Mikrosam robotic filament winding cell to aid Cidetec composites projects

Delivery of the single-spindle robotic setup with an ATP head will advance the R&D organization’s work in CUBIC, GENEX and Carbo4power initiatives targeting sustainable composites development.

Mikrosam (Prilep, Macedonia) has deliveredy one of its robotic filament winding machine, equipped with an automated tape placement (ATP) head, to private applied research organization Cidetec (San Sebastián, Spain). The technology will support Cidetec’s projects surrounding the development of sustainable composites using its 3R (recyclable, repairable and reprocessable) epoxy resin.

Mikrosam’s single-spindle robotic setup is designed to handle wet and towpreg winding processes — for materials including carbon, glass, aramid fibers and different epoxy resin systems — as well as precise tape placement of thermoset unidirectional (UD) slit prepreg tapes, offering Cidetec optimal flexibility. There are eight interpolated axes in the winding process. Equipped with a six-axis robotic arm for accurate placement and two-axis control for spindle rotation and payout eye movement, the system can accommodate mandrels with different diameters and lengths. Mikrosam says that this enables the production of a wide range of parts, including hydrogen (H2) storage tanks — a hot topic in the market — but also another large range of products.

The single-tape placement head offers high-speed, bi-directional layup of thermoset UD prepreg tapes, emphasizing precision and adaptability for complex composite structures. Designed for both 2D and mild 3D geometries, this head is ideal for advanced aerospace and wind energy applications.

The system accommodates tapes of ½-inch width, achieving a placement tolerance of ±0.1 millimeter. A compact fiber creel minimizes material distortion and allows quick tape changes, reducing downtime. Integrated with an infrared (IR) heating unit, the system preheats the prepreg tape, ensuring optimal bonding during layup. The programmable heating power adjusts in real time to match the layup speed, ensuring consistent temperature control.

Mikrosam’s Winding Expert software further enhances the system’s capabilities with simulation and programming features, and a Quality Control System tracks and records essential production data.

Cidetec plans to use this equipment for several European epoxy development projects, starting with the CUBIC project, which focuses on the development of bio-based sustainable composites. These composites, using Mikrosam’s filament winding technology, will be a critical component in the production of H2 tanks. The goal is to offer a bio-based alternative that supports the green and digital transformation of the manufacturing industry.

According to Dr. Eva García Lecina, deputy director of Cidetec Surface Engineering, “this equipment will help us take our developments to the next level, contributing to the use of more sustainable composites in the energy, aerospace and automotive sectors.”

Cidetec will also employ this system in two other projects. The Carbo4Power project aims to manufacture sustainable wind turbine blades using the ATP machine with Cidetec’s 3R epoxy resin. This initiative seeks to enhance the performance and durability of offshore wind and tidal turbine blades while reducing energy production costs, maintenance needs and environmental impact. The project’s goal is to recycle up to 95% of blade materials thanks to the properties of Cidetec’s 3R resins, which enable debonding on demand.

The second project, GENEX, targets the aerospace sector and focuses on optimizing manufacturing and maintenance for next-generation aircraft composite structures. Cidetec has been collaborating on this project for a year, working on formulating and characterizing aeronautical-grade 3R resins and developing prepreg tapes with integrated fiber optic sensors. These materials will be used to manufacture access panels for aircraft through Mikrosam’s ATP process.

“One of Mikrosam’s key strengths is the flexibility of its machines, which can be tailored to meet our customers’ unique requirements,” says Vele Samak, vice president of Mikrosam. “The delivery of this advanced filament winding and tape placement system will empower Cidetec to achieve the highest levels of performance and efficiency in their manufacturing processes. Additionally, our collaboration on these projects positions us at the forefront of the global challenge for a cleaner, greener future.”

#composites #Mikrosam #FilamentWinding

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Biesterfeld to distribute Saertex on the German market

A new partnership has just been signed between specialist chemicals distributor Biesterfeld and Saertex, a manufacturer of textile reinforcements for composite materials.

Biesterfeld is Saertex’s new distributor for the German market since November. The specialist chemicals distributor had already been working with the manufacturer of multi-axial textile reinforcements on the Polish market for many years.

Biesterfeld is taking over from Halarit Composites, a subsidiary of the French Gazechim Group, which until now has been responsible for Saertex’s presence on the German market.

As part of the new cooperation, Biesterfeld will receive the distribution rights for Saertex Non-Crimp Fabrics in the German market. These include Saertex Glass and Carbon NCF as well as the Saerfix, Saerflow and Saercore product solutions. In addition, Biesterfeld will also offer other products from the Saertex portfolio.

“Biesterfeld brings valuable market knowledge and an established network, which helps us to position our products optimally. Through even closer cooperation and increased joint customer visits, we want to ensure that our customers always receive the best possible solutions” explained Steven Bakker, commercial director at Saertex.

“The demand for high-performance fiber composites is growing continuously, and we are convinced that the synergies between our two companies will offer our customers significant added value and that together we can further develop the innovation potential of the German lightweight construction market”, said Johannes Martin, market manager performance products at Biesterfeld Spezialchemie.

Heading photo: Saercore is one of Saertex products now distributed in Germany by Biesterfeld.

#composites #Biesterfeld #Saertex

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KPS Capital Partners to acquire composites business from Ineos Enterprises

KPS Capital Partners, LP (“KPS”) announced that, through a newly formed affiliate, it has signed a definitive agreement to acquire INEOS Composites (the “Company”) from INEOS Enterprises Holdings II Ltd (“INEOS Enterprises”) for an estimated consideration of approximately €1.7bn (US$ 1.8 bn) at completion. Completion of the transaction is expected in the first half of 2025 subject to regulatory approvals and consultation processes (in particular, with respect to the French business, for which the parties have entered into exclusive negotiations).

Ineos Composites is a leading global manufacturer of unsaturated polyester resins, vinyl ester resins and gelcoats used in the production of plastic composites for a wide range of applications across large global end-markets, including building materials, recreation, transportation and wind energy, among others.

Ineos Composites sells a broad range of resins that allow customers to optimise certain characteristics of their products, including corrosion resistance, fire retardance, ultraviolet resistance, water and chemical resistance, thermal and electrical insulation, impact and scratch resistance, and high strength-to-weight ratios. Headquartered in Dublin, Ohio, and Barcelona, Spain, Ineos Composites has approximately 900 employees and operates 17 manufacturing facilities and 3 technology centres across North and South America, Europe, Asia and the Middle East.

Raquel Vargas Palmer, Managing Partner of KPS, said, “We are thrilled to acquire Ineos Composites, a leading global manufacturer of specialty composite resins. The Company’s leading market position and long-tenured customer base is a testament to its differentiated product quality, reliability and strong technical service capabilities. We will leverage KPS’ successful, multi-decade experience of investing in process industries, along with our commitment to manufacturing excellence and global network, to drive profitability and create an entrepreneurial culture centered on innovation, continuous improvement and superior customer experience. We look forward to partnering with Chief Executive Officer Andrew Miller and the INEOS Composites team to accelerate the Company’s value creation opportunities.”

Andrew Miller, Chief Executive Officer of Ineos Composites, said, “We are excited for our future as an independent company under KPS’ ownership. KPS is an ideal partner, given its demonstrated track record of establishing and growing world-class industrial companies. KPS’ commitment to manufacturing excellence, capital investment, and research and development, accompanied by its global platform and significant capital resources, will elevate our ability to provide customers with industry-leading products and superior service.”

Ashley Reed, Chairman of Ineos Enterprises said, “Composites has been part of Ineos Enterprises for the past five years, during which time it has achieved significant improvements in safety and financial performance. Furthermore, it has solidified its market position through enhanced product quality, consistency, and strengthened operational and commercial capabilities, ensuring a strong foundation for further future growth.”

Paul, Weiss, Rifkind, Wharton & Garrison LLP served as legal counsel to KPS. Piper Sandler served as financial advisor and Slaughter and May acted as legal counsel to Ineos Enterprises. Committed debt financing to support the transaction has been provided by Goldman Sachs Bank USA, Barclays, Citi, Intesa Sanpaolo – IMI CIB Division and MUFG Bank.

About Ineos Composites

Ineos Composites is a leading global manufacturer of unsaturated polyester resins, vinyl ester resins and gelcoats used in the production of plastic composites for a wide range of applications across large global end-markets including building materials, recreation, transportation and wind energy, among others. Ineos Composites sells a broad range of resins that allow customers to optimize certain characteristics of their products, including corrosion resistance, fire retardance, ultraviolet resistance, water and chemical resistance, thermal and electrical insulation, impact and scratch resistance, and high strength-to-weight ratios.

About KPS Capital Partners, LP

KPS, through its affiliated management entities, is the manager of the KPS Special Situations Funds, a family of investment funds with approximately $21.4 billion of assets under management (as of September 30, 2024). For over three decades, the Partners of KPS have worked exclusively to realize significant capital appreciation by making controlling equity investments in manufacturing and industrial companies across a diverse array of industries, including basic materials, branded consumer, healthcare and luxury products, automotive parts, capital equipment, and general manufacturing. KPS creates value for its investors by working constructively with talented management teams to make businesses better and generates investment returns by structurally improving the strategic position, competitiveness, and profitability of its portfolio companies, rather than primarily relying on financial leverage. The KPS Funds’ portfolio companies currently generate aggregate annual revenues of approximately $23.7 billion, operate 251 manufacturing facilities in 30 countries, and have approximately 65,000 employees, directly and through joint ventures worldwide (as of September 30, 2024, pro forma for recent acquisitions).

About Ineos Enterprises

Ineos Enterprises comprises a portfolio of businesses manufacturing chemical products in Northern Europe, the USA and Canada, with sales of €2.7bn around the world. The business is focused on the developing needs of its customers and rapid growth through investment in new products and manufacturing facilities or by acquisition. It employs c. 3,100 people across sites in the UK, Germany, Sweden, Switzerland, Canada and the USA. INEOS Enterprises is not part of the INEOS Group Holdings bank group.

#composites #Ineos #KPSCapitalPartners

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Metyx celebrates dual achievements: R&D centre certification and a new CFM product introduction

Metyx, a global leader in composite materials and technical textiles, announces two landmark achievements that underscore its commitment to innovation and sustainability in the composites industry. The company’s Research & Development (R&D) Center in Manisa, Turkey, has been officially licensed, highlighting its role as a key player in advancing composite technologies. Simultaneously, Metyx has unveiled its latest product innovation, the Continuous Filament Mat (CFM), designed to enhance performance and efficiency across industries.

Metyx R&D Center: a new era of innovation
The licensing of the Metyx R&D Center is a testament to the company’s dedication to
advancing technology and delivering sustainable solutions. This recognition places Metyx among an exclusive group of companies in Turkey, with only 1,331 certified R&D centres as of December, 2024. The rigorous licensing process underscores the center’s compliance with the highest standards in research and development.

Introducing Continuous Filament Mat (CFM)
Complementing this achievement is the launch of the advanced Continuous Filament Mat (CFM). Designed to deliver superior tensile strength and structural integrity, the CFM is engineered for a wide range of applications in industries such as construction, automotive, and infrastructure.

What sets Metyx’s CFM apart is its ability to optimize production efficiency. By streamlining workflows, it reduces labor requirements and production costs while improving overall shop efficiency. The product is also compatible with general-purpose and corrosion-resistant polyester, vinyl ester, and epoxy resin systems, making it a versatile solution for manufacturers.

“These two milestones represent METYX’s dual commitment to innovation and sustainability,” said Uğur Üstünel. “Our R&D Center enables us to lead the way in technological advancements, while the launch of CFM addresses immediate market needs by enhancing efficiency and reducing environmental impact. Together, these developments solidify METYX’s position as a trusted partner in the composites industry.”

Key features and benefits of Metyx CFM
• Enhanced Performance: Offers exceptional tensile strength and durability.
• Process Optimization: Saves labor and improves shop efficiency.
• Sustainability Focused: Minimizes waste while supporting streamlined production.
• Cost Efficiency: Reduces production costs with simplified workflows.
• Versatility: Compatible with multiple resin systems for diverse applications.

#composites #Metyx #CFM

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“Our material combines stones with a negative carbon footprint and biosourced carbon fibres”, says Kolja Kuse, CEO at TechnoCarbon Technologies

TechnoCarbon Technologies has developed a new solution designed to reduce the carbon footprint of buildings. Winner of a JEC Innovation Award, the Daccuss enclosure wall (for Direct Air Carbon Capture, Utilisation and Safe Storage) combines the effects of different materials to promote energy efficiency and CO2-negativity, while guaranteeing access to accessible and flexible resources. We spoke to Kolja Kuse, CEO at TechnoCarbon Technologies.

How does CarbonFibreStone (CFS) work?

Our system is based on a compression-stable core of stone, to the surface of which a glue-bonded fibre material is applied on one side, both sides or the entire surface. This technology makes possible the production of ‘stone slabs’ from 20mm thickness down to 1.2 mm. The gravity of the stone is only a bit more than of aluminum. If they are between 1 and 2 mm thin, they will be even lighter.

The surface coating gives the composite pre-stressing. Thanks to the carbon fibre, the stone acquires tensile stability and becomes a construction material with a specific weight much less than that of steel at same performance.

Slabs and other stone geometries can be bent within adjustable limits, while being returned to their original position under lighter loads without any fatigue. This feature distinguishes the material from the metal. The elastic limits of the CarbonFibreStone (CFS) are higher than those of metal, and the material remains elastic until it breaks. The damping properties are superior to those of metals and pure carbon fibre materials. Stone slabs can be produced with 2m x 3m in size.

How do you explain the CO2 function?

CFS is a material that combines stones with a negative carbon footprint and biosourced carbon fibres. We use CO2-absorbing igneous stone (one of the three main types of rock resulting from the solidification of magma in the deep layers of the Earth’s crust or in the upper layer of the mantle), such as basalt, granite or gabbro, combined with carbon fibre, developed by the DITF – Deutsche Institute für Textil- und Faserforschung Denkendorf, which is also designed to be CO2 negative. Carbon fibres are produced either from lignin from the wood industry (biomass) or from algae oil or vegetable oil.

Natural stone is particularly interesting in this composite, as it can be extracted with low energy consumption and has a high degree of homogeneity from a mechanical point of view. It is also capable of absorbing high pressure and shear force without damage, since it has with about 60PGa a comparable low Young’s modulus of elasticity, in many cases even lower than aluminum.

Compared with concrete, natural stone has the advantage of being at least twice as stable under pressure and four times as stable under tension, and does not age within the timescales relevant to construction. Certainly, the Young’s modulus depends on the type of stone we are using. The catalogue of granite types records more than 6000 different stones. This is one of the interesting things about CFS, that there is a wide range of technical specifications we can meet. Many of these granites are literally limitless available. CFS replaces reinforced concrete, a major C02 emitter due to the use of fossil lime stone, in house walls. Each square metre of CFS wall captures 59 kg of CO2, whereas traditional cement walls emit 98 kg. Stone slabs reinforced with polyacrylonitrile (PAN) carbon fibres made from algae oil, for example, create highly carbon-negative walls. The material is also twice as light and two to three times stronger than cement. We need to get rid of all fossil material, not only in the energy sector, but in buildings as well: cement today is based by 100% on fossil-based material.

What are DACCUSS bricks?

DACCUSS (Direct Air Carbon Capture, Utilisation and Safe Storage) building blocks enclosure walls (and eventually ceilings in the future) are based on CFS technology, with the effect amplified by the use of an insulating filling of carbon-negative charcoal or biochar granules. Biochar can be produced from any plant material, heated without oxygen to between 300°C and 700°C. This biomass pyrolysis residue generated green energy and is typically used already in agriculture to regenerate soils depleted by intensive farming, retain water and trap CO2 and avoid artificial fertilisation of soil.The material can be easily reused by peeling off the fibre on one side and the stone on the other. Our material requires a very small amount of carbon fibre and the stone residues, recovered in powder form when sliced for example, are used as fertiliser to absorb atmospheric CO2 by natural weathering processes. In case we would replace all concrete worldwide, we could eventally capture 4Gt of CO2 per year and avoid6 GT of CO2 of fossil origin. In a nutshell, we promote the replacement of fossil stone treatment to produce artificial stone like concrete by ultimate available igneous rock. Our project was supported by the German Goverment, Ministry of Research and Education, as part of the CDRterra project, and included Life Cycle Assessment (LCA) and Techno Economical Analysis (TEA) as part of the projects milestones. The results are encouraging because, as building blocks are produced in large quantities, their costs are slightly below that of a comparable wall of concrete. First collaborations with other countries and local start-ups have already been established.

#composites #TechnoCarbon #CarbonFibreStone

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