables the integration of complex functions required for housing components, resulting in a smaller number of parts and a simplified assembly process as well as lighter weight.
Moreover, the new battery housing part has been adopted to series production of EV models launched by a Korean OEM this year. “Success in mass production of battery housing demonstrates Lanxess Durethan’s excellence in EV batteries, in which technology and safety are of utmost importance. Our high-performance plastics will make a significant contribution to the EV and battery markets,” says Milan Vignjevic, head of Lanxess’ High Performance Materials (HPM) business unit in Asia-Pacific.
According to Lanxess, Durethan BKV30FN04 is not only mechanically robust, but also boasts high-voltage insulation, is resistant to up to 800 volts and effectively blocking high-voltage current, characteristics that are critical in order to protect the battery from external shock. In addition to maintaining high strength and stiffness when in contact with electrolyte or cooling media, and enabling chemical resistance to suppress chemically-induced damage, the material’s flame-retardant properties help prevent or delay flames from spreading in case of a fire. Lanxess claims glass fiber-reinforced Durethan BKV30FN04’s durability to mechanical loads is also superior to unfilled PA6.
Lanxess’ engineering plastics can reportedly be applied to a wide range of battery components including battery covers, high-voltage connectors, cable brackets and battery cell cooling system pipes as well as parts for hydrogen fuel cell vehicles such as hydrogen storage tanks. It can also replace metals in various components, enabling lightweight design. Overall, it allows the production of several functional components in one process, a driver behind continuous growth in demand in the next-generation mobility market where a number of technologies and components come into play.
“High-quality materials, technical expertise and customized engineering services from Lanxess enabled us to speed up our development. This helped solidify our position in the fast-evolving EV battery parts market,” says Gyuso Lee, head of Purchasing & Development at INFAC.
Sanghun Han, head of HPM in Korea, adds that Lanxess has closely cooperated with globally leading automotive OEMs, including from Korea. “That is why we were able to identify the trends and the challenges of e-mobility at an early stage and participate in various EV and battery development projects,” Han says. “With accumulated success stories with our customers, we are establishing ourselves as a key material partner in new mobility.”
#composites #electricvehicles #Lanxess
> source
The halogen-free, flame-retardant and glass fiber-reinforced polyamide 6 (PA6) part lowers battery module assembly weight, improves insulation and flame resistance and retains a high level of functional integration.
Specialty chemicals company Lanxess (Cologne, Germany) and Korean auto parts specialist INFAC (Seoul), which specializes in automotive control cables, actuators, antennas, and battery packs, have together developed a battery module housing for electric vehicles (EVs).
The battery housing uses Durethan BKV30FN04 from Lanxess to satisfy stringent mechanical and chemical property requirements for latest EV components. The halogen-free, flame-retardant and glass fiber-reinforced polyamide 6 (PA6) is characterized by its optimized flame-retardant and electrical properties. Lanxess notes that the material is highly processable and enables the integration of complex functions required for housing components, resulting in a smaller number of parts and a simplified assembly process as well as lighter weight.
Moreover, the new battery housing part has been adopted to series production of EV models launched by a Korean OEM this year. “Success in mass production of battery housing demonstrates Lanxess Durethan’s excellence in EV batteries, in which technology and safety are of utmost importance. Our high-performance plastics will make a significant contribution to the EV and battery markets,” says Milan Vignjevic, head of Lanxess’ High Performance Materials (HPM) business unit in Asia-Pacific.
According to Lanxess, Durethan BKV30FN04 is not only mechanically robust, but also boasts high-voltage insulation, is resistant to up to 800 volts and effectively blocking high-voltage current, characteristics that are critical in order to protect the battery from external shock. In addition to maintaining high strength and stiffness when in contact with electrolyte or cooling media, and enabling chemical resistance to suppress chemically-induced damage, the material’s flame-retardant properties help prevent or delay flames from spreading in case of a fire. Lanxess claims glass fiber-reinforced Durethan BKV30FN04’s durability to mechanical loads is also superior to unfilled PA6.
Lanxess’ engineering plastics can reportedly be applied to a wide range of battery components including battery covers, high-voltage connectors, cable brackets and battery cell cooling system pipes as well as parts for hydrogen fuel cell vehicles such as hydrogen storage tanks. It can also replace metals in various components, enabling lightweight design. Overall, it allows the production of several functional components in one process, a driver behind continuous growth in demand in the next-generation mobility market where a number of technologies and components come into play.
“High-quality materials, technical expertise and customized engineering services from Lanxess enabled us to speed up our development. This helped solidify our position in the fast-evolving EV battery parts market,” says Gyuso Lee, head of Purchasing & Development at INFAC.
Sanghun Han, head of HPM in Korea, adds that Lanxess has closely cooperated with globally leading automotive OEMs, including from Korea. “That is why we were able to identify the trends and the challenges of e-mobility at an early stage and participate in various EV and battery development projects,” Han says. “With accumulated success stories with our customers, we are establishing ourselves as a key material partner in new mobility.”
#composites #electricvehicles #Lanxess
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MAE Museum dedicated to and built largely from new and recycled carbon fiber
Museum showcases the advancements in carbon fiber development where visitors can observe transformation process of acrylic fiber into carbon fiber.
MAE Museum, designed by Carlo Ratti Associatti (CRA) and architect Italo Rota for equipment manufacturer MAE. Renderings by CRA graphic team: Gary di Silvio, Pasquale Milieri, Gianluca Zimbardi.
“From high-performance bikes to the Lamborghini Aventador car, carbon fiber is driving innovation in multiple sectors. The MAE museum celebrates a defining material of modernity, by focusing on its new circular frontier and envisioning new applications for its use,” says Carlo Ratti, founding partner at CRA and a professor at the Massachusetts Institute of Technology (MIT, Cambridge, Mass., U.S.). “We are delighted to work with MAE, a company whose history and know-how pioneered the transition from the original use of acrylic fiber in clothing to today’s use of carbon fiber in industries as varied as aerospace and automotive.”
International design and innovation office CRA-Carlo Ratti Associati and architect Italo Rota have unveiled the design of the MAE Museum, an exhibition space dedicated to carbon fiber, a material that is central to the future of manufacturing. The museum itself will be built largely out of carbon fiber, both new and recycled, pursuing a circular approach to design. The exhibition path will employ robotics to guide visitors through what is said to be the world’s largest archive of acrylic fiber technologies, documenting scientific advancements in the development of carbon fiber, as well as parallel changes in society and fashion. Developed for leading polymer and fiber machinery manufacturing company MAE (Fiorenzuola d’Arda, Italy), the new museum will be located near the company’s headquarters, south of Piacenza, Italy.
Carbon fiber is a lightweight, high-strength material used in everything from aerospace to the automotive industry to bicycle manufacturing. It is manufactured using a type of acrylic fiber, similar to the one commonly used in clothing, which is transformed into carbon fiber through a complex chemical process made possible by the machines produced by MAE.
Similarly, the MAE museum’s exhibition path is conceived as a twofold journey from the past into the future, from the heyday of synthetic fibers in postwar European clothing, to the latest breakthroughs in chemical and engineering research. While the museum is located inside a renovated warehouse, most interior components are built with acrylic and carbon fiber, including the entrance doors which open like a curtain.
In the first section of the museum, visitors will encounter a robotic archive warehouse, lit with dazzling white light and filled with MAE’s historical documents. A series of mechanical arms will move along the walls to extract photos, technical dossiers and campaigns from the brand’s 50-year history, and bring these items to a raised central platform, where visitors can sit and browse through them. After that, visitors will go through a long corridor where they can observe the process by which acrylic fiber is transformed into carbon fiber. This will be followed by the second section of the museum dedicated to the use of carbon fiber in contemporary industry. Within a black room enriched by an immersive installation, a set of interactive artifacts will explore the experimental applications of carbon fiber and show the most innovative prototypes made with it by leading companies in automotive and aerospace, for example.
Museum showcases the advancements in carbon fiber development where visitors can observe transformation process of acrylic fiber into carbon fiber.
MAE Museum, designed by Carlo Ratti Associatti (CRA) and architect Italo Rota for equipment manufacturer MAE. Renderings by CRA graphic team: Gary di Silvio, Pasquale Milieri, Gianluca Zimbardi.
“From high-performance bikes to the Lamborghini Aventador car, carbon fiber is driving innovation in multiple sectors. The MAE museum celebrates a defining material of modernity, by focusing on its new circular frontier and envisioning new applications for its use,” says Carlo Ratti, founding partner at CRA and a professor at the Massachusetts Institute of Technology (MIT, Cambridge, Mass., U.S.). “We are delighted to work with MAE, a company whose history and know-how pioneered the transition from the original use of acrylic fiber in clothing to today’s use of carbon fiber in industries as varied as aerospace and automotive.”
International design and innovation office CRA-Carlo Ratti Associati and architect Italo Rota have unveiled the design of the MAE Museum, an exhibition space dedicated to carbon fiber, a material that is central to the future of manufacturing. The museum itself will be built largely out of carbon fiber, both new and recycled, pursuing a circular approach to design. The exhibition path will employ robotics to guide visitors through what is said to be the world’s largest archive of acrylic fiber technologies, documenting scientific advancements in the development of carbon fiber, as well as parallel changes in society and fashion. Developed for leading polymer and fiber machinery manufacturing company MAE (Fiorenzuola d’Arda, Italy), the new museum will be located near the company’s headquarters, south of Piacenza, Italy.
Carbon fiber is a lightweight, high-strength material used in everything from aerospace to the automotive industry to bicycle manufacturing. It is manufactured using a type of acrylic fiber, similar to the one commonly used in clothing, which is transformed into carbon fiber through a complex chemical process made possible by the machines produced by MAE.
Similarly, the MAE museum’s exhibition path is conceived as a twofold journey from the past into the future, from the heyday of synthetic fibers in postwar European clothing, to the latest breakthroughs in chemical and engineering research. While the museum is located inside a renovated warehouse, most interior components are built with acrylic and carbon fiber, including the entrance doors which open like a curtain.
In the first section of the museum, visitors will encounter a robotic archive warehouse, lit with dazzling white light and filled with MAE’s historical documents. A series of mechanical arms will move along the walls to extract photos, technical dossiers and campaigns from the brand’s 50-year history, and bring these items to a raised central platform, where visitors can sit and browse through them. After that, visitors will go through a long corridor where they can observe the process by which acrylic fiber is transformed into carbon fiber. This will be followed by the second section of the museum dedicated to the use of carbon fiber in contemporary industry. Within a black room enriched by an immersive installation, a set of interactive artifacts will explore the experimental applications of carbon fiber and show the most innovative prototypes made with it by leading companies in automotive and aerospace, for example.
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The MAE Museum will be located at MAE’s Italian headquarters, just south of Piacenza and a one-hour drive from Milan. It will cater to different audiences including the general public and schools, as well as chemistry and engineering specialists. In early July 2021, MAE announced a collaboration with Leonardo (Rome, Italy), one of the world’s largest defense contractors, to build a €17-million pilot plant at this same location, which will produce innovative materials for use in the fields of aerospace, defense and security.
The MAE Museum project builds on recent CRA research in both the design of cultural spaces and the concept of circularity in architecture. The Italian Pavilion at Expo Dubai 2020, designed by CRA and Italo Rota along with F&M Ingegneria and Matteo Gatto, focuses specifically on the use of experimental construction materials, and will open in early October 2021. CRA also recently completed the construction of the MEET Digital Arts Center in Milan and curated the “Eyes of the City” exhibition at the eighth Bi-City Biennale of Urbanism and Architecture in Shenzhen, China.
#composites #MAEMuseum #RecycledCarbonFiber
Renderings by Carlo Ratti Associatti (CRA).
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The MAE Museum project builds on recent CRA research in both the design of cultural spaces and the concept of circularity in architecture. The Italian Pavilion at Expo Dubai 2020, designed by CRA and Italo Rota along with F&M Ingegneria and Matteo Gatto, focuses specifically on the use of experimental construction materials, and will open in early October 2021. CRA also recently completed the construction of the MEET Digital Arts Center in Milan and curated the “Eyes of the City” exhibition at the eighth Bi-City Biennale of Urbanism and Architecture in Shenzhen, China.
#composites #MAEMuseum #RecycledCarbonFiber
Renderings by Carlo Ratti Associatti (CRA).
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Airbus Single-Aisle Airspace cabin enters into service with Lufthansa Group
Lufthansa becomes the first airline in Europe to feature Airbus’ new Airspace cabin, which makes extensive use of composites, on single-aisle aircraft.
As of Sept. 6, the Deutsche Lufthansa AG airline (Lufthansa, Frankfurt, Germany) has started operations with its first A320 Family aircraft — an A321neo — featuring Airbus’ new Single-Aisle Airspace cabin, which makes extensive use of composites. In doing so, the airline is said to becomes the first operator in Europe to introduce the new Airspace cabin feature for passengers on board A320 Family aircraft. In 2018 Lufthansa Group, a long-time A320 Family customer, chose to equip more than 80 of its new A320 Family aircraft on order from Airbus with Airspace cabins.
The new Airspace features include slimmer sidewall panels for extra personal space at shoulder level; better views through the windows with redesigned bezels and completely integrated window shades; large, composite overhead bins for 60% more bags; the latest full LED lighting technologies; LED-lit “entrance area”; and new lavatories with hygienic touchless features and antimicrobial surfaces.
“Lufthansa has once again made a choice of innovation and passenger appeal, raising the bar for the flying public at large to experience next-level, Airbus leading cabin innovations,” says Christian Scherer, Airbus chief commercial officer and head of international. “I am delighted to welcome one of our long-term partners, Lufthansa, to become the first European operator for the A320neo Family Airspace cabin. I can’t wait to fly on one of these aircraft.”
Head of Customer Experience, Lufthansa Group Heike Birlenbach emphasizes that, regardless of the crisis, Lufthansa continues to focus emphatically on a premium product for its guests. “For us, premium means providing high-quality, individualized and relevant offers for all our passengers at all times,” says Birlenbach. “With the new Airspace Cabin, we are significantly improving the travel experience on short-haul routes and setting a new industry benchmark.”
Lufthansa has been operating the A320-family since the 1980s and is reported to have been the first operator of the A321 and the A320neo. The airline group is one of the biggest Airbus operators worldwide.
At the end of July 2021, the A320neo Family had received more than 7,400 orders from more than 120 customers worldwide.
#composites #airbus
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Lufthansa becomes the first airline in Europe to feature Airbus’ new Airspace cabin, which makes extensive use of composites, on single-aisle aircraft.
As of Sept. 6, the Deutsche Lufthansa AG airline (Lufthansa, Frankfurt, Germany) has started operations with its first A320 Family aircraft — an A321neo — featuring Airbus’ new Single-Aisle Airspace cabin, which makes extensive use of composites. In doing so, the airline is said to becomes the first operator in Europe to introduce the new Airspace cabin feature for passengers on board A320 Family aircraft. In 2018 Lufthansa Group, a long-time A320 Family customer, chose to equip more than 80 of its new A320 Family aircraft on order from Airbus with Airspace cabins.
The new Airspace features include slimmer sidewall panels for extra personal space at shoulder level; better views through the windows with redesigned bezels and completely integrated window shades; large, composite overhead bins for 60% more bags; the latest full LED lighting technologies; LED-lit “entrance area”; and new lavatories with hygienic touchless features and antimicrobial surfaces.
“Lufthansa has once again made a choice of innovation and passenger appeal, raising the bar for the flying public at large to experience next-level, Airbus leading cabin innovations,” says Christian Scherer, Airbus chief commercial officer and head of international. “I am delighted to welcome one of our long-term partners, Lufthansa, to become the first European operator for the A320neo Family Airspace cabin. I can’t wait to fly on one of these aircraft.”
Head of Customer Experience, Lufthansa Group Heike Birlenbach emphasizes that, regardless of the crisis, Lufthansa continues to focus emphatically on a premium product for its guests. “For us, premium means providing high-quality, individualized and relevant offers for all our passengers at all times,” says Birlenbach. “With the new Airspace Cabin, we are significantly improving the travel experience on short-haul routes and setting a new industry benchmark.”
Lufthansa has been operating the A320-family since the 1980s and is reported to have been the first operator of the A321 and the A320neo. The airline group is one of the biggest Airbus operators worldwide.
At the end of July 2021, the A320neo Family had received more than 7,400 orders from more than 120 customers worldwide.
#composites #airbus
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