Composites
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Composites, technologies, equipment.

"Composite-Expo 2027" Exhibition
March 16 - 18, Pavilion 1, Halls 1 and 4, IEC Crocus-Expo, Moscow, Russia.

Website: composite-expo.com
Youtube: youtube.com/user/compositeexpo
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Composites Germany releases composites market survey

This is the fifteenth member survey from Composites Germany that identifies up-to-date key performance indicators (KPIs) for the fiber-reinforced plastics market.

Composites Germany (Berlin, Germany), a trade association with an aim to strengthen the German composite industry, particularly in the field of research, has made the results of its 15th Composites Market Survey available and identified the latest key performance indicators (KPIs) for the fiber-reinforced plastics market.

The survey also covers all the member companies of the three major umbrella organizations of Composites Germany including the Industrievereinigung Verstärkte Kunststoffe (AVK; Frankfurt, Germany), Leichtbau Baden-Württemberg (Stuttgart, Germany) and the VDMA Working Group (Frankfurt, Germany) on hybrid lightweight construction technologies. As before, to ensure a smooth comparison with the previous surveys, the organization notes that the questions in this half-yearly survey have been left unchanged and that the data obtained in the survey was largely qualitative and related to current and future market developments. It should also be noted that, while the current business situation is negative, the survey outlook is generally positive.

Negative rating of current business situation
Following the rather cautious rating of the prevailing business situation in the last survey earlier this year, the most recent survey is now continuing this trend. Partly due to the current impact of the coronavirus pandemic on numerous business segments and areas of application, many companies are facing negative circumstances. The general economic situation has been deteriorating further in recent weeks and months, and this is reflected in the negative ratings given by respondents. Ratings have reached the lowest figures since the surveys were started in January 2013 (see Fig.1).
However, not only did companies give rather unfavorable assessments of the general business situation, Composites Germany says they also continued to be pessimistic about their own situations (see Fig. 2).
Although the tense situation is beginning to relax, e.g. in the automotive industry, and although the crisis has not yet taken full effect in other sectors, e.g. construction, many companies are nevertheless full of uncertainty. There has been a variety of opportunities and measures to stimulate industry and the economy in general, but it seems that they have not yet had the desired positive economic impact.

Variety of developments expected in the future
When asked about their expectations for future business developments, respondents give quite contrasting answers. While they are expecting to see an improvement in the general economic situation, both in Europe and worldwide, they are still pessimistic about the outlook for Germany (see Fig. 3), and also with regard to their own business situation in the future.

Varied expectations for application industries
Like expectations for the development of the business situation, expectations for selected areas of application have also turned out to be extremely diverse.
The automotive and aviation industries are the main areas where respondents are expecting to see a deterioration in the market environment. However, other sectors, such as sports and leisure and infrastructure/construction, are expected to develop far more positively (see Fig. 4).
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Growth drivers developing at different rates
While, as in the last surveys, growth stimuli for the composites segment can mainly be expected to come from Germany, Europe and Asia as global regions, we can observe a paradigmatic shift with regard to materials.
Whereas, in the first 13 surveys, respondents always believed that the composites segment would receive its prevailing growth stimuli from carbon fiber-reinforced plastics (CRP) as a material, the current survey is now the second one where respondents have mentioned glass fiber-reinforced plastics (GRP) as the most important material (see Fig. 4). Considering the number of times it is mentioned, this trend is in fact increasing.

Composites Index continues to decline
The current situation has created major uncertainty, not only in the composites sector. The mood in companies continues to be negative. This is partly due to production losses and a sharp decline in both investment and consumer confidence caused by the coronavirus pandemic, and partly also due to political uncertainties and squabbles about economic policies. Many of the measures that have been taken still seem to be insufficient to create a positive environment. Although expectations of the future business situation are generally becoming more positive, this is not yet leading to a more positive assessment of the companies’ own positions in the market. Following these assessments, the Composites Development Index is therefore continuing to fall, sometimes significantly (see Fig. 6).
It remains to be seen how the economy will develop in the rest of the year, especially in the autumn. Over the last few years there has been success in establishing composites in many new areas of application, thus achieving an almost consistently positive development. Composites therefore remain important materials for the future, not least because of their positive and diverse qualities, so that they will continue to find their way into industry, despite the current crisis.

The next Composites Market Survey will be published in February 2021.

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3D printed carbon fibre e-bike blasts through Indiegogo goal

Superstrata’s 3D printed e-bike has soared past the company’s initial crowdfunding target, hitting £3.3 million in pre-orders

More than 2,800 backers from 66 countries have supported the project so far, and due to demand has decided to extend the campaign until 12th September 2020.

The Superstrata 3D printed, fully-customised bikes have attracted the attention of some major brands wanting to work in partnership with Superstrata, like SmartTech, which is currently showcasing the exclusive Superstrata Oxford in Selfridges’ new The Bike Shop on Oxford Street in London.

The exclusive Superstrata Oxford Edition includes carbon fibre wheels with a highly premium groupset, which are two of the most requested features so far.

Even Sadiq Khan, the Mayor of London, has already been along to Oxford Street to see the Superstrata Oxford in Selfridges for himself

The Superstrata’s design has no glue, joints or bolts, is stronger than Kevlar and lighter than 2 bottles of water. Superstrata’s proprietary composite 3D printing manufacturing technology makes each frame individually according to each rider’s precise body measurements.

The bike and e-bike will literally be made to measure. Buyers send in their measurements and their individual bike will be 3D printed – bespoke down to the spokes.

With more than 500,000 unique combinations, including mix and match colours, wheels, handlebars and more, the Superstrata bike and e-bike are made exclusively with carbon fibre reinforced thermoplastic technology, and 100% recyclable materials that won’t rust.

Arevo, the company behind Superstrata, automates the design and fabrication of large, geometrically complex, continuous CFRP composite products through a suite of innovations in materials science, robotics and design software.

It recently introduced its newest system, the Aqua 2, the world’s first high speed additive manufacturing system for large continuous carbon fibre composite structures, which in addition to enabling higher quality print, is able to print 4x faster than its predecessor.

This enables the rapid, on-demand production of large (up to one cubic meter) custom composite parts, making the process to scale manufacturing even easier.

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OCSiAl opens graphene nanotube R&D center in Europe

The major part of all developments in the Group’s new, Luxembourg facility will be targeted towards elastomers and thermoplastic composites enhanced with graphene nanotubes.

Global graphene nanotube manufacturer OCSiAl (Leudelange, Luxembourg and Columbus, Ohio, U.S.) announced that it has opened its state-of-the-art research and development (R&D) and technical support center designed to develop next-generation materials with graphene nanotubes. The new center is located in Luxembourg, place deemed a hub for advanced technology companies.

With other centers located in Asia and Eastern Europe, the Group’s current decision to open a new center in Luxembourg was in response to Europe’s forefront position in developing material engineering solutions, especially for the ongoing automotive industry revolution. Lightweight and smart car bodies, energy efficient and safe tires, are among the main focuses of OCSiAl’s European team of experts in nanotechnology and materials engineering.

According to the company, the new, 350-square-meter center has more than 50 items of high-end equipment. The major part of all developments will be targeted towards elastomers and thermoplastic composites enhanced with graphene nanotubes, which are said will be widely applied in the cars of the future.

“OCSiAl’s product line is constantly growing. We have developed high-performance solutions for Li-ion batteries and various polymers, many of which have already been accepted as an industry standard. And in fact, one of the best demonstrators and drivers of most nanotube developments is the automotive industry,” says Konstantin Notman, OCSiAl senior vice president, OCSiAl Europe CEO. “Graphene nanotubes significantly enhance and even grant new properties to all the materials that are being used in cars. We make it possible to make safer, lighter, smarter and more eco-friendly vehicles.”

The company plans to launch the world’s largest graphene nanotube synthesizing facility in Luxembourg in 2023. Together with the R&D and technical support center, OCSiAl says its new production facility will form a cluster for the most advanced developments in the field of materials of the future.

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Machine learning replicates the secrets of composites

Aerospace and automotive applications increasingly rely on lightweight composite parts made from polymers reinforced with carbon or glass fibers. With the rise of additive manufacturing methods like 3D printing, it is becoming possible to design novel filaments and control their orientation within composites to tailor performance to specific applications. But the ease of manufacturing advanced composite parts via 3D printing has a downside. The ubiquity of 3D printers makes it much easier for counterfeiters to copy parts.

“A lot of intellectual property is invested in developing composites material and 3D printing conditions,” points out Nikhil Gupta of New York University. “Reverse engineering using imaging methods can allow this IP to be stolen. Machine learning can even automate this process… [to] produce high quality replicas by unauthorized personnel.”

Gupta and his team show that novel and innovative composite materials can be reverse engineered using three-dimensional imaging and reconstruction techniques combined with powerful machine learning [Yanamandra et al., Composites Science & Technology 198 (2020) 108318]. Not only can the size and shape of a part be reconstructed in this way, but also the tool path – or unique instructions – that the 3D printer needs to manufacture it.

The researchers took a set of scanning electron microscopy (SEM) to measure dimensions and micro-CT (µCT) scans to identify the orientation of fibers within a composite. A sub-set of these images was then used to train the machine learning algorithm. The accuracy of the algorithm in identifying the 3D printing tool path was then verified with a second sub-set of images. The team used over 78,000 images to train the algorithm and a further 5000 µCT images to test the accuracy of its predictions.
“Compared with the manual methods of reverse engineering, the machine learning algorithm is a powerful method where a few CT scan images are able to provide the part design and 3D printing tool path,” explains Gupta. “Our study shows that products developed with investment of significant amount of time and money can be easily reverse engineered.”

The work raises concerns over the security of intellectual property in 3D-printed composite parts. Modern capabilities in designing and producing high-performance fiber-reinforced composites can be harnessed to produce almost-indistinguishable high-quality replica parts quickly and cheaply.

“Machine learning methods are being used in the design of complex parts but, as our study shows, they can be a double-edged sword, also making reverse engineering easier,” says Gupta. “Awareness of security issues will encourage researchers to develop new tool paths and composite materials that consider security as a design constraint.”

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High volume fiber composites

TRB Lightweight Structures (TRB) reports that it has developed a new process to make continuous fiber thermoset composite parts at higher volume.

The process, which focuses on combining materials science with robotic manufacturing is being used to supply a powertrain manufacturer with battery components for electric buses, the company said. It involves feeding custom materials into an integrated process which covers automating cutting, layup, pressing and curing, allowing parts to be manufactured more quickly and more cost effectively, TRB said.

The manufacturing method is suitable for the high-volume production of components for electric vehicles (EV) and can be adapted to include additional material layers offering thermal, electrical conductivity and electromagnetic radiation protection.

‘While high volume composites have many applications, we have chosen to focus on the fast-expanding EV market – both on the road and in the sky – given our mission to accelerate the transition to sustainable transportation,’ said Richard Holland, MD.

This story uses material from TRB, with editorial changes made by Materials Today. The views expressed in this article do not necessarily represent those of Elsevier.

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Vestas to acquire offshore business in joint venture

Per the agreement, Vestas will acquire Tokyo-based Mitsubishi Heavy Industries’ shares in the MHI Vestas Offshore Wind (MVOW) joint venture. MHI gets 2.5% in Vestas and a seat on the Vestas board.

Vestas (Aarhus, Denmark), and Mitsubishi Heavy Industries, Ltd. (MHI, Tokyo, Japan), have signed an agreement that Vestas will acquire MHI’s shares in the MHI Vestas Offshore Wind (MVOW) joint venture, against MHI acquiring 2.5% in Vestas and being nominated to a seat in Vestas’ Board of Directors. This decision is said to have strengthened the partnership within sustainable energy between the two companies.

Vestas is to acquire MHI’s 50% share of the MVOW joint venture against 5,049,337 shares in Vestas that will be issued at closing of the transaction, corresponding to 2.5% of Vestas’ nominal share capital after the capital increase. The transaction has a value of approximately €709 million EUR (approx. $828 million USD), based on the volume-weighted average of the price for shares in Vestas as quoted on Nasdaq Copenhagen the last five days up to and including Oct. 28, 2020. Following a decision made on Oct. 29 by the Board of Directors of Vestas, and subject to completion of the transaction, the share capital of Vestas will be increased by a nominal value of DKK 5,049,337 (about $791,568) USD, divided into shares of DKK 1 ($0.16 USD) each, pursuant to the authorisation in article 3(1)(b) of Vestas’ Articles of association.

If the transaction is approved by the competition authorities, MHI will— through MHI Holding Denmark ApS (MHI, Copenhagen, Denmark) — subscribe for nominally DKK 5,049,337 new shares, divided into shares of DKK 1 each, by contribution in kind of MHI Denmark’s shares in the MHI Vestas Offshore Wind (MVOW) joint venture. The new shares will be subscribed at a price of DKK 1,045 (approx. $164 USD) per share of nominally DKK 1, calculated as the volume-weighted average of the price for shares in Vestas as quoted on Nasdaq Copenhagen A/S the last five business days open for trading up to and including Oct. 28.

Subscription and payment of the new shares will be made by MHI Denmark at the date of completion of the transaction, but no later than 12 months after the date of the decision by the Board of Directors to issue the shares. Vestas is subject to certain obligations to offer MHI Denmark rights to subscribe for shares against cash payment in the event of a rights issue to shareholders in the period until closing of the transaction to ensure that any changes to the size of the nominal value of Vestas shares do not subsequently impact MHI Denmark’s proportionate holdings.

The new shares will have the same rank (“pari passu”) as the existing shares in Vestas and will carry a right to dividend from the date of registration of the capital increase with the Danish Business Authority. Following completion of the capital increase, the registered share capital of Vestas will amount to nominally DKK 201,973,452 (approx. $31,662,751 USD), divided into 201,973,452 shares of DKK 1 each. The new shares are expected to be admitted to trading and official listing on Nasdaq Copenhagen as soon as possible following closing of the transaction.

The share issue will be made pursuant to applicable exemptions from the obligation to publish a prospectus as a directed issue and private placement at market value and without pre-emption rights for Vestas’ existing shareholders.
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Vestas’ planning of the expected integration of MVOW into the Vestas group will commence immediately and run until transaction closing, focusing on synergies in sales, technology, manufacturing footprint and procurement to sustain customer relationships, lower costs and the building of a strong shared Vestas culture. Until transaction closing, the executive management of MVOW will consist of Johnny Thomsen, CEO of MVOW, Tatsuichiro Honda, co-chief executive officer and CFO of MVOW, Kentaro Hosomi, deputy chairman of MVOW and CEO, Energy Systems, MHI, and Henrik Andersen, chairman of MVOW and Group president and CEO of Vestas.

On a stand-alone basis, MVOW is expected to report a consolidated revenue for 2020 of approximately €1.4 billion EUR (approx. $1.6 billion USD), with an EBIT margin of around 4%.

Closing of the transaction is expected to take place within either the fourth quarter of 2020 or the first quarter of 2021.

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JEC WORLD ANNOUNCES NEW 2021 DATES NEW DIGITAL PLATFORM UNVEILED

Paris, November 3, 2020 – Due to the continued impact of the Covid-19 pandemic and after thorough consultation of clients and partners, the JEC World team today announces that the next edition of JEC World is postponed from March 9 to 11 to June 1 to 3, 2021.

With the growing concern among our exhibitors and partners surrounding the critical situation of the Covid 19, travel restrictions, quarantine, and lockdown measures announced recently in many countries, the JEC World team has decided to work on a new timeline to hold the next edition of the event in safer conditions in 2021.
Thus, JEC World exhibitors answered a survey proposing three dates to determine which one would suit them the most. It appeared that a large majority of respondents favored holding the next JEC World session from June 1 to 3, 2021.
“We truly regret having to make this difficult decision. However, we are all committed, starting today to deliver the best JEC World experience to our clients. We look forward to welcoming the international composites community back to Paris in June 2021″, says Eric Pierrejean, CEO of JEC Group.

Join us from June 1 to 3, 2021, at Paris Nord Villepinte (same venue) and online for a new augmented experience.
As the leading trade show of the composites industry, JEC World brings together the whole composites materials value chain and professionals from application sectors, experts from the scientific and academic world, associations and media from more than 112 countries.
JEC World is also proud to introduce its audience this year, its new digital platform, JEC World Augmented. This online platform, programmed to take place alongside JEC World, is tailored primarily for attendees who cannot be present physically at the show but still want to experience a tremendous digital event immersion.

“JEC World and its augmented platform will bring the international composites community and specialists together to network with exhibitors, hold digital business meetings, access online conferences, workshops, and discover the latest composites innovation,” says Adeline Larroque, Show director and EMEA events. “Now, more than ever, the international composites sector needs to come together to discuss today’s challenges and tomorrow’s composites solutions,” adds Larroque.

About JEC Group
JEC Group is the world’s leading company dedicated entirely to developing information and business connections channels and platforms supporting the growth and promotion of the composite materials industry. The company publishes the sector’s leading magazine, JEC Composites Magazine, and coordinates international programs in innovation. It organizes several events worldwide, including JEC World, the biggest international trade fair in composites and their use, which takes place every year in Paris.

Press contact
Farah Boudjemia – Tel. +33 1 58 36 43 99 – boudjemia@jeccomposites.com

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Photo: IR thermograms of six impact damage defects/ Composites Part B: Engineering.
Photo: Experimental setup for performing ultrasonic IR thermography/ Composites Part B: Engineering.
Composites
Photo: IR thermograms of six impact damage defects/ Composites Part B: Engineering.
Heat and ultrasonic help scientists to detect 'kissing-bond' defects in a promising space material

Scientists from Tomsk Polytechnic University together with their colleagues from Malaysia have studied for the first time a carbon-carbon (C/C) composite by a new non-destructive method – ultrasonic IR thermography. The material itself is promising for aerospace engineering since it can withstand the temperature of up to 2,500 °C. Experiments showed that the method makes it possible to detect so-called ‘kissing-bond’ defects in the materials with high accuracy and online. If they are not detected in time they can cause emergency situations. The study results were published in the journal Composites Part B: Engineering.

‘Due to its high strength with relative less mass and resistance against corrosion, composite materials are often used for aerospace engineering, shipbuilding, and automobile industry. However, they have substantial limitations – composites are vulnerable to shock damage.

If they are used for external parts in aircraft (airplanes, rockets, and others), for example, hail, bird strikes, and tools can damage them. Defects in such materials, e.g. the smallest delamination, cracks, breaks in the fibers are often invisible. Over time, during their operation, they enlarge and potential danger increases. Therefore manufacturing of critical parts out of composites requires new methods of non-destructive testing, ’ says research fellow Zaki Umar from Malaysian Nuclear Agency. Recently he has been on internship at Tomsk Polytechnic University. The carbon-carbon composite has a complex fibrous structure. It features ‘’kissing-bond’ defects. Such defects look like, for example, cracks in which the edges closely adjoin each other. They are difficult to detect by standard ultrasonic and X-ray methods because they do not resist mechanical waves and ionizing radiation. At TPU Zaki Umar was proposed to test the C/C composite by ultrasonic infrared thermography. It unites two methods of non-destructive testing at once: an ultrasonic and a thermal.

Tomsk Polytechnic University is one of few Russian scientific centers where the research of ultrasonic infrared thermography is conducted.

TPU Professor Vladimir Vavilov, the head of the Research Laboratory for Thermal Testing says:
‘The method is still new in the world and not adopted at manufacturing in Russia. Though it has a series of advantages. The idea of the method is simple: powerful ultrasound with a frequency of 20-40 kHz, which is more powerful than in the traditional ultrasonic testing, is introduced into the tested object. Ultrasonic waves propagating in a solid body causes friction of the defect walls, generating thermal energy. We identify the energy with an infrared camera installed at a short distance from the tested object. The thermal ‘footprints’ of defects show their location and characteristics.’

Experiments showed that ultrasonic infrared thermography is very effective in detecting defects in a carbon-carbon composite. The scientists received clear signals that are difficult to confuse with ‘noises’ that are usual for standard ultrasonic testing.

‘Composites, including carbon-carbon ones are materials for manufacturing parts which are difficult to test by usual ultrasound. Ultrasonic thermography is more accessible from the perspective of the point of ultrasonic introduction, therefore it is appropriate for testing complex shaped parts. The testing process is carried out online, all data obtained are immediately available for analysis,’ explains Professor Vavilov.

In the framework of the study, TPU scientists developed ThermoSource software to solve a basic problem on the evaluation of the energy released during internal friction. This will determine the limiting capabilities of the method and optimize the procedure of non-destructive testing. In addition, 3D modeling of thermal release in defects makes it possible to study the structure of complex defects that occur in composites due to external exposure.
Composites
Photo: IR thermograms of six impact damage defects/ Composites Part B: Engineering.
The elaborated testing method and the model for calculation releasing energy are now possible to apply for different composite materials, in particular, carbon-fiber plastic, fiberglass, composite ceramics, and others.

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