Composites
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Solvay and 9T Labs mass-productionise composite AM parts
Solvay is working with advanced manufacturing solution OEM, 9T Labs to help bring additively-manufactured CFRP composite parts to mass production.
The joint effort enables 9T Labs’ additive manufacturing technology to produce low-to-medium volume size parts for the aerospace, medical, luxury/leisure, automation, and oil & gas industries.
Solvay will focus on the development of carbon fibre-reinforced polyetheretherketone (CF/PEEK), CF-reinforced bio-based high performance polyamides and CF-reinforced polyphenylene sulfide (CF/PPS) composite materials. The partnership significantly expands the types of neat and carbon fibre-reinforced materials portfolio that 9T Labs currently offers to customers.
“With 9T Labs’ innovative process and equipment and Solvay’s high-performance thermoplastic materials, we are well positioned to address problems that have long plagued manufacturers in many industries trying to use advanced composites — namely high incremental costs, high scrap, and problems achieving repeatability and traceability at high volumes,” explained Marco Apostolo, director of technology at Solvay. “We believe this collaboration will help solve many challenges and will open entirely new markets and mass production applications to CFRP materials.”
Solvay offers a portfolio of high-performance thermoplastic polymers and expertise in the production of thermoplastic composite prepreg tape. As one of the leaders in thermoplastic composites, Solvay brings expertise in the engineering of production processes to ensure the technology can be integrated seamlessly into manufacturing lines.
“For the fabrication of structural parts metals still prevail because the manufacturing of structural CFRP parts has not been cost-competitive,” added Giovanni Cavolina, 9T Labs’ co-founder and chief commercial officer. “The Red Series platform in combination with Solvay’s high-performance and recyclable materials will change this and make CFRP parts more sustainable, accessible and cost-competitive, especially at higher volumes.”
9T Labs’ hybrid manufacturing technology enables high-performance structural parts in challenging small-to-medium size and thick sections to be produced in carbon fibre-reinforced thermoplastic composites in production volumes ranging from 100 to 10,000 parts/year.
#composites #Solvay #CFRP
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Solvay is working with advanced manufacturing solution OEM, 9T Labs to help bring additively-manufactured CFRP composite parts to mass production.
The joint effort enables 9T Labs’ additive manufacturing technology to produce low-to-medium volume size parts for the aerospace, medical, luxury/leisure, automation, and oil & gas industries.
Solvay will focus on the development of carbon fibre-reinforced polyetheretherketone (CF/PEEK), CF-reinforced bio-based high performance polyamides and CF-reinforced polyphenylene sulfide (CF/PPS) composite materials. The partnership significantly expands the types of neat and carbon fibre-reinforced materials portfolio that 9T Labs currently offers to customers.
“With 9T Labs’ innovative process and equipment and Solvay’s high-performance thermoplastic materials, we are well positioned to address problems that have long plagued manufacturers in many industries trying to use advanced composites — namely high incremental costs, high scrap, and problems achieving repeatability and traceability at high volumes,” explained Marco Apostolo, director of technology at Solvay. “We believe this collaboration will help solve many challenges and will open entirely new markets and mass production applications to CFRP materials.”
Solvay offers a portfolio of high-performance thermoplastic polymers and expertise in the production of thermoplastic composite prepreg tape. As one of the leaders in thermoplastic composites, Solvay brings expertise in the engineering of production processes to ensure the technology can be integrated seamlessly into manufacturing lines.
“For the fabrication of structural parts metals still prevail because the manufacturing of structural CFRP parts has not been cost-competitive,” added Giovanni Cavolina, 9T Labs’ co-founder and chief commercial officer. “The Red Series platform in combination with Solvay’s high-performance and recyclable materials will change this and make CFRP parts more sustainable, accessible and cost-competitive, especially at higher volumes.”
9T Labs’ hybrid manufacturing technology enables high-performance structural parts in challenging small-to-medium size and thick sections to be produced in carbon fibre-reinforced thermoplastic composites in production volumes ranging from 100 to 10,000 parts/year.
#composites #Solvay #CFRP
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Left to right: Claus Wilde, managing director of Engel Deutschland, Prof. Peter Michel, head of the polymer applications business unit at the Fraunhofer IMWS and responsible for polymer processing at the Fraunhofer PAZ, and Franz Füreder, vice president, automotive, at Engel Austria.
Photo Credit: Engel
Photo Credit: Engel
Composites
Left to right: Claus Wilde, managing director of Engel Deutschland, Prof. Peter Michel, head of the polymer applications business unit at the Fraunhofer IMWS and responsible for polymer processing at the Fraunhofer PAZ, and Franz Füreder, vice president, automotive…
Fraunhofer commissions automated Engel production cells for thermoplastic composite R&D
Fraunhofer PAZ pilot plant center installs v-duo 700 vertical machine and duo 900 injection molding machine to combine thermoplastic composite processes with a variety of injection molding technologies.
Fraunhofer’s Pilot Plant Centre for Polymer Synthesis and Processing PAZ located in Schkopau, Germany, recently commissioned two Engel (Schwertberg, Austria) machines to strengthen its research and development (R&D) of lightweight applications using thermoplastic composites. The two state-of-the-art production cells enable the integration and fully automated production of functional composite components and are now available for customer projects.
“Engel combines a great deal of know-how in lightweight construction with thermoplastic composites and many years of experience in injection molding and the automation of series processes. This is a prerequisite to developing particularly cost-effective series production processes for the automotive and aerospace industries,” says Franz Füreder, vice president, automotive, at Engel. “The two new Engel systems at the Fraunhofer PAZ make it possible to combine thermoplastic-based composite processes with a variety of injection molding technologies, such as foaming or coining.”
From monomer to polymer synthesis and plastics processing on a pilot scale, to the tested series component, Fraunhofer PAZ says it develops new production processes and technologies along the entire value chain of lightweight components. Thermoplastics-based lightweight construction is one development focus, which it shares in common with Engel. “On the one hand, thermoplastic composites enable excellent cost efficiency in series production,” Füreder notes. “On the other, these materials can be returned to the material cycle easily.”
Engel delivered a v-duo 700 vertical machine, which was combined with an Engel easix articulated robot and a large IR oven. An Engel duo 900 injection molding machine with a horizontal clamping unit and two Engel easix robots make up the second commissioned production cell. A vertical IR oven is located above the clamping unit of the latter, enabling fast, hot handling of thermoplastic sheets and blanks made of unidirectional (UD) tapes. Engel has also integrated injection molding technology packages, such as physical foaming.
#ThermoplasticСomposites #Fraunhofer #LightweightConstructions
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Fraunhofer PAZ pilot plant center installs v-duo 700 vertical machine and duo 900 injection molding machine to combine thermoplastic composite processes with a variety of injection molding technologies.
Fraunhofer’s Pilot Plant Centre for Polymer Synthesis and Processing PAZ located in Schkopau, Germany, recently commissioned two Engel (Schwertberg, Austria) machines to strengthen its research and development (R&D) of lightweight applications using thermoplastic composites. The two state-of-the-art production cells enable the integration and fully automated production of functional composite components and are now available for customer projects.
“Engel combines a great deal of know-how in lightweight construction with thermoplastic composites and many years of experience in injection molding and the automation of series processes. This is a prerequisite to developing particularly cost-effective series production processes for the automotive and aerospace industries,” says Franz Füreder, vice president, automotive, at Engel. “The two new Engel systems at the Fraunhofer PAZ make it possible to combine thermoplastic-based composite processes with a variety of injection molding technologies, such as foaming or coining.”
From monomer to polymer synthesis and plastics processing on a pilot scale, to the tested series component, Fraunhofer PAZ says it develops new production processes and technologies along the entire value chain of lightweight components. Thermoplastics-based lightweight construction is one development focus, which it shares in common with Engel. “On the one hand, thermoplastic composites enable excellent cost efficiency in series production,” Füreder notes. “On the other, these materials can be returned to the material cycle easily.”
Engel delivered a v-duo 700 vertical machine, which was combined with an Engel easix articulated robot and a large IR oven. An Engel duo 900 injection molding machine with a horizontal clamping unit and two Engel easix robots make up the second commissioned production cell. A vertical IR oven is located above the clamping unit of the latter, enabling fast, hot handling of thermoplastic sheets and blanks made of unidirectional (UD) tapes. Engel has also integrated injection molding technology packages, such as physical foaming.
#ThermoplasticСomposites #Fraunhofer #LightweightConstructions
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Composites
Photo Credit: Getty Images
Grafen AB introduces graphene-coated textiles
The G-Heatex series uses graphene flakes to entirely impregnate textiles for uniform electrical resistance properties. It is available for a range of textile substrate types.
Grafren AB (Linköping, Sweden) has introduced G-Heatex, a series of graphene-coated textiles, which reportedly supply powerful and uniform heat while remaining soft, flexible, breathable and ultra-lightweight.
Grafren AB has recently patented two innovations, which are now covering its full production cycle. The company now has the technology for separating high-quality graphene flakes from any grade of incoming material. The access to the high-quality graphene will enable the company to work on graphene textiles.
“We invented the method to incorporate [the] smallest flakes of graphene inside of the fabric on the nanoscale level,” says Grafren’s Technical Director, Dr. Mike Zhyback. Graphene nanoparticles — or flakes — are entirely impregnated inside the fabric and coating layer by layer in every individual textile fiber. Because of the high electrical conductivity of graphene, attached flakes create a “conductive skin” on every fiber, which makes the entire fabric electrically active. Graphene can be coated on diverse textile substrates and the electrical resistance can be tailored depending on the application requirements.
Graphene textiles are said to have applications in defense, aerospace, healthcare, mobility and automotive due to the number of functions it possesses. Grafren says it is currently focused on the heating function of the fabric, as well as creating fully textile electrical heating elements to deliver uniform, homogeneous heat. The company claims that this is the only solution of its kind on the market.
#composites #graphene #nanoparticles
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The G-Heatex series uses graphene flakes to entirely impregnate textiles for uniform electrical resistance properties. It is available for a range of textile substrate types.
Grafren AB (Linköping, Sweden) has introduced G-Heatex, a series of graphene-coated textiles, which reportedly supply powerful and uniform heat while remaining soft, flexible, breathable and ultra-lightweight.
Grafren AB has recently patented two innovations, which are now covering its full production cycle. The company now has the technology for separating high-quality graphene flakes from any grade of incoming material. The access to the high-quality graphene will enable the company to work on graphene textiles.
“We invented the method to incorporate [the] smallest flakes of graphene inside of the fabric on the nanoscale level,” says Grafren’s Technical Director, Dr. Mike Zhyback. Graphene nanoparticles — or flakes — are entirely impregnated inside the fabric and coating layer by layer in every individual textile fiber. Because of the high electrical conductivity of graphene, attached flakes create a “conductive skin” on every fiber, which makes the entire fabric electrically active. Graphene can be coated on diverse textile substrates and the electrical resistance can be tailored depending on the application requirements.
Graphene textiles are said to have applications in defense, aerospace, healthcare, mobility and automotive due to the number of functions it possesses. Grafren says it is currently focused on the heating function of the fabric, as well as creating fully textile electrical heating elements to deliver uniform, homogeneous heat. The company claims that this is the only solution of its kind on the market.
#composites #graphene #nanoparticles
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Composites
Ariane 6 kick stage. Photo Credit: FACC AG
FACC develops and manufactures composite structures for Ariane 6 launch vehicle
Astris kick stage main structure will be characterized by high strength and the use of ultralight carbon fiber material, with first delivery scheduled for October 2022.
In an effort to use its composites technologies to tap into end markets outside of its core aerospace business, FACC AG (Ried im Innkreis, Austria) has secured its first project under its New Space business segment, with an order from the ArianeGroup (Paris, France) to develop and manufacture the Astris kick stage main structure for the Ariane 6 family of launch vehicles.
“By awarding us a contract to participate in the Ariane 6 rocket, the ArianeGroup has placed its trust in us to help shape the new generation of European launch vehicles as a development and manufacturing partner,” notes Robert Machtlinger, CEO of FACC. “For us, space is an important future topic, which we have defined as a new business field in our 2030 corporate strategy. This is an area where we can make valuable use of our FACC composite technologies, which we have been developing for the aviation industry over the past decades. Our goal is to apply our lightweight construction expertise and state-of-the-art manufacturing facilities to provide a carbon fiber solution for the load-bearing structure of Ariane 6 kick stage that will reduce weight and enable use for commercial space transportation through efficient series production.”
The ArianeGroup is a leading enterprise in the field of space transportation. With its new launch vehicle, the company aims to offer maximum flexibility to its customers in institutional and commercial markets. Ariane 6 is a program of the European Space Agency (ESA), and is designed to provide independent access to space for a wide range of missions.
The kick stage main structure, which will be developed and produced by FACC, is the load-bearing structure of an additional optional stage which is designed to expand the Ariane 6’s mission range and make the rocket more versatile in terms of the types of payloads it could carry. The component is characterized by high strength and the use of ultralight carbon fiber materials; it carries, in addition to the actual payload, four fuel tanks, the newly developed Berta engine and state-of-the-art flight electronics into higher spheres. In addition, the use of carbon fiber for the launch vehicle’s rocket stage is also under development.
The first delivery is scheduled to arrive in Bremen, Germany, in October 2022. There, the kick stage will undergo further tests for a potential first mission, the ESA’s Hera mission, which is to demonstrate planetary asteroid defense technologies. The goal of Hera is to test the extent to which an asteroid can be deflected from its trajectory by means of two comets passing by Earth.
Overall, FACC’s contribution brings the company a step closer to looking beyond existing horizons and establishing itself as an innovator in multiple fields.
#composites #CompositeStructures #CarbonFiber
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Astris kick stage main structure will be characterized by high strength and the use of ultralight carbon fiber material, with first delivery scheduled for October 2022.
In an effort to use its composites technologies to tap into end markets outside of its core aerospace business, FACC AG (Ried im Innkreis, Austria) has secured its first project under its New Space business segment, with an order from the ArianeGroup (Paris, France) to develop and manufacture the Astris kick stage main structure for the Ariane 6 family of launch vehicles.
“By awarding us a contract to participate in the Ariane 6 rocket, the ArianeGroup has placed its trust in us to help shape the new generation of European launch vehicles as a development and manufacturing partner,” notes Robert Machtlinger, CEO of FACC. “For us, space is an important future topic, which we have defined as a new business field in our 2030 corporate strategy. This is an area where we can make valuable use of our FACC composite technologies, which we have been developing for the aviation industry over the past decades. Our goal is to apply our lightweight construction expertise and state-of-the-art manufacturing facilities to provide a carbon fiber solution for the load-bearing structure of Ariane 6 kick stage that will reduce weight and enable use for commercial space transportation through efficient series production.”
The ArianeGroup is a leading enterprise in the field of space transportation. With its new launch vehicle, the company aims to offer maximum flexibility to its customers in institutional and commercial markets. Ariane 6 is a program of the European Space Agency (ESA), and is designed to provide independent access to space for a wide range of missions.
The kick stage main structure, which will be developed and produced by FACC, is the load-bearing structure of an additional optional stage which is designed to expand the Ariane 6’s mission range and make the rocket more versatile in terms of the types of payloads it could carry. The component is characterized by high strength and the use of ultralight carbon fiber materials; it carries, in addition to the actual payload, four fuel tanks, the newly developed Berta engine and state-of-the-art flight electronics into higher spheres. In addition, the use of carbon fiber for the launch vehicle’s rocket stage is also under development.
The first delivery is scheduled to arrive in Bremen, Germany, in October 2022. There, the kick stage will undergo further tests for a potential first mission, the ESA’s Hera mission, which is to demonstrate planetary asteroid defense technologies. The goal of Hera is to test the extent to which an asteroid can be deflected from its trajectory by means of two comets passing by Earth.
Overall, FACC’s contribution brings the company a step closer to looking beyond existing horizons and establishing itself as an innovator in multiple fields.
#composites #CompositeStructures #CarbonFiber
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Composites
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NCC and Nexam find solution for composites use in extreme temperatures
In collaboration with Nexam Chemical, The National Composites Centre (NCC) says it has successfully manufactured a composite using a high temperature resin, providing a solution to the challenge of using advanced materials in components that need to withstand extreme temperatures.
The NCC’s interdisciplinary expertise in the fields of High Volume Manufacturing, Tooling, Design, Materials Science and Flow Simulation solved the manufacturing challenges existing at elevated temperatures and proved a composite part can be made using resin. This development paves the way for industry to take advantage of the unique qualities composites offer in elements that get very hot, such as sections of engines and the housing for electric batteries, which wasn’t previously possible.
Throughout its research, the specialist team used Nexam Chemical’s new resin system, NEXIMID. Produced in the UK, NEXIMID can operate at temperatures up to 400°C, higher than almost all other resin systems. Whilst resin transfer moulding is usually conducted at around 120°C, by developing high temperature specialist equipment – including unique tooling design and high temperature sealings – the NCC were able to keep the resin above 250°C throughout the injection process, allowing the resin’s high temperature capability to be combined with a high processing temperature for a final product that can cope with much higher temperatures than previous composites.
Throughout the process, the NCC, part of the High Value Manufacturing Catapult, has also shown that the resin system is safe, not emitting the high levels of toxic gases that other Polyimide resins can.
“Being able manufacture carbon fibre composites using a UK-produced high temperature resin system is a huge step forward in enabling industry to adopt advanced materials in components that were previously unable to take advantage of them,” said Dr David King, Advanced Research Engineer at the NCC. “The excellent thermal capability of the material expands the boundaries of composites into more demanding applications. Based on the emerging details of this expanded capability we are already working with industry customers on new applications for composite parts, and are excited to further develop our High Temperature Resin Transfer Moulding capability by collaborating closely with Nexam and other partners.”
Boyd Cushing, Business Development for Nexam Chemical UK & Ireland, added: “We are delighted that our five years of collaboration with the NCC has resulted in a major innovation breakthrough for high temperature RTM composites. We look forward to welcoming industrial partners who may have interest with our Scottish origin NEXIMID non ITAR restricted resin in aerospace and defence applications that are looking for high performance material composite parts.”
Following this successful collaboration, Nexam Chemical has joined the NCC as an SME Affiliate Member, paving the way for further projects that will aid industry in using high temperature resin transfer moulding to their advantage.
#composites #ExtremeTemperatures
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In collaboration with Nexam Chemical, The National Composites Centre (NCC) says it has successfully manufactured a composite using a high temperature resin, providing a solution to the challenge of using advanced materials in components that need to withstand extreme temperatures.
The NCC’s interdisciplinary expertise in the fields of High Volume Manufacturing, Tooling, Design, Materials Science and Flow Simulation solved the manufacturing challenges existing at elevated temperatures and proved a composite part can be made using resin. This development paves the way for industry to take advantage of the unique qualities composites offer in elements that get very hot, such as sections of engines and the housing for electric batteries, which wasn’t previously possible.
Throughout its research, the specialist team used Nexam Chemical’s new resin system, NEXIMID. Produced in the UK, NEXIMID can operate at temperatures up to 400°C, higher than almost all other resin systems. Whilst resin transfer moulding is usually conducted at around 120°C, by developing high temperature specialist equipment – including unique tooling design and high temperature sealings – the NCC were able to keep the resin above 250°C throughout the injection process, allowing the resin’s high temperature capability to be combined with a high processing temperature for a final product that can cope with much higher temperatures than previous composites.
Throughout the process, the NCC, part of the High Value Manufacturing Catapult, has also shown that the resin system is safe, not emitting the high levels of toxic gases that other Polyimide resins can.
“Being able manufacture carbon fibre composites using a UK-produced high temperature resin system is a huge step forward in enabling industry to adopt advanced materials in components that were previously unable to take advantage of them,” said Dr David King, Advanced Research Engineer at the NCC. “The excellent thermal capability of the material expands the boundaries of composites into more demanding applications. Based on the emerging details of this expanded capability we are already working with industry customers on new applications for composite parts, and are excited to further develop our High Temperature Resin Transfer Moulding capability by collaborating closely with Nexam and other partners.”
Boyd Cushing, Business Development for Nexam Chemical UK & Ireland, added: “We are delighted that our five years of collaboration with the NCC has resulted in a major innovation breakthrough for high temperature RTM composites. We look forward to welcoming industrial partners who may have interest with our Scottish origin NEXIMID non ITAR restricted resin in aerospace and defence applications that are looking for high performance material composite parts.”
Following this successful collaboration, Nexam Chemical has joined the NCC as an SME Affiliate Member, paving the way for further projects that will aid industry in using high temperature resin transfer moulding to their advantage.
#composites #ExtremeTemperatures
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Composites
Photo Credit: Losi Group
Avio Commerciale S.r.l., Nano-Tech to expand nano-engineered prepregs, resins to new markets
The strategic partnership aims to introduce Nano-Tech R&D and production capabilities to new customers and provide tailor-made customer solutions.
Beginning Nov. 2021, Avio Commerciale S.r.l (part of Losi Group, Casalpusterlengo, Italy) has entered into a strategic partnership with Nano-Tech S.p.A. (Ascoli Piceno, Italy) to present new advanced composite materials to the market.
The partnership aims to combine Losi Group’s market and sales expertise with Nano-Tech’s R&D and production capabilities for prepregs, nano-engineered prepregs and nano-engineered resins.
The initial focus will be introduction and promotion of Nano-Tech products to different market segments, including potential new qualification processes in the aerospace, automotive, motorsport and marine industries.
Going forward, the partners also plan to develop tailor-made solutions for customers. Through this partnership, Losi Group will lead the sales and qualification process of this product portfolio and support Nano-Tech to reach new markets and new customers globally.
Andrea Losi, Losi Group’s sales director, says, “Losi Group and Nano-Tech’s partnership is a powerful combination. Nano-Tech’s superior quality prepregs and technical capabilities combined with our deep knowledge of the market and applications will help us to expand our business capabilities in the composite market globally.”
Clemente Letizia, Nano-Tech’s COO and sales director, says, “This exciting partnership will benefit both partners to bring a higher value to our customers. We believe that this strategic partnership with Losi Group will help us reach new markets and introduce our product portfolio. The target is the composite part manufacturers and OEMs who want improve their products.”
#composites #prepregs
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The strategic partnership aims to introduce Nano-Tech R&D and production capabilities to new customers and provide tailor-made customer solutions.
Beginning Nov. 2021, Avio Commerciale S.r.l (part of Losi Group, Casalpusterlengo, Italy) has entered into a strategic partnership with Nano-Tech S.p.A. (Ascoli Piceno, Italy) to present new advanced composite materials to the market.
The partnership aims to combine Losi Group’s market and sales expertise with Nano-Tech’s R&D and production capabilities for prepregs, nano-engineered prepregs and nano-engineered resins.
The initial focus will be introduction and promotion of Nano-Tech products to different market segments, including potential new qualification processes in the aerospace, automotive, motorsport and marine industries.
Going forward, the partners also plan to develop tailor-made solutions for customers. Through this partnership, Losi Group will lead the sales and qualification process of this product portfolio and support Nano-Tech to reach new markets and new customers globally.
Andrea Losi, Losi Group’s sales director, says, “Losi Group and Nano-Tech’s partnership is a powerful combination. Nano-Tech’s superior quality prepregs and technical capabilities combined with our deep knowledge of the market and applications will help us to expand our business capabilities in the composite market globally.”
Clemente Letizia, Nano-Tech’s COO and sales director, says, “This exciting partnership will benefit both partners to bring a higher value to our customers. We believe that this strategic partnership with Losi Group will help us reach new markets and introduce our product portfolio. The target is the composite part manufacturers and OEMs who want improve their products.”
#composites #prepregs
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Composites
Photo Credit: Hexcel, Fairmat
Hexcel, Fairmat partnership aims to recycle carbon fiber prepregs
Cuttoffs generated by Hexcel’s European plants will be repurposed by the end of 2022 into high value-added products
Hexcel Corp. (Stamford, Conn., U.S.) and Fairmat (Paris, France), a deep technology startup, have announced an agreement to build the capability to recycle carbon fiber prepreg from Hexcel’s European operations for reuse in composite panels sold into commercial markets.
“With Fairmat, Hexcel has found an industrial recycling solution for the carbon fiber prepreg cutoffs generated at our European facilities,” says Thierry Merlot, president, aerospace – Europe, MEA/AP & Industrial at Hexcel. “This partnership represents a significant step as we continue striving to be an industry leader and a responsible steward of resources. From lightweight composites that help reduce emissions to improving our processes to reduce our impact on the environment, Hexcel is relentless in our pursuit of innovations that will lead to a more sustainable future.”
Under the partnership, Fairmat will lease a former Hexcel facility in Bouguenais (Loire-Atlantique) where it will recycle cutoffs generated during carbon fiber prepreg production at Hexcel European plants. Hexcel expects most of its carbon fiber prepreg cutoffs in Europe will be recycled as part of this partnership by the end of 2022. Fairmat will begin to set up the new site in early 2022 with production scheduled to start in March 2022.
Fairmat has reportedly developed a recycling process capable of circularizing the manufacture of carbon fiber composite materials, for its reuse in high value-added material. Carbon fiber and resins are mainly cold treated, leading to reduced energy costs and avoiding traditional landfill or incineration solutions. Fairmat’s clean recycling process is expected to save 41 kilograms of CO2 emissions per kilogram of recycled carbon fiber composite compared to virgin prepregs. Fairmat is aiming for a capacity of 5,000 tons of recycled material annually in this first production site.
“We are proud of the trust Hexcel has placed in us by signing this strategic partnership,” says Fairmat Founding Chairman Benjamin Saada. “The commercial agreement covering the first tons to be recycled in Europe will enable us to complete the industrial scale up of our virtuous recycling technology by the end of the year. I originally founded Fairmat with a totally circular vision in mind, so it was important for me to be able to reuse an existing industrial facility to launch our production. I’m delighted that Fairmat is rapidly advancing toward its goal of giving advanced materials a second life.”
#composites #CarbonFiberPrepregs #CarbonFiber
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Cuttoffs generated by Hexcel’s European plants will be repurposed by the end of 2022 into high value-added products
Hexcel Corp. (Stamford, Conn., U.S.) and Fairmat (Paris, France), a deep technology startup, have announced an agreement to build the capability to recycle carbon fiber prepreg from Hexcel’s European operations for reuse in composite panels sold into commercial markets.
“With Fairmat, Hexcel has found an industrial recycling solution for the carbon fiber prepreg cutoffs generated at our European facilities,” says Thierry Merlot, president, aerospace – Europe, MEA/AP & Industrial at Hexcel. “This partnership represents a significant step as we continue striving to be an industry leader and a responsible steward of resources. From lightweight composites that help reduce emissions to improving our processes to reduce our impact on the environment, Hexcel is relentless in our pursuit of innovations that will lead to a more sustainable future.”
Under the partnership, Fairmat will lease a former Hexcel facility in Bouguenais (Loire-Atlantique) where it will recycle cutoffs generated during carbon fiber prepreg production at Hexcel European plants. Hexcel expects most of its carbon fiber prepreg cutoffs in Europe will be recycled as part of this partnership by the end of 2022. Fairmat will begin to set up the new site in early 2022 with production scheduled to start in March 2022.
Fairmat has reportedly developed a recycling process capable of circularizing the manufacture of carbon fiber composite materials, for its reuse in high value-added material. Carbon fiber and resins are mainly cold treated, leading to reduced energy costs and avoiding traditional landfill or incineration solutions. Fairmat’s clean recycling process is expected to save 41 kilograms of CO2 emissions per kilogram of recycled carbon fiber composite compared to virgin prepregs. Fairmat is aiming for a capacity of 5,000 tons of recycled material annually in this first production site.
“We are proud of the trust Hexcel has placed in us by signing this strategic partnership,” says Fairmat Founding Chairman Benjamin Saada. “The commercial agreement covering the first tons to be recycled in Europe will enable us to complete the industrial scale up of our virtuous recycling technology by the end of the year. I originally founded Fairmat with a totally circular vision in mind, so it was important for me to be able to reuse an existing industrial facility to launch our production. I’m delighted that Fairmat is rapidly advancing toward its goal of giving advanced materials a second life.”
#composites #CarbonFiberPrepregs #CarbonFiber
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Composites
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Westlake Chemical to acquire Hexion's epoxy business for $1.2 billion
Global supplier of coatings and composites used in wind turbine blades and automotive structural components to expand Westlake’s chemicals portfolio.
Westlake Chemical Corp. (Houston, Texas, U.S.), an international manufacturer and supplier of petrochemicals, polymers and fabricated building products, has entered into a definitive agreement with Hexion Inc. (Columbus, Oho, U.S.) to acquire Hexion’s global epoxy business for approximately $1.2 billion. Based in Rotterdam, the Netherlands, Hexion’s epoxy business manufactures and develops specialty resins, coatings and composites for a variety of industries, including high-growth and sustainability-oriented end uses such as wind turbine blades and lightweight automotive structural components. In the twelve months ending Sept. 30, 2021, Hexion’s epoxy business had reported net sales of approximately $1.5 billion.
With this transaction, which is anticipated to be completed in the first half of 2022 following customary closing conditions, Westlake expects to significantly expand its integrated business by adding a downstream portfolio of coatings and composite products to its chloro-vinyls businesses.
“Lightweighting is a critical feature for the manufacture of structural components for automobiles and for renewable energy, particularly the composite blades used by wind turbines, and epoxies are key ingredients for these sustainable products,” says Westlake president and CEO Albert Chao. “The industries served by Hexion Epoxy are very attractive to Westlake and the business is expected to be a synergistic addition to Westlake’s existing businesses. We look forward to welcoming the Hexion epoxy employees to the Westlake family and realizing the tremendous opportunities to grow the combined businesses.”
Hexion Epoxy is a global producer of epoxy resins, modifiers and curing agents for high-performance materials, coatings and composites. The fully integrated business includes upstream base epoxy resins and intermediates delivered as liquid or solid epoxy resins, as well downstream specialty epoxy resins used in coatings and composites. Hexion Epoxy operates globally on three continents with eight manufacturing facilities and five research and development labs located in Asia, Europe and the U.S., as well as tolling sites in Asia.
#composites #epoxy #Hexion
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Global supplier of coatings and composites used in wind turbine blades and automotive structural components to expand Westlake’s chemicals portfolio.
Westlake Chemical Corp. (Houston, Texas, U.S.), an international manufacturer and supplier of petrochemicals, polymers and fabricated building products, has entered into a definitive agreement with Hexion Inc. (Columbus, Oho, U.S.) to acquire Hexion’s global epoxy business for approximately $1.2 billion. Based in Rotterdam, the Netherlands, Hexion’s epoxy business manufactures and develops specialty resins, coatings and composites for a variety of industries, including high-growth and sustainability-oriented end uses such as wind turbine blades and lightweight automotive structural components. In the twelve months ending Sept. 30, 2021, Hexion’s epoxy business had reported net sales of approximately $1.5 billion.
With this transaction, which is anticipated to be completed in the first half of 2022 following customary closing conditions, Westlake expects to significantly expand its integrated business by adding a downstream portfolio of coatings and composite products to its chloro-vinyls businesses.
“Lightweighting is a critical feature for the manufacture of structural components for automobiles and for renewable energy, particularly the composite blades used by wind turbines, and epoxies are key ingredients for these sustainable products,” says Westlake president and CEO Albert Chao. “The industries served by Hexion Epoxy are very attractive to Westlake and the business is expected to be a synergistic addition to Westlake’s existing businesses. We look forward to welcoming the Hexion epoxy employees to the Westlake family and realizing the tremendous opportunities to grow the combined businesses.”
Hexion Epoxy is a global producer of epoxy resins, modifiers and curing agents for high-performance materials, coatings and composites. The fully integrated business includes upstream base epoxy resins and intermediates delivered as liquid or solid epoxy resins, as well downstream specialty epoxy resins used in coatings and composites. Hexion Epoxy operates globally on three continents with eight manufacturing facilities and five research and development labs located in Asia, Europe and the U.S., as well as tolling sites in Asia.
#composites #epoxy #Hexion
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Composites
New sensor technology offers multidirectional and large-area sensing in fiber-reinforced composites for monitoring mechanical deformation and damage. Photo Credit: The German Institutes of Textile and Fiber Research (DITF)
DITF develops textile sensors for composites
German Institutes of Textile and Fiber Research are advancing large-area sensors that can detect deformations and stress using printing onto textiles which are then incorporated into composite structures.
The growth of composites technology for large-scale structures such as wind turbine blades, aircraft and automotive parts has created a need to monitor for damage and mechanical deformation. Current options are not fully satisfactory — small sensors cannot cover sufficient area, while fiber optic and piezoelectric sensors reportedly still require significant investment and expertise. The German Institutes of Textile and Fiber Research (DITF, Denkendorf) is looking to address this with its development of a large-area sensor produced by printing onto a reinforcing textile.
This DITF fabric sensor enables mechanical deformation to be detected over a large area as it responds with a measurable electrical resistance to external tension or pressure. By detecting and measuring mechanical stress parameters — such as the degree of deformation and bending speed on the shape of the sensor signal — even the smallest of deformations can be detected.
DITF researcher Dr. Reinhold Schneider, in his presentation at the Industrial Fabrics Association International (IFAI) EXPO 2021, described how the utilization of the reinforcing textile effectively allows for the creation of a textile-based sensor.
The process begins with screen or inkjet printing of an electroconductive interdigital pattern of electrodes onto the textile, which are used to record and measure the electrical resistance signal of the structure. This is followed by a coating or printing using sensor materials such as an electroconductive polymer or some form of carbon (e.g., powdered carbon black, milled carbon fiber, nanocarbon, etc.). Finally, the composite is manufactured, for example, using vacuum infusion processing with an epoxy matrix resin.
Once produced, the textile-based composite sensor can be tested for ohmic resistivity using a three-point bending method with mechanical load applied and released over a period of time. This is compared with the sensor data which correlate perfectly. In tests, it was revealed that the resistance change is dependent on the coating thickness and the percentage of carbon content in the printing paste. Specifically, a thin layer of sensing coating or printing produces a low amount of carbon, which results in a high resistance change.
“Effective large-scale composites monitoring is essential for health and safety as well as cost,” says Dr. Marie O’Mahony, an industry consultant, visiting professor at the Royal College of Art (RCA, London, U.K.) and author of several books on advanced and smart textiles. Beyond that, it is also an important way of reducing risk into the future as large scale composites become ever more ubiquitous.”
#composites #GermanInstitutesofTextile&FiberResearch #FiberReinforcedComposites
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German Institutes of Textile and Fiber Research are advancing large-area sensors that can detect deformations and stress using printing onto textiles which are then incorporated into composite structures.
The growth of composites technology for large-scale structures such as wind turbine blades, aircraft and automotive parts has created a need to monitor for damage and mechanical deformation. Current options are not fully satisfactory — small sensors cannot cover sufficient area, while fiber optic and piezoelectric sensors reportedly still require significant investment and expertise. The German Institutes of Textile and Fiber Research (DITF, Denkendorf) is looking to address this with its development of a large-area sensor produced by printing onto a reinforcing textile.
This DITF fabric sensor enables mechanical deformation to be detected over a large area as it responds with a measurable electrical resistance to external tension or pressure. By detecting and measuring mechanical stress parameters — such as the degree of deformation and bending speed on the shape of the sensor signal — even the smallest of deformations can be detected.
DITF researcher Dr. Reinhold Schneider, in his presentation at the Industrial Fabrics Association International (IFAI) EXPO 2021, described how the utilization of the reinforcing textile effectively allows for the creation of a textile-based sensor.
The process begins with screen or inkjet printing of an electroconductive interdigital pattern of electrodes onto the textile, which are used to record and measure the electrical resistance signal of the structure. This is followed by a coating or printing using sensor materials such as an electroconductive polymer or some form of carbon (e.g., powdered carbon black, milled carbon fiber, nanocarbon, etc.). Finally, the composite is manufactured, for example, using vacuum infusion processing with an epoxy matrix resin.
Once produced, the textile-based composite sensor can be tested for ohmic resistivity using a three-point bending method with mechanical load applied and released over a period of time. This is compared with the sensor data which correlate perfectly. In tests, it was revealed that the resistance change is dependent on the coating thickness and the percentage of carbon content in the printing paste. Specifically, a thin layer of sensing coating or printing produces a low amount of carbon, which results in a high resistance change.
“Effective large-scale composites monitoring is essential for health and safety as well as cost,” says Dr. Marie O’Mahony, an industry consultant, visiting professor at the Royal College of Art (RCA, London, U.K.) and author of several books on advanced and smart textiles. Beyond that, it is also an important way of reducing risk into the future as large scale composites become ever more ubiquitous.”
#composites #GermanInstitutesofTextile&FiberResearch #FiberReinforcedComposites
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Composites
Photo Credit: Irkut Corp.
Irkut completes final assembly of composite-intensive MC-21-300 aircraft
The MC-21-300 design is approximately 40% composite, which Irkut says is a record figure for medium-range aircraft. After switching to local production, the first aircraft is about to fly.
Russian aircraft manufacturer Irkut Corp. (Moscow) has completed the construction of its first MC-21-300 passenger aircraft, which has what is said to have the world’s largest infused, out-of-autoclave carbon fiber composite wings, manufactured by AeroComposite (Moscow Russia).
On Nov. 30, 2021 the aircraft was transferred from the final assembly shop of the Irkutsk Aviation Plant, a branch of Irkut Corp., to the flight test division. Plant specialists and allied enterprises will carry out the ground checks of the aircraft and its systems, and prepare the aircraft for the first flight.
“The use of strong and lightweight composites allowed the designers to make the wing of high aspect ratio and improve the aerodynamics of the aircraft at the same time as increasing the diameter of the fuselage,” says Rostec CEO Sergei Chemezov. “I would like to note that Irkut specialists were able to solve the problem of import substitution [the U.S. imposed trade restrictions on AeroComposite in September 2018] in the shortest possible time and start building production aircraft with a Russian wing. The assembly of the first airliner is a big step for the UAC [United Aircraft Corp.] and the entire Russian aircraft industry. This is proof of the maturity of our aviation technologies and another victory over the sanctions.”
The share of composites in the MC-21 design is about 40%, which Irkut says is a record figure for medium-range aircraft. Domestic materials for power composite structures were developed with the participation of scientists from Moscow State University and Rosatom (Moscow) enterprises. The wing consoles and center section of the MC-21-300 aircraft are manufactured at the AeroComposite-Ulyanovsk enterprise. In the production of the wing, the technology of vacuum infusion is used, which is patented in Russia.
#composites #Irkut #MC21300aircraft
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The MC-21-300 design is approximately 40% composite, which Irkut says is a record figure for medium-range aircraft. After switching to local production, the first aircraft is about to fly.
Russian aircraft manufacturer Irkut Corp. (Moscow) has completed the construction of its first MC-21-300 passenger aircraft, which has what is said to have the world’s largest infused, out-of-autoclave carbon fiber composite wings, manufactured by AeroComposite (Moscow Russia).
On Nov. 30, 2021 the aircraft was transferred from the final assembly shop of the Irkutsk Aviation Plant, a branch of Irkut Corp., to the flight test division. Plant specialists and allied enterprises will carry out the ground checks of the aircraft and its systems, and prepare the aircraft for the first flight.
“The use of strong and lightweight composites allowed the designers to make the wing of high aspect ratio and improve the aerodynamics of the aircraft at the same time as increasing the diameter of the fuselage,” says Rostec CEO Sergei Chemezov. “I would like to note that Irkut specialists were able to solve the problem of import substitution [the U.S. imposed trade restrictions on AeroComposite in September 2018] in the shortest possible time and start building production aircraft with a Russian wing. The assembly of the first airliner is a big step for the UAC [United Aircraft Corp.] and the entire Russian aircraft industry. This is proof of the maturity of our aviation technologies and another victory over the sanctions.”
The share of composites in the MC-21 design is about 40%, which Irkut says is a record figure for medium-range aircraft. Domestic materials for power composite structures were developed with the participation of scientists from Moscow State University and Rosatom (Moscow) enterprises. The wing consoles and center section of the MC-21-300 aircraft are manufactured at the AeroComposite-Ulyanovsk enterprise. In the production of the wing, the technology of vacuum infusion is used, which is patented in Russia.
#composites #Irkut #MC21300aircraft
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