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26.07.2022

Composites Germany – Results of the 19th Market Survey

  • Current crises are dampening mood in composites industry
  • Pessimistic outlook
  • Subdued investment climate
  • Varying expectations for application industries
  • GRP is still a growth driver
  • Composites Index continues to decline

This is the 19th time that Composites Germany has identified the latest performance indicators for the fibre-reinforced plastics market. The survey covered all the member companies of the three major umbrella organisations of Composites Germany: AVK, Leichtbau Baden-Württemberg and the VDMA Working Group on Hybrid Lightweight Construction Technologies.

As before, to ensure a smooth comparison with the previous surveys, the questions in this half-yearly survey have been left unchanged. Once again, the data obtained in the survey is largely qualitative and relates to current and future developments in the market.

  • Current crises are dampening mood in composites industry
  • Pessimistic outlook
  • Subdued investment climate
  • Varying expectations for application industries
  • GRP is still a growth driver
  • Composites Index continues to decline

This is the 19th time that Composites Germany has identified the latest performance indicators for the fibre-reinforced plastics market. The survey covered all the member companies of the three major umbrella organisations of Composites Germany: AVK, Leichtbau Baden-Württemberg and the VDMA Working Group on Hybrid Lightweight Construction Technologies.

As before, to ensure a smooth comparison with the previous surveys, the questions in this half-yearly survey have been left unchanged. Once again, the data obtained in the survey is largely qualitative and relates to current and future developments in the market.

Current crises are dampening mood in composites industry
Both the economy in general and industry in particular are struggling with numerous challenges at the moment. The Covid-19 pandemic has now had a negative impact for over two years and is still affecting a range of segments of the composites industry. One area that has been hit especially hard by the resulting losses is the mobility sector. Another major strain has been a sharp rise in energy costs recently. Above all, we can expect price increases in fuel and gas to become a central issue over the next few months. In addition, there are still problems along international supply chains, coupled with steep increases in raw material prices, partly due to bottlenecks in the supply. The war in Ukraine has put an additional strain on many business sectors, affecting their supply chains, in particular.

In the current survey, both these and other effects have had a major negative impact on the mood in the composites industry.

The assessment index for the current general economic situation is showing a clear decline.

Compared to the last survey, the assessment of the respondents’ own business situations has dropped significantly and for the first time in eighteen months. However, this decline has been far less severe than during the onset of the Covid-19 pandemic.

Pessimistic outlook
Furthermore, there has been a substantial decline in expectations for the future market development. The key figures for the general economic situation have been declining sharply and have reached an all-time low since the beginning of the survey. The respondents are also less optimistic about future expectations for their own companies.

However, respondents are less extreme when assessing the business situations of their own companies. Despite negative spikes, this curve is far less steep, showing that respondents are expecting less dramatic effects on their own companies than on the industry as a whole.

Subdued investment situation
Although, as expected, the investment climate has also become subdued, it should be noted that, in all, expectations are still relatively high. 70% of all respondents believe that machine investments are possible, or they are planning for it. This figure is somewhat lower than in the previous market survey, but it shows a far less dramatic development than the other factors mentioned above .

Varied expectations for application industries
We already mentioned the high level of heterogeneity of applications in the composite sector. In the survey, respondents were asked to provide assessments of market developments in various core sectors.

Their expectations clearly differ substantially from one another.

The proportion of pessimistic expectations has generally been rising for all application industries. While these expectations are almost entirely within a single-digit range, there has been a clear rise in the proportion of those expecting a deterioration of the market in the various application industries. Similar to the last surveys, major drops are expected above all for the automotive, aviation and mechanical engineering sectors. For the first time, however, we can now also see rather negative expectations on the infrastructure and building sector. Yet this is a segment which often reacts quite slowly to temporary economic fluctuations and has so far shown itself to be relatively resilient towards the above-mentioned crises. It remains to be seen whether such forebodings will come true, or whether the construction industry will continue to hold its own in the face of the current negative forces.

Growth drivers remain stable
Geographically, the survey shows that the most important growth stimuli for the composites segment are expected to come from Germany, Europe and Asia.

Where materials are concerned, we are seeing a continuation of the ongoing paradigm shift. Whereas, in the first 13 surveys, respondents always mentioned CRP as the material with the most important growth drivers in its environment, the most important stimuli are now being expected to come consistently either from GRP or from all materials.

Composites Index continues to decline
The industry is currently going through an extremely tense and difficult period, characterised by rising costs, supply chain issues, lack of availability of certain semifinished products and raw materials, increasing political instability and very pessimistic expectations for the future. All the relevant indicators of the current composites survey are pointing downwards at the moment. After some slight recovery over the last 18 months, the Composite Index has therefore clearly been weakening this time and has been dropping to new low points, especially concerning future expectations.

Industry in general, but particularly also Germany’s composite industry, has always shown itself to be very resilient towards crises and has often cushioned negative developments quickly. The total production volume for composites in Europe last year already reached its pre-crisis level of 2019. Germany continues to be the most important manufacturing country in Europe, with a market share of nearly 20%. Hopefully, the slowdown in the coming months will be less severe than expected and the composites industry will remain on an upward trajectory. We will continue to be optimistic, as composites are highly diverse and therefore a key material of the future.

The next Composites Market Survey will be published in January 2023.

Source:

Composites Germany

(c) MAI Carbon
24.05.2022

From waste to secondary raw material - wetlaid nonwovens made from recycled carbon fibers

MAI Scrap SeRO | From Scrap to Secondary Ressources – Highly Orientated Wet-Laid-Nonwovens from CFRP-Waste

The »Scrap SeRO« project is an international joint project in the field of »recycling of carbon fibers«.

The technical project goal is the demonstration of a continuous process route for processing pyrolytically recycled carbon fibers (rCF) in high-performance second-life component structures. In addition to the technological level, the focus of the project is particularly on the international transfer character, in the sense of a cross-cluster initiative between the top cluster MAI Carbon (Germany) and CVC (South Korea).

MAI Scrap SeRO | From Scrap to Secondary Ressources – Highly Orientated Wet-Laid-Nonwovens from CFRP-Waste

The »Scrap SeRO« project is an international joint project in the field of »recycling of carbon fibers«.

The technical project goal is the demonstration of a continuous process route for processing pyrolytically recycled carbon fibers (rCF) in high-performance second-life component structures. In addition to the technological level, the focus of the project is particularly on the international transfer character, in the sense of a cross-cluster initiative between the top cluster MAI Carbon (Germany) and CVC (South Korea).

Through direct cooperation between market-leading companies and research institutions of the participating cluster members, the technical project processing takes place in the context of the global challenge of recycling, as well as the need for increased resource efficiency, with reference to the economically strategic material carbon fibers.

Efficient processing of recycled carbon fibers
The technological process route within the project runs along the industrial wet-laying technology, which is comparable to classic paper production. This enables a robust production of high-quality rCF nonwovens, which are characterized, among other things, by particularly high homogeneity and stability of characteristic values.

A special development focus is on a specific process control, which allows the generation of an orientation of the individual fiber filaments in the nonwoven material.

The given preferred fiber direction of the discontinuous fiber structure opens up strong synergy effects in relation to increased packing densities, i.e. fiber volume content, as well as a significantly optimized processing behavior in relation to impregnation, forming and consolidation, in addition to a load path-oriented mechanics.

The innovative wetlaid nonwovens are then further processed into thermoset and thermoplastic semi-finished products, i.e. prepregs or organosheets, using impregnation processes that are suitable for large-scale production.

rCF tapes are produced from this in an intermediate slitting step. By means of automated fiber placement, load path-optimized preforms can be deposited, which are then consolidated into complex demonstrator components.

The process chain is monitored at key interfaces by innovative non-destructive measurement technology and supplemented by extensive characterization methods. Especially for the processing of pyrolysed recycled carbon fibers, which were recovered from end-of-life waste or PrePreg waste, for example, there are completely new potentials with significant added value compared to the current state of the art for the overall process route presented here.

International Transfer
The fundamentally global challenge of recycling and the striving for increased sustainability is strongly influenced by national recycling strategies as a result of country-specific framework conditions. The globalized way in which companies deal with high-volume material flows places additional demands on a functioning circular economy. A networked solution can only be created on the basis of and in compliance with the respective guidelines and structural factors.

In the case of the high-performance material carbon fiber, there is a particularly high technical requirement for an ecologically and economically viable recycling industry. At the same time, the specific market size already opens up interesting scaling effects and potential for market penetration.

The Scrap SeRO project connects two of the world's leading top clusters in the field of carbon composites from South Korea and Germany on the basis of a cross-cluster initiative. As part of this first promising technology project, the foundation stone for future cooperation is to be laid that supports the effective recycling of carbon fibers. The project makes an important contribution to closing the material cycle for carbon fibers and thus paves the way for renewed use in further life cycles of this high-quality and energy-intensive material.

Info »Scrap SeRO«

  • Duration: 05/2019 – 04/2022
  • Funding: BMBF
  • Funding Amount: 2.557.000 €

National Consortium

  • Fraunhofer Institute for Casting, Composite and Processing Technology IGCV
  • ELG Carbon Fibre
  • J.M. Voith SE & Co. KG
  • Neenah Gessner
  • SURAGUS GmbH
  • LAMILUX Composites GmbH
  • Covestro Deutschland AG
  • BA Composites GmbH
  • SGL Carbon

International Consortium

  • KCarbon
  • Hyundai
  • Sangmyung University
  • TERA Engineering
Source:

Fraunhofer Institute for Casting, Composite and Processing Technology IGCV

Graphik: Pixabay
11.01.2022

FIMATEC innovation network enters second funding phase

The network for the development of fiber materials technology for healthcare and sports will receive funding from the Central Innovation Programme for SMEs (ZIM) for another two years.

The Federal Ministry for Economic Affairs and Climate Action (BMWi) approved a corresponding application in December 2021. This will continue to provide funding for the development of innovative functional fibers, smart textiles and application-optimized fiber composite materials until June 2023 and strengthen the technological competitiveness and innovative strength of small and medium-sized enterprises (SMEs).

The network for the development of fiber materials technology for healthcare and sports will receive funding from the Central Innovation Programme for SMEs (ZIM) for another two years.

The Federal Ministry for Economic Affairs and Climate Action (BMWi) approved a corresponding application in December 2021. This will continue to provide funding for the development of innovative functional fibers, smart textiles and application-optimized fiber composite materials until June 2023 and strengthen the technological competitiveness and innovative strength of small and medium-sized enterprises (SMEs).

For this purpose, the FIMATEC innovation network combines competences from different engineering and scientific disciplines with small and medium-sized manufacturers and service providers from the target sectors in medicine and sports (e.g. orthopaedics, prosthetics, surgery, smart textiles) as well as players from the textile and plastics industry.      

This interdisciplinary combination of industrial partners and application-oriented research institutions increases competitiveness and enables the players to realise their technical research and development projects quickly and in a targeted manner. The focus for the joint R&D projects of the companies and research institutions is on the development of innovative materials and efficient manufacturing technologies. 
          
Fiber-based materials have become indispensable in many applications in medicine and sports. As a pure fiber, processed into a textile or as a fiber composite plastic, they offer an almost unlimited variety for adjusting property and functional profiles. At the same time, the demands on the range of functions, performance and cost-effectiveness are constantly increasing, so that there is great potential for innovation. Developments are driven on the one hand by new materials and manufacturing processes, and on the other by innovative applications. Products with new and superior functions create a technological advantage over international competitors and enable higher sales revenues. In addition, efficient processes, application-optimized materials or even the integration of functions into the basic structure of textile materials lead to lower production costs and improved marketing opportunities in the future.
For developments in this context, the partners have joined forces in the FIMATEC innovation network, thus combining their expertise. Within the network, innovative materials and processes are being developed jointly in the following areas and tested in future-oriented products and services:

  • Functional fibers
    Innovative fiber materials with integrated functionalities
  • Preforming
    Highly load path optimized fiber orientations for complex fiber composite components.    
  • Smart Textiles
    Textile-based sensors and actuators
  • Hybrid material and manufacturing technologies
    Application-optimized components through cross-technology solution approaches.    
  • Fiber composites  
    Intelligent matrix systems and function-optimized fiber materials.    
  • Fiber-reinforced 3D printing  
    High-quality additive manufacturing processes for the efficient production of individualized products.

 
17 network partners are researching fiber-based materials for medical and sports technologyCurrently, ten companies and seven research institutions are involved in FIMATEC. Interested companies and research institutions as well as potential users can continue to participate in the cooperation network or R&D projects. In the course of membership, the partners are actively supported in identifying and initiating innovation projects as well as securing financing through funding acquisition. One application for ZIM project funding has already been approved by FIMATEC in its first year.

The aim of the already approved project "CFKadapt" is to develop a thermoformable fiber-plastic composite material for optimally adaptable orthopedic aids such as prostheses and orthoses. In the "Modul3Rad" project, which is currently being worked out in detail, the project partners intend to develop a modular lightweight frame system for the construction of user-friendly therapy tricycles, suitable for everyday use by severely and very severely disabled children. Three further collaborative projects are already in the planning stage.

The technology and knowledge transfer enables in particular small and medium-sized enterprises (SMEs) to access cutting-edge technological research, especially these are often denied access to innovations due to the lack of their own research departments. The IWS GmbH has taken over the network management for FIMATEC and supports the partners from the first idea to the search for suitable project partners and the preparation and coordination of funding applications. The aim is to obtain funding from the Central Innovation Programme for SMEs (ZIM), which offers companies funding opportunities for a wide range of technical innovation projects in cooperation with research institutions.

FIMATEC-netzwork partners
all ahead composites GmbH | Veitshöchheim | www.bike-ahead-composites.de
Altropol Kunststoff GmbH | Stockelsdorf | www.altropol.de
Diondo GmbH | Hattingen | www.diondo.com
Mailinger innovative fiber solutions GmbH | Sontra | www.mailinger.de
Sanitätshaus Manfred Klein GmbH & Co. KG | Stade | www.klein-sanitaetshaus.de
STREHL GmbH & Co KG | Bremervörde | www.rehastrehl.de
WESOM Textil GmbH | Olbersdorf | www.wesom-textil.de
Faserinstitut Bremen e.V. (FIBRE) | www.faserinstitut.de
E.F.M. GmbH | Olbersdorf | www.efm-gmbh.de
REHA-OT Lüneburg Melchior und Fittkau GmbH | Olbersdorf | www.rehaot.de
Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM | Bremen | www.ifam.fraunhofer.de
Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) | www.ipfdd.de
Institut für Polymertechnologien Wismar e.V. (IPT) | www.ipt-wismar.de
Institut für Verbundwerkstoffe GmbH | Kaiserslautern | www.ivw.uni-kl.de

Associated network partners
9T Labs AG | Zürich, Schweiz | www.9tlabs.com
Fachhochschule Nordwestschweiz, Institut für Kunststofftechnik (FHNW) | www.fhnw.ch
KATZ - Kunststoff Ausbildungs- und Technologie-Zentrum | Aarau, Schweiz | www.katz.ch

Source:

Textination / IWS Innovations- und Wissensstrategien GmbH

(c) nova-Institut GmbH
07.12.2021

Finalists for „Cellulose Fibre Innovation of the Year 2022” announced

Cellulose Fibre Innovation of the Year 2022: Cellulose Fibre Solutions are expanding from hygiene and textiles as well as non-wovens up to alternatives for carbon fibres for light-weight applications.

Great submissions made the nomination for the Innovation Award difficult. All of them present promising sustainable solutions in the field of cellulose fibres value chain. Six of them now get the chance to demonstrate their potential to a wide audience in Cologne (Germany), and online.

Cellulose Fibre Innovation of the Year 2022: Cellulose Fibre Solutions are expanding from hygiene and textiles as well as non-wovens up to alternatives for carbon fibres for light-weight applications.

Great submissions made the nomination for the Innovation Award difficult. All of them present promising sustainable solutions in the field of cellulose fibres value chain. Six of them now get the chance to demonstrate their potential to a wide audience in Cologne (Germany), and online.

For the second time, nova-Institute grants the “Cellulose Fibre Innovation of the Year” within the framework of the “International Conference on Cellulose Fibres 2022” (2-3 February 2022). The advisory board of the conference nominated six  products, ranging from cellulose made of orange- and wood pulp to a novel technology for cellulose fibre production. The presentations, election of the winner by the conference audience and the award ceremony will take place on the first day of the conference.

Cellulose fibres show an increasingly expanding wide range of applications, while at the same time markets are driven by technological developments and political framework conditions, especially bans and restrictions on plastics and increasing sustainability requirements. The conference provides rich information on opportunities for cellulose fibres through policy assessment, a session on sustainability, recycling and alternative feedstocks as well as latest development in pulp, cellulose fibres and yarns. This includes application such as non-wovens, packaging and composites.

Here are the nominees:
Carbon Fibres from Wood – German Institutes of Textile and Fiber Research Denkendorf (Germany)
The HighPerCellCarbon® technology is a sustainable and alternative process for the production of carbon fibres made from wood. The technology starts with wet spinning of cellulosic fibres using ionic liquids (IL) as direct solvent in an environmentally friendly, closed loop filament spinning process (HighPerCell® technology). These filaments are directly converted into carbon fibres by a low-pressure stabilisation process, followed by a suitable carbonisation process. No exhaust fumes or toxic by-products are formed during the whole process. Furthermore, the approach allows a complete recycling of solvent and precursor fibres, creating a unique and environmentally friendly process. Carbon fibres are used in many lightweight applications and the fibres are a sustainable alternative to fossil-based ones.

Fibers365, Truly Carbon-Negative Virgin Fibres from Straw – Fibers365 (Germany)
Fibers365 are the first carbon-negative virgin straw fibres on the market. The Fibers365 concept is based on a unique, state of the art process to provide functional, carbon negative, and competitive non-wood biomass products such as virgin fibres for paper, packaging and textile purposes as well as high value process energy, biopolymer and fertilizer side streams. The products are extracted from the stems of annual food plants such as straw by a chemical-free, regional, farm level steam explosion pulping technology, allowing an easy separation of the fibres from sugars, lignin, organic acid and minerals. In the case of annual plants, CO2 emissions are recaptured within 12 months from their production date, offering “instant”, yearly compensation of corresponding emissions.

Iroony® Hemp and Flax Cellulose – RBX Créations (France)
Iroony® is a branded cellulose made by RBX Créations from hemp. This resistant hemp plant grows quickly within in a few months, massively captures carbon and displays a high content of cellulose. The biomass is directly collected from French farmers who cultivate without chemicals or irrigation, in extended rotation cycles, contributing to soil regeneration and biodiversity. For a diversified supply, the hemp can be combined with organically-grown flax. Through its patented process, RBX Créations extracts high-purity cellulose, perfectly suitable for spinning technologies such as HighPerCell® of DITF research centre. The resulting fibres display versatile properties of fineness, tenacity and stretch, for applications like clothing or technical textiles. Iroony® combines low impact, trackability and performance.

SPINNOVA, Sustainable Textile Fibre without Harmful Chemicals – Spinnova (Finland)
Spinnova’s innovative technology enables production of sustainable textile fibres in a mechanical process, without dissolving or any harmful chemicals. The process involves use of paper-grade pulp and mechanical refining to turn pulp into microfibrillated cellulose (MFC). The fibre suspension consisting of MFC is extruded to form textile fibre, without regeneration processes. The Spinnova process does not generate any side waste, and the environmental footprint of SPINNOVA® including 65 % less CO2 emissions and 99 % less water compared to cotton production. Spinnova’s solution is also scalable: Spinnova targets to reach 1 million tonnes annual production capacity in the next 10 to 12 years.    

Sustainable Menstruation Panties: Application-driven Fibre Functionalisation – Kelheim Fibres (Germany)
Kelheim’s plant-based and biodegradable fibres contribute significantly to a sustainable future in the field of reusable hygiene textiles. Through innovative functionalisation they are specifically adjusted to the requirements of the single layers and thereby reach a performance comparable to that of synthetic fibres. A unique duality in fibre technology is created: sustainably manufactured cellulosic fibres that allow for high wearing comfort and reusability with extraordinary, durable performance. Fibre concepts comprise Celliant® Viscose, an in-fibre infrared solution and Danufil® Fibres in the top sheet, Galaxy, a trilobal fibre for the ADL, Bramante, a hollow viscose fibre, in the absorbing core and a water repellent woven fabric, a biodegradable PLA film or a sustainable coating as a back sheet.

TENCEL™ branded Lyocell Fibre made of Orange and Wood Pulp – Orange Fiber (Italy)
Orange Fiber is the world's first company to produce a sustainable textile fibre from a patented process for the extraction of cellulose to be spun from citrus juice leftovers, which are more than 1 million tonnes a year just in Italy. The result of our partnership with Lenzing Group, leading global producer of wood-based specialty fibres, is the first ever TENCEL™ branded lyocell fibre made of orange and wood pulp. A novel cellulosic fibre to further inspire sustainability across the value chain and push the boundaries of innovation. This fibre, part of the TENCEL™ Limited Edition initiative, is characterized by soft appeal and high moisture absorbance and has already obtained the OEKO-TEX Standard 100 certificate and is undergoing a diverse set of other sustainability assessments.

(c) Toray
23.11.2021

Toray Industries: A Concept to change Lives

Founded in January 1926, Tokyo-based Japanese chemical company Toray Industries, Inc. is known as the world's largest producer of PAN (polyacrylonitrile)-based carbon fibers. But its overall portfolio includes much more. Textination spoke with Koji Sasaki, General Manager of the Textile Division of Toray Industries, Inc. about innovative product solutions, new responsibilities and the special role of chemical companies in today's world.

Toray Industries is a Japanese company that - originating in 1926 as a producer of viscose yarns - is on the home stretch to its 100th birthday. Today, the Toray Group includes 102 Japanese companies and 180 overseas. They operate in 29 countries. What is the current significance of the fibers and textiles business unit for the success of your company?

Founded in January 1926, Tokyo-based Japanese chemical company Toray Industries, Inc. is known as the world's largest producer of PAN (polyacrylonitrile)-based carbon fibers. But its overall portfolio includes much more. Textination spoke with Koji Sasaki, General Manager of the Textile Division of Toray Industries, Inc. about innovative product solutions, new responsibilities and the special role of chemical companies in today's world.

Toray Industries is a Japanese company that - originating in 1926 as a producer of viscose yarns - is on the home stretch to its 100th birthday. Today, the Toray Group includes 102 Japanese companies and 180 overseas. They operate in 29 countries. What is the current significance of the fibers and textiles business unit for the success of your company?

The fibers’ and textiles’ business is both the starting point and the foundation of Toray's business development today. We started producing viscose yarns in 1926 and conducted our own research and development in nylon fibers as early as 1940. And since new materials usually require new processing methods, Toray also began investing in its own process technology at an early stage. On the one hand, we want to increase our sales, and on the other hand, we want to expand the application possibilities for our materials. For this reason, Toray also began to expand its business from pure fibers to textiles and even clothing. This allows us to better respond to our customers' needs while staying at the forefront of innovation.

Over the decades, Toray has accumulated a great deal of knowledge in polymer chemistry and organic synthesis chemistry - and this know-how is the foundation for almost all of our other business ventures. Today, we produce a wide range of advanced materials and high-value-added products in plastics, chemicals, foils, carbon fiber composites, electronics and information materials, pharmaceuticals, medicine and water treatment. However, fibers and textiles remain our most important business area, accounting for around 40% of the company's sales.

What understanding, what heritage is still important to you today? And how do you live out a corporate philosophy in the textile sector that you formulate as "Contributing to society through the creation of new value with innovative ideas, technologies and products"?

Toray has consistently developed new materials that the world has never seen before. We do this by focusing on our four core technologies: Polymer chemistry, organic synthetic chemistry, biotechnology and nanotechnology. We do this by focusing on our four core technologies: Polymer chemistry, organic synthetic chemistry, biotechnology and nanotechnology. For textiles, this means we use new polymer structures, spinning technologies and processing methods to develop yarns with unprecedented properties. We always focus on the needs and problems of the market and our customers.

This approach enables us to integrate textiles with new functions into our everyday lives that natural fibers and materials cannot accomplish. For example, we offer sportswear and underwear that absorb water excellently and dry very quickly, or rainwear and outdoor clothing with excellent water-repellent properties that feature a less bulky inner lining. Other examples include antibacterial underwear, uniforms, or inner linings that provide a hygienic environment and reduce the growth of odor-causing bacteria. People enjoy the convenience of these innovative textiles every day, and we hope to contribute to their daily comfort and improve their lives in some way.

In 2015, the United Nations adopted 17 sustainable development goals – simply known as the 2030 Agenda, which came into force on January 01, 2016. Countries were given 15 years to achieve them by 2030. In your company, there is a TORAY VISION 2030 and a TORAY SUSTAINABILITY VISION. How do you apply these principles and goals to the textile business? What role does sustainability play for this business area?

Sustainability is one of the most important issues facing the world today - not only in the textile sector, but in all industries. We in the Toray Group are convinced that we can contribute to solving various problems in this regard with our advanced materials. At the same time, the trend towards sustainability offers interesting new business approaches. In our sustainability vision, we have set four goals that the world should achieve by 2050. And we have defined which problems need to be addressed to achieve this.

We must:

  1. accelerate measures to combat climate change,
  2. implement sustainable, recycling-oriented solutions in the use of resources and in production,
  3. provide clean water and air, and
  4. contribute to better healthcare and hygiene for people around the world.

We will drive this agenda forward by promoting and expanding the use of materials that respond to environmental issues. In the textile sector, for example, we offer warming and cooling textiles – by eliminating the need for air conditioning or heating in certain situations, they can help reduce energy costs. We also produce environmentally friendly textiles that do not contain certain harmful substances such as fluorine, as well as textiles made from biomass, which use plant-based fibers instead of conventional petrochemical materials. Our product range also includes recycled materials that reduce waste and promote effective use of resources.

The TORAY VISION 2030, on the other hand, is our medium-term strategic plan and looks at the issue of sustainability from a different angle: Toray has defined the path to sustainable and healthy corporate growth in it. In this plan, we are focusing on two major growth areas: Our Green Innovation Business, which aims to solve environmental, resource and energy problems, and the Life Innovation Business, which focuses on improving medical care, public health, personal safety and ultimately a longer expectancy of life.

Innovation by Chemistry is the claim of the Toray Group. In a world where REACH and Fridays for Future severely restrict the scope of the chemical industry, the question arises as to what position chemistry can have in the textile industry. How do chemistry, innovation and sustainability fit together here?

The chemical industry is at a turning point today. The benefits that this industry can bring to civilization are still enormous, but at the same time, disadvantages such as the waste of resources and the negative impact on the environment and ecosystems are becoming increasingly apparent. In the future, the chemical industry will have to work much more towards sustainability - there is no way around it.

As far as textiles are concerned, we believe there are several ways to make synthetic materials more sustainable in the future. One of these, as I said, is materials made from plants instead of petrochemical raw materials. Another is to reduce the amount of raw materials used in production in the first place – this can be achieved, for example, by collecting and recycling waste materials from production or sales. Biodegradable materials that reduce the impact of waste products on the environment are another option worth pursuing, as is the reduction of environmentally harmful substances used in the production process. We are already looking at all of these possibilities in Toray's synthetic textiles business. At the same time, by the way, we make sure to save energy in our own production and minimize the impact on the environment.

Toray's fibers & textiles segment focuses on synthetic fibers such as nylon, polyester and acrylic, as well as other functional fibers. In recent years, there has been a clear trend on the market towards cellulosic fibers, which are also being traded as alternatives to synthetic products. How do you see this development – on the one hand for the Toray company, and on the other hand under the aspect of sustainability, which the cellulosic competitors claim for themselves with the renewable raw material base?

Natural fibers, including cellulose fibers and wool, are environmentally friendly in that they can be easily recycled and are rapidly biodegradable after disposal. However, to truly assess their environmental impact, a number of other factors must also be considered: Primarily, there is the issue of durability: precisely because natural fibers are natural, it is difficult to respond to a rapid increase in demand, and quality is not always stable due to weather and other factors.

Climatic changes such as extreme heat, drought, wind, floods and damages from freezing can affect the quantity and quality of the production of natural fibers, so that the supply is not always secured. In order to increase production, not only does land have to be cleared, but also large amounts of water and pesticides have to be used to cultivate it – all of which is harmful to the environment.

Synthetic fibers, on the other hand, are industrial products manufactured in controlled factory environments. This makes it easier to manage fluctuations in production volume and ensure consistent quality. In addition, certain functional properties such as resilience, water absorption, quick drying and antibacterial properties can be embedded into the material, which can result in textiles lasting longer in use.

So synthetic fibers and natural fibers, including cellulose fibers, have their own advantages and disadvantages – there is no panacea here, at least not at the moment. We believe: It is important to ensure that there are options that match the consumer's awareness and lifestyle. This includes comfort in everyday life and sustainability at the same time.

To what extent has the demand for recycled products increased? Under the brand name &+™, Toray offers a fiber made from recycled PET bottles. Especially with the "raw material base: PET bottles", problems can occur with the whiteness of the fiber. What distinguishes your process from that of other companies and to what extent can you compete with new fibers in terms of quality?

During the production of the "&+" fiber, the collected PET bottles are freed from all foreign substances using special washing and filtering processes. These processes have not only allowed us to solve the problem of fiber whiteness – by using filtered, high-purity recycled polyester chips, we can also produce very fine fibers and fibers with unique cross sections. Our proven process technologies can also be used to incorporate specific textures and functions of Toray into the fiber. In addition, "&+" contains a special substance in the polyester that allows the material to be traced back to the recycled PET bottle fibers used in it.

We believe that this combination of aesthetics, sustainability and functionality makes the recycled polyester fiber "&+" more competitive than those of other companies. And indeed, we have noticed that the number of requests is steadily increasing as companies develop a greater awareness of sustainability as early as the product planning stage.

How is innovation management practiced in Toray's textile division, and which developments that Toray has worked on recently are you particularly proud of?

The textile division consists of three sub-divisions focusing on the development and sale of fashion textiles (WOMEN'S & MEN'S WEAR FABRICS DEPT.), sports and outdoor textiles (SPORTS WEAR & CLOTHING MATERIALS FABRICS DEPT.) and, specifically for Japan, textiles for uniforms used in schools, businesses and the public sector (UNIFORM & ADVANCED TEXTILES DEPT.).

In the past, each division developed its own materials for their respective markets and customers. However, in 2021, we established a collaborative space to increase synergy and share information about textiles developed in different areas with the entire department. In this way, salespeople can also offer their customers materials developed in other departments and get ideas for developing new textiles themselves.

I believe that the new structure will also help us to respond better to changes in the market. We see, for example, that the boundaries between workwear and outdoor are blurring – brands like Engelbert Strauss are a good example of this trend. Another development that we believe will accelerate after the Corona pandemic is the focus on green technologies and materials. This applies to all textile sectors, and we need to work more closely together to be at the forefront of this.

How important are bio-based polyesters in your research projects? How do you assess the future importance of such alternatives?

I believe that these materials will play a major role in the coming years. Polyester is made from purified terephthalic acid (PTA), which again consists of paraxylene (PX) and ethylene glycol (EG). In a first step, we already offer a material called ECODEAR™, which uses sugar cane molasses waste as a raw material for EG production.

About 30% of this at least partially bio polyester fiber is therefore biologically produced, and the material is used on a large scale for sportswear and uniforms. In the next step, we are working on the development of a fully bio-based polyester fiber in which the PTA component is also obtained from biomass raw materials, such as the inedible parts of sugar cane and wood waste.

Already in 2011, we succeeded in producing a prototype of such a polyester fiber made entirely from biomass. However, the expansion of production at the PX manufacturer we are working with has proven to be challenging. Currently, we are only producing small sample quantities, but we hope to start mass production in the 2020s.

Originally starting with yarn, now a leading global producer of synthetic fibers for decades, you also work to the ready-made product. The range extends from protective clothing against dust and infections to smart textiles and functional textiles that record biometric data. What are you planning in these segments?

In the field of protective clothing, our LIVMOA™ brand is our flagship material. It combines high breathability to reduce moisture inside the garment with blocking properties that keep dust and other particles out. The textile is suitable for a wide range of work environments, including those with high dust or grease levels and even cleanrooms. LIVMOA™ 5000, a high quality, also demonstrates antiviral properties and helps to ease the burden on medical personnel. The material forms an effective barrier against bacteria and viruses and is resistant to hygroscopic pressure. Due to its high breathability, it also offers high wearing comfort.

Our smart textile is called hitoe™. This highly conductive fabric embeds a conductive polymer – a polymer compound that allows electricity to pass through - into the nanofiber fabric. hitoe™ is a high-performance material for detecting biosignals, weak electrical signals that we unconsciously emit from our bodies.

In Japan, Toray has developed products for electrocardiographic measurements (ECGs) that meet the safety and effectiveness standards of medical devices. And in 2016, we submitted an application to the Japanese medical administrative authorities to register a hitoe™ device as a general medical device – this registration process is now complete. Overall, we expect the healthcare sector, particularly medical and nursing applications, to grow – not least due to increasing infectious diseases and growing health awareness among the elderly population. We will therefore continue to develop and sell new products for this market.

In 1885, Joseph Wilson Swan introduced the term "artifical silk" for the nitrate cellulose filaments he artificially produced. Later, copper, viscose and acetate filament yarns spun on the basis of cellulose were also referred to as artifical silk. Toray has developed a new innovative spinning technology called NANODESIGN™, which enables nano-level control of the fineness and shape of synthetic fibers. This is expected to create functions, aesthetics and textures that have not existed before. For which applications do you intend to use these products?

In NANODESIGN™ technology, the polymer is split into a number of microscopic streams, which are then recombined in a specific pattern to form a new fiber. By controlling the polymer flow with extreme precision, the fineness and cross-sectional shape of the fiber can be determined much more accurately than was previously possible with conventional microfiber and nanofiber spinning technologies. In addition, this technology enables the combination of three or more polymer types with different properties in one fiber – conventional technologies only manage two polymer types. This technology therefore enables Toray to specify a wide range of textures and functions in the production of synthetic fibers that were not possible with conventional synthetic fibers – and even to outperform the texture and feel of natural fibers. Kinari, our artificial silk developed with NANODESIGN technology, is a prime example here, but the technology holds many more possibilities – especially with regard to our sustainability goals.

What has the past period of the pandemic meant for Toray's textile business so far? To what extent has it been a burden, but in which areas has it also been a driver of innovation? What do you expect of the next 12 months?

The Corona catastrophe had a dramatic impact on the company's results: The Corona catastrophe had a dramatic impact on the company's results: In the financial year 2020, Toray's total sales fell by about 10% to 188.36 billion yen (about 1.44 billion euros) and operating profit by about 28% to 90.3 billion yen (about 690 million euros). The impact on the fiber and textile business was also significant, with sales decreasing by around 13% to 719.2 billion yen (approx. 5.49 billion euros) and operating profit by around 39% to 36.6 billion yen (approx. 280 million euros).

In the financial year 2021, however, the outlook for the fibers and textiles sector is significantly better: So far, the segment has exceeded its goals overall, even if there are fluctuations in the individual areas and applications. In the period from April to June, we even returned to the level of 2019. This is partly due to the recovering sports and outdoor sector. The fashion apparel market, on the other hand, remains challenging due to changing lifestyles that have brought lock-downs and home-office. We believe that a full recovery in business will not occur until the travel and leisure sector returns to pre-Corona levels.

Another side effect of the pandemic that we feel very strongly, is the growing concern about environmental issues and climate change. As a result, the demand for sustainable materials has also increased in the apparel segment. In the future, sustainability will be mandatory for the development and marketing of new textiles in all market segments. Then again, there will always be the question of how sustainable a product really is, and data and traceability will become increasingly important. In the coming years, the textile division will keep a close eye on these developments and develop materials that meet customers' needs.

About the person:
Koji Sasaki joined Toray in 1987. In his more than 30 years with the company, he has held various positions, including a four-year position as Managing Director of Toray International Europe GmbH in Frankfurt from 2016 to 2020. Since 2020, Koji Sasaki has been responsible for Toray's textile division and serves as acting chairman of Toray Textiles Europe Ltd. In these roles, he supervises the company's development, sales and marketing activities in the apparel segment, including fashion, sports and work or school uniforms.

The interview was conducted by Ines Chucholowius, Managing partner Textination GmbH

Photo: Pixabay
03.08.2021

Composites Germany presents results of the 17th Composites Market Survey

  • Highly positive rating of current business situation
  • Future expectations are optimistic
  • Varied expectations for application industries
  • Still the same growth drivers

This is the seventeenth time that Composites Germany has identified the latest KPIs for the fibre-reinforced plastics market. The survey covered all the member companies of the three major umbrella organisations of Composites Germany: AVK (Industrievereinigung Verstärkte Kunststoffe e.V.), Leichtbau Baden-Württemberg and the VDMA Working Group on Hybrid Lightweight Construction Technologies.

As before, to ensure a smooth comparison with the previous surveys, the questions in this half-yearly survey have been left unchanged. Once again, the data obtained in the survey is largely qualitative and relates to current and future market developments.

  • Highly positive rating of current business situation
  • Future expectations are optimistic
  • Varied expectations for application industries
  • Still the same growth drivers

This is the seventeenth time that Composites Germany has identified the latest KPIs for the fibre-reinforced plastics market. The survey covered all the member companies of the three major umbrella organisations of Composites Germany: AVK (Industrievereinigung Verstärkte Kunststoffe e.V.), Leichtbau Baden-Württemberg and the VDMA Working Group on Hybrid Lightweight Construction Technologies.

As before, to ensure a smooth comparison with the previous surveys, the questions in this half-yearly survey have been left unchanged. Once again, the data obtained in the survey is largely qualitative and relates to current and future market developments.

Highly positive rating of current business situation
After ratings of the current business situation had been steadily declining for nearly two years in succession, last year’s survey already displayed a trend reversal towards a more positive outlook. This positive trend has now continued in the latest survey, with entirely positive ratings for all three regions (Germany, Europe and worldwide). For ex-ample, 80% described the current general business situation as either positive or indeed very positive.

Moreover, unlike in the last survey, this more optimistic assessment applies not only to the general business situation, but also to the respondents’ own businesses, as they gave even more positive ratings than last year.     

There are currently quite a few challenges in the industrial environment. In many cases, the Covid-19 pandemic, for example, has merely receded, but has not disappeared.      
Business models have been and are still requiring adjustments. In some cases, supply chains have been severely disrupted and there are still some serious bottlenecks. The blockage of the Suez Canal by the Ever Given has once again highlighted the vulnerability of international commerce.

Shortages of raw materials, sharp increases in the prices of many raw materials and, most recently, a shortage of chips are having a major impact on various application industries. Nevertheless, the overall picture in the composites in-dustry is extremely optimistic. Similarly positive ratings were last achieved in the autumn 2018 and spring 2019 surveys.

Future expectations are optimistic
The positive prevailing mood is further reinforced by positive expectations for the future. A consistently optimistic picture emerged when respondents were asked about their ex-pectations for future business developments. For example, more than 80% of respond-ents are expecting the business situation in Europe to improve over the next six months. The pattern is similar for the other regions.

Varied expectations for application industries
Expectations on selected application industries vary substantially. As in the previous survey, significant declines are expected, above all, in automotive, aviation and wind energy. However, we can see that the proportion of respondents giving more pessimistic assessments has once again declined significantly.
Whereas, in the last sur-vey, 46% were expecting to see the situation get worse in aviation, this value has now dropped to a “mere” 17%. In the automotive sector, it has dropped from 17% (second half of 2020) to only 14%.

Two areas of application, in particular – infrastructure/construction and sports/leisure – have long been seen by many respondents as major growth stimulants for the composites industry. Even in times of a more difficult industrial environment, these two areas are currently proving to be especially robust.

GRP is still a growth driver
As before, the current market survey shows Germany, Europe and Asia as the global regions expected to deliver the most important growth stimuli for the composites segment. Expectations for Asia, on the other hand, have declined somewhat in favour of Europe. Where materials are concerned, we are seeing a continuation of the ongoing paradigm shift.      

Respondents are still convinced that CRP (carbon fibre reinforced plastic) is losing ground as a growth driver. However, GRP (glass fibre reinforced plastic) is now ranking as the most important material for the third time in succession. A large number of respondents have also mentioned the area entitled “Across All Segments” this time.

Composites are still relatively young materials with a great deal of potential. It remains exciting to see to what extent composites will continue to emerge as alternative materials and whether they can benefit from the major forthcoming developments (e.g. alternative drives, a growing demand for sustainability, alternative power sources, 5G, etc.).
The next Composites Market Survey will be published in January 2022. 

(c) Fraunhofer IAP
08.06.2021

Fraunhofer IAP: Recyclable, Fiber-reinforced Material made from Bio-based Polylactic Acid

"Packaging made from bio-based plastics has long been established. We are now supporting the further development of these materials for new areas of application. If in the future the market also offers plant-based materials for technically demanding tasks such as vehicle construction, the bioeconomy will take a decisive step forward," explained Uwe Feiler, Parliamentary State Secretary at the Federal Ministry of Food and Agriculture, in Potsdam. The occasion was the handover of a grant to the Fraunhofer Institute for Applied Polymer Research IAP. The Fraunhofer IAP wants to develop a composite material that consists entirely of bio-based polylactic acid (PLA) and is significantly easier to recycle than conventional fiber composites.

"Packaging made from bio-based plastics has long been established. We are now supporting the further development of these materials for new areas of application. If in the future the market also offers plant-based materials for technically demanding tasks such as vehicle construction, the bioeconomy will take a decisive step forward," explained Uwe Feiler, Parliamentary State Secretary at the Federal Ministry of Food and Agriculture, in Potsdam. The occasion was the handover of a grant to the Fraunhofer Institute for Applied Polymer Research IAP. The Fraunhofer IAP wants to develop a composite material that consists entirely of bio-based polylactic acid (PLA) and is significantly easier to recycle than conventional fiber composites.

The German Federal Ministry of Food and Agriculture (BMEL) is intensively promoting the development of biomaterials as part of its Renewable Resources funding program. More than 100 projects are currently underway, covering a wide range of topics: from plastics that are degradable in the sea to natural fiber-reinforced lightweight components for the automotive sector. The projects are supported by the Agency for Renewable Resources, the BMEL project management agency responsible for the Renewable Resources funding program.

Easier recycling of fiber-reinforced plastics
PLA is one of the particularly promising bio-based materials. The global market for this polymer is growing by around 10 percent a year. PLA is also used, among other things, as a matrix in fiber-reinforced plastics. In these mechanically resilient plastics, reinforcing fibers are embedded in a plastic matrix.

The Fraunhofer IAP project is now focusing on these reinforcing fibers: "We are further developing our PLA fibers in order to transfer them to industrial scale together with partners from industry. These fibers are ideally suited for reinforcing PLA plastics. The resulting self-reinforcing single-component composite promises great recycling benefits. Since the fiber and the matrix of PLA are chemically identical, complex separation steps are not necessary," explains Dr. André Lehmann, expert for fiber technology at Fraunhofer IAP.

Novel PLA fibers and films are more thermally stable
The challenge with this approach is that conventional PLA has a relatively low temperature resistance. Technical fibers can be produced most economically using the melt spinning process. The Fraunhofer IAP team is now using more thermally stable stereocomplex PLA (sc-PLA) for the fibers. The term stereocomplex refers to a special crystal structure that the PLA molecules can form. Sc-PLA fibers have a melting point that is 40 - 50 °C higher and can therefore withstand the incorporation process in a matrix made of conventional PLA. In the project, the researchers are developing and optimizing a melt spinning process for sc-PLA filament yarns. The partner in this work package is Trevira GmbH, a manufacturer of technical and textile fiber and filament yarn specialties that are in demand from automotive suppliers and contract furnishers, among others. Furthermore, the development of a manufacturing process for sc-PLA reinforced flat films is planned. The international adhesive tape manufacturer tesa SE is participating in this task, and will test the suitability of sc-PLA films as adhesive foils. In a third work package, the Fraunhofer IAP will finally process the filaments in a double pultrusion process to produce granules suitable for injection molding.

Bio-based solutions for the automotive and textile industries
The scientists led by Dr. André Lehmann are certain that the self-reinforced PLA material can conquer many new areas of application. The automotive and textile industries are already showing interest in bio-based materials that are also easier to recycle. In terms of price, PLA would already be competitive here, and now the material is also to be made technically fit for the new tasks.

Professor Alexander Böker, head of Fraunhofer IAP, says: "The steadily growing demand from industry for sustainable solutions underlines how important it is to develop biobased and at the same time high-performance materials. With our research, we are also actively driving the development of a sustainable and functioning circular economy and therefore very much welcome the support from the federal government."

Information on the project is available at fnr.de under the funding code 2220NR297X.

(c) Porsche AG
04.05.2021

Fraunhofer: Lightweight and Ecology in Automotive Construction

  • The “Bioconcept-Car” moves ahead

In automobile racing, lightweight bodies made from plastic and carbon fibers have been standard for many years because they enable drivers to reach the finish line more quickly. In the future, lightweight-construction solutions could help reduce the energy consumption and emissions of everyday vehicles. The catch is that the production of carbon fibers is not only expensive but also consumes considerable amounts of energy and petroleum. In collaboration with Porsche Motorsport and Four Motors, researchers at the Fraunhofer WKI have succeeded in replacing the carbon fibers in a car door with natural fibers. This is already being installed in small series at Porsche. The project team is now taking the next step: Together with HOBUM Oleochemicals, they want to maximize the proportion of renewable raw materials in the door and other body parts - using bio-based plastics and paints.

  • The “Bioconcept-Car” moves ahead

In automobile racing, lightweight bodies made from plastic and carbon fibers have been standard for many years because they enable drivers to reach the finish line more quickly. In the future, lightweight-construction solutions could help reduce the energy consumption and emissions of everyday vehicles. The catch is that the production of carbon fibers is not only expensive but also consumes considerable amounts of energy and petroleum. In collaboration with Porsche Motorsport and Four Motors, researchers at the Fraunhofer WKI have succeeded in replacing the carbon fibers in a car door with natural fibers. This is already being installed in small series at Porsche. The project team is now taking the next step: Together with HOBUM Oleochemicals, they want to maximize the proportion of renewable raw materials in the door and other body parts - using bio-based plastics and paints.

Carbon fibers reinforce plastics and therefore provide lightweight components with the necessary stability. Mass-produced natural fibers are not only more cost-effective but can also be produced in a considerably more sustainable manner. For the “Bioconcept-Car” pilot vehicle, researchers at the Fraunhofer WKI have developed body parts with 100 percent natural fibers as reinforcing components.

“We utilize natural fibers, such as those made from hemp, flax or jute. Whilst natural fibers exhibit lower stiffnesses and strengths compared to carbon fibers, the values achieved are nonetheless sufficient for many applications,” explained Ole Hansen, Project Manager at the Fraunhofer WKI. Due to their naturally grown structure, natural fibers dampen sound and vibrations more effectively. Their lesser tendency to splinter can help to reduce the risk of injury in the event of an accident. Furthermore, they do not cause skin irritation during processing.

The bio-based composites were successfully tested by the Four Motors racing team in the “Bioconcept-Car” on the racetrack under extreme conditions. Porsche has actually been using natural fiber-reinforced plastics in a small series of the Cayman GT4 Clubsport since 2019. During production, the researchers at the Fraunhofer WKI also conducted an initial ecological assessment based on material and energy data. “We were able to determine that the utilized natural-fiber fabric has a better environmental profile in its production, including the upstream chains, than the fabric made from carbon. Thermal recycling after the end of its service life should also be possible without any problems,” confirmed Ole Hansen.

In the next project phase of the "Bioconcept-Car", the researchers at the Fraunhofer WKI, in collaboration with the cooperation partners HOBUM Oleochemicals GmbH, Porsche Motorsport and Four Motors, will develop a vehicle door with a biogenic content of 85 percent in the overall composite consisting of fibers and resin. They intend to achieve this by, amongst other things, utilizing bio-based resin-hardener blends as well as bio-based paint systems. The practicality of the door - and possibly additional components - will again be tested by Four Motors on the racetrack. If the researchers are successful, it may be possible to transfer the acquired knowledge into series production at Porsche.

The German Federal Ministry of Food and Agriculture (BMEL) is funding the “Bioconcept-Car” project via the project-management agency Fachagentur Nachwachsende Rohstoffe e. V. (FNR).

Background
Sustainability through the utilization of renewable raw materials has formed the focus at the Fraunhofer WKI for more than 70 years. The institute, with locations in Braunschweig, Hanover and Wolfsburg, specializes in process engineering, natural-fiber composites, surface technology, wood and emission protection, quality assurance of wood products, material and product testing, recycling procedures and the utilization of organic building materials and wood in construction. Virtually all the procedures and materials resulting from the research activities are applied industrially.

 

  • EU Project ALMA: Thinking Ahead to Electromobility

E-mobility and lightweight construction are two crucial building blocks of modern vehicle development to drive the energy transition. They are the focus of the ALMA project (Advanced Light Materials and Processes for the Eco-Design of Electric Vehicles). Nine European organizations are now working in the EU project to develop more energy-efficient and sustainable vehicles. Companies from research and industry are optimizing the efficiency and range of electric vehicles, among other things by reducing the weight of the overall vehicle. The Fraunhofer Institute for Industrial Mathematics ITWM is providing support with mathematical simulation expertise.

According to the low emissions mobility strategy, the European Union aims to have at least 30 million zero-emission vehicles on its roads by 2030. Measures to support jobs, growth, investment, and innovation are taken to tackle emissions from the transport sector. To make transport more climate-friendly, EU measures are being taken to promote jobs, investment and innovation. The European Commission's Horizon 2020 project ALMA represents one of these measures.

Photo: Pixabay
16.02.2021

Carbon with Multiple Lives: Bringing Innovations in Carbon Fiber Recycling to Market

When it comes to the future of motorized mobility, everyone talks about the power drive: How much e-car, how much combustion engine can the environment tolerate and how much do people need? At the same time, new powertrains place ineased demands not only on the engine, but also on its housing and the car body: Carbon fibers are often used for such demanding applications. Like the powertrain of the future, the materials on the vehicle should also be environmentally friendly. That is why recycling of carbon fibers is required. Institutes of the Zuse Community have developed solutions for this.

Carbon fibers consist almost completely of pure carbon. It is extracted from the plastic polyacrylonitrile at 1,300 degrees Celsius, using a lot of energy. The advantages of carbon fibers: They have almost no dead weight, are enormously break-resistant and sturdy. These properties are needed, for example, in the battery box of electric vehicles in structural components of a car body.

When it comes to the future of motorized mobility, everyone talks about the power drive: How much e-car, how much combustion engine can the environment tolerate and how much do people need? At the same time, new powertrains place ineased demands not only on the engine, but also on its housing and the car body: Carbon fibers are often used for such demanding applications. Like the powertrain of the future, the materials on the vehicle should also be environmentally friendly. That is why recycling of carbon fibers is required. Institutes of the Zuse Community have developed solutions for this.

Carbon fibers consist almost completely of pure carbon. It is extracted from the plastic polyacrylonitrile at 1,300 degrees Celsius, using a lot of energy. The advantages of carbon fibers: They have almost no dead weight, are enormously break-resistant and sturdy. These properties are needed, for example, in the battery box of electric vehicles in structural components of a car body.

The Saxon Textile Research Institute (STFI), for instance, is currently working with industrial partners on combining the static-mechanical strengths of carbon fibers with vibration damping properties to improve the housings of electric motors in cars. The project, which is funded by the German Federal Ministry for Economic Affairs and Energy, is aimed at developing hybrid nonwovens that contain other fibers, in addition to carbon fiber, as a reinforcement. "We want to combine the advantages of different fiber materials and thereby develop a product that is optimally tailored to the requirements", explains Marcel Hofmann, head of department of Textile Lightweight Construction at STFI.

The Chemnitz researchers would therefore complement previous nonwoven solutions. They look back on 15 years of working with recycled carbon fibers. The global annual demand for the high-value fibers has almost quadrupled in the past decade, according to the AVK Industry Association to around 142,000 t most recently. "Increasing demand has brought recycling more and more into focus", says Hofmann. According to him, carbon fiber waste is available for about one-tenth to one-fifth of the price of primary fibers, but they still need to be processed. The key issue for the research success of recycled fibers is competitive applications. STFI has found these not only in cars, but also in the sports and leisure sector as well as in medical technology, for example in components for computer tomography. "While metals or glass fibers cast shadows as potential competing products, carbon does not interfere with the image display and can fully exploit its advantages", explains Hofmann.
 
Using Paper Know-How
If recycled carbon fibers can pass through the product cycle again, this significantly improves their carbon footprint. At the same time it applies: The shorter the carbon fibers, the less attractive they are for further recycling. With this in mind, the Cetex Research Institute and the Papiertechnische Stiftung (PTS), both members of the Zuse Community, developed a new process as part of a research project that gives recycled carbon fibers, which previously seemed unsuitable, a second product life. "While classic textile processes use dry processing for the already very brittle recycled carbon fibers in fiber lengths of at least 80 mm, we dealt with a process from the paper industry that processes the materials wet. At the end of the process, in very simplified terms, we obtained a laminar mat made of recycled carbon fibers and chemical fibers", says Cetex project engineer Johannes Tietze, explaining the process by which even 40 mm short carbon fibers can be recycled into appealing intermediates.

The resulting product created in a hot pressing process serves as the base material for heavy-duty structural components. In addition, the mechanical properties of the semi-finished products were improved by combining them with continuous fiber-reinforced tapes. The researchers expect the recycled product to compete with glass-fiber-reinforced plastics, for example in applications in rail and vehicle construction. The results are now being incorporated into further research and development in
the cooperation network of Ressourcetex, a funded association with 18 partners from industry and science.

Successful Implementation in the Automotive Industry
Industrial solutions for the recycling of carbon fiber production waste are being developed at the Thuringian Institute of Textile and Plastics Research (TITK). Several of these developments were industrially implemented with partners at the company SGL Composites in Wackersdorf, Germany. The processing of the so-called dry waste, mainly from production, is carried out in a separate procedure. "Here, we add the opened fibers to various processes for nonwoven production", says the responsible head of the department at TITK, Dr. Renate Lützkendorf . In addition to developments for applications e.g. in the BMW i3 in the roof or rear seat shell, special nonwovens and processes for the production of Sheet Molding Compounds (SMC) were established at TITK. These are thermoset materials consisting of reaction resins and reinforcing fibers, which are used to press fiber-plastic composites. This was used, for example, in a component for the C-pillar of the BMW 7 Series. "In its projects, TITK is primarily focusing on the development of more efficient processes and combined procedures to give carbon fiber recycling materials better opportunities in lightweight construction applications, also in terms of costs", says Lützkendorf. The focus is currently on the use of CF recycled fibers in thermoplastic processes for sheet and profile extrusion. "The goal is to combine short- and continuous-fiber reinforcement in a single, high-performance process step."

1) Since February 1st, 2021, Dr.-Ing. Thomas Reussmann succeeds Dr.-Ing. Renate Lützkendorf, who retired 31 January.

Source:

Zuse Community

Photocredits: Hohenstein
01.09.2020

Research Projects of the Zuse Community: Think about Recycling when Designing …

How applied research in cooperation with industry can lead to high-quality recycling solutions is explained by the Zuse community with its "Design for Recycling" series.

How applied research in cooperation with industry can lead to high-quality recycling solutions is explained by the Zuse community with its "Design for Recycling" series.

Artificial Turf of the Future
Textiles are much more than just clothes. The industry is a key customer for both synthetic and natural fibers. However, their textile products are often close to the consumer - this applies, for example, to the leisure industry or sports field construction, as is the case with artificial turf.
     
On sports fields, textiles are, so to speak, trampled underfoot, namely when playing on artificial turf. In Germany alone there are around 5,000 artificial turf pitches registered for football. But under the green stubble hides a heavy burden - for clubs and the environment. According to information from the IAKS Germany trade association, around 5 kg of granulate per square meter of artificial turf is infilled in Germany, and this figure is likely to be considerably higher in other countries. "In the case of artificial turf with a fiber length of 42 mm, only 12 mm look out of the mass of infill materials that have been applied to the surface," Dr. Ulrich Berghaus of Morton Extrusionstechnik GmbH, a leading manufacturer of artificial turf, explains. Nowadays, a new pitch is calculated to contain almost 50 percent of the old pitch - as infill material. But as a microplastic this can cause problems - alternatives have to be found. Together with the Aachen Institute for Floor Systems (TFI), Morton Extrusionstechnik is working on the artificial turf of the future, which can do without problematic infill materials.

The researchers at the TFI are now called upon to ensure that the nubs of the artificial turf will hold well in the carrier material in future, even without polyurethane and latex. "Ideally, artificial turf would be made of just one polymer," TFI project manager Dirk Hanuschik says. Because, similar to food packaging, inseparable material composites are poison for high-quality recycling. Hanuschik and his team are therefore researching with their industrial partner into an artificial turf design that does not require any polyurethane or latex for the backing of the carrier material. In a thermobonding facility, the artificial turf nubs are to be melted directly onto the base material, not glued on. Nevertheless, a durability of around 12-15 years is the goal - as with artificial turf laid today. He can test the new materials on the industrial coating plant, which is on a smaller scale at the TFI. The first production plant is scheduled to go into operation as early as the middle of next year.
     
"The practical project of the TFI is an excellent example of how industrial research from the Zuse community creates concrete benefits for people through sustainable recycling management. Research on 'Design for Recycling' is the focus of many of our institutes. Their close cooperation with companies and their interdisciplinary approach offer the best conditions for further innovations," explains the President of the Zuse Community, Prof. Martin Bastian.


Recycling in the Fashion Industry
Recycling is more than just a trend. In the future, fashion should increasingly include useful recycling: People in Germany buy an average of 26 kg of textiles per capita per year, including 12-15 kg of clothing. Given these large quantities, high-quality recycling is a major challenge. Improved recycling includes a circular economy that thinks about the "life after", i.e. the next or renewed product, already when designing products. A current research project of the Zuse community shows how this can work for clothing.
     
Beverage bottles made of the plastic PET are already ideally suited for recycling, and not only for packaging, because of their purity of type. Under the motto "From the fiber to the fiber", this is what the applied research in the joint project DiTex is using for rental linen. The fibers used come from recycled PET bottles, and the rented linen itself is to be recycled back into linen after its first life cycle.

"Rented linen is also well suited to the 'Design for Recycling' concept because its use can be precisely tracked, which provides optimum conditions for recycling," project manager Dr. Anja Gerhardts from the Hohenstein Research Institute explains. The institute from Baden-Württemberg is responsible for textile testing and product specifications in the project initiated and coordinated by the Institute for Ecological Economic Research (IÖW). For benefit rather than ownership, the partners in the alliance are developing a recyclable line of bed linen, as well as polo and business shirts. The shirts will serve as uniforms for police and rescue services.

Intelligent label stores information
The laundry is equipped with a digital tracking ID throughout the entire usage cycle. This "intelligent" label stores information such as fiber origin, material composition and composition of the textile. This enables recycling companies to sort the products better, increase the recycling share and upgrade them. Numerous washing trials are now being carried out at Hohenstein to test how well the tracking tool is performing and what the tensile strength, degree of whiteness, color quality, durability and wearing comfort of the textiles are when they are washed, spun and dried up to 200 times in commercial textile services. "In DiTex we bring users, procurers and recyclers of textiles to one table to make recyclable product design a reality", Anja Gerhardts explains.

"Practical research on fibers and textiles is one of the core competences of many of our institute, be it for industrial technical products or consumer-oriented products. Projects like DiTex show innovative solutions for design for recycling. Thanks to the interdisciplinary approach in our association, other industries can also learn from such solutions," explains Dr. Annette Treffkorn, managing director of the Zuse community.

Source:

Zuse-Gemeinschaft

The Fraunhofer WKI double-rapier weaving machine with the Jacquard attachment in the upper of the photo.  © Fraunhofer WKI | Melina Ruhr. The Fraunhofer WKI double-rapier weaving machine with the Jacquard attachment in the upper of the photo.
02.06.2020

Fraunhofer WKI: Climate-friendly hybrid-fiber materials on the basis of renewable natural fibers

As a result of the new combination possibilities for bio-based hybrid-fiber materials achieved at the Fraunhofer Institute for Wood Research, Wilhelm-Klauditz-Institut WKI, the industrial application possibilities for renewable raw materials, for example in the automotive industry or for everyday objects such as helmets or skis, can be expanded.

By increasing the proportion of flax fiber in hybrid-fiber materials to up to 50 percent, the scientists have demonstrated that it is possible to significantly increase the biogenic proportion in composite materials. The special aspect of the tested methods: The fabrics can be individually composed with the help of a weaving machine. In this way, process steps in industrial production, in which materials first have to be merged together, can be omitted. This will achieve reductions in energy and CO2 throughout the entire production process.

As a result of the new combination possibilities for bio-based hybrid-fiber materials achieved at the Fraunhofer Institute for Wood Research, Wilhelm-Klauditz-Institut WKI, the industrial application possibilities for renewable raw materials, for example in the automotive industry or for everyday objects such as helmets or skis, can be expanded.

By increasing the proportion of flax fiber in hybrid-fiber materials to up to 50 percent, the scientists have demonstrated that it is possible to significantly increase the biogenic proportion in composite materials. The special aspect of the tested methods: The fabrics can be individually composed with the help of a weaving machine. In this way, process steps in industrial production, in which materials first have to be merged together, can be omitted. This will achieve reductions in energy and CO2 throughout the entire production process.

Successfully woven: Different hybrid fabrics
In view of the increased demands being placed upon environmental and climate protection, science and industry are seeking sustainable alternatives to conventional materials in all branches of production. As a material, natural fibers offer a sustainable solution. Due to their low density and simultaneous high stability, natural fibers can be used to produce highly resilient light-weight-construction materials which are easy to recycle. In the “ProBio” project, scientists from the Fraunhofer WKI have therefore addressed the question as to how the proportion of natural fibers in bio-based hybrid-fiber materials can be increased as significantly as possible. A double-rapier weaving machine with Jacquard attachment was thereby utilized in order to produce the bio-based hybrid-fiber materials.

The researchers thereby focused specifically on bio-based hybrid-fiber composites (Bio-HFC). Bio-HFC consist of a combination of cellulose-based fibers, such as flax fibers, and synthetic high-performance fibers, such as carbon or glass fibers, for reinforcement. Bio-HFC can be utilized in, for example, vehicle construction. As an innovation in the “ProBio” project, the researchers interwove differing fiber-material combinations, reinforcing fibers and matrix fibers with the aid of the double-rapier weaving machine. This procedure differs from the process in which finished fabrics are layered on top of one another.

“We have combined the advantageous properties of the fiber materials within a composite material in such a way that we have been able to compensate for weak points in individual components, thereby achieving new properties in some cases. In addition, we have succeeded in increasing the proportion of bio-based fibers to up to 50 percent flax fibers, which we have combined with 50 percent reinforcing fibers,” says project team member Jana Winkelmann, describing the procedure. The bio-hybrid textiles, each consisting of 50 percent by weight carbon and flax fabric, are introduced into a bio-based plastic matrix. The composite material possesses a flexural strength which is more than twice as high as that of the corresponding composite material made from flax-reinforced epoxy resin. This mechanical performance capability can significantly expand the application range of renewable raw materials for technical applications.

With the weaving machine, the scientists have successfully combined innovative light-weight-construction composite materials with complex application-specific fabric structures and integrated functions. Reinforcing fibers, such as carbon and natural fibers, as well as multilayer fabrics and three-dimensional structures, can be woven together in a single work step. This offers advantages for industrial production, as production steps in which materials first have to be merged together can be omitted. “We have succeeded, for example, in utilizing conductive yarns or wires as sensors or conductor paths directly in the weaving process, thereby producing fabrics with integrated functions. The introduction of synthetic fibers as weft threads enables the production of bio-hybrid composites with isotropic mechanical properties,” explains Ms. Winkelmann.

Weaving technology makes it possible to create new products with a high proportion of bio-based components on a pilot scale. The project results provide an insight into the diverse combination possibilities of natural and reinforcing fibers and demonstrate opportunities for utilization not only in vehicle construction but also for everyday objects such as helmets or skis. The results will be presented within the framework of the 4th International Conference on Natural Fibers, ICNF, July 2019 in Porto, Portugal. The “ProBio” project, which ran from 1st July 2014 to 30th June 2019, was funded by the Lower Saxony Ministry of Science and Culture (MWK).

Background
Sustainability through the utilization of renewable raw materials has formed the focus at the Fraunhofer WKI for more than 70 years. The institute, with locations in Braunschweig, Hanover and Wolfsburg, specializes in process engineering, natural-fiber composites, wood and emission protection, quality assurance of wood products, material and product testing, recycling procedures and the utilization of organic building materials and wood in construction. Virtually all the procedures and materials resulting from the research activities are applied industrially.

Source:

Fraunhofer Institute for Wood Research WKI

INVENTING TECHNOLOGIES NO ONE CAN COPY… I.S.T © I.S.T Corporation
03.03.2020

INVENTING TECHNOLOGIES NO ONE CAN COPY… I.S.T

NEW HIGH-TECH FIBERS AND YARNS FOR THE SPORTS AND LEISURE MARKET 

With its trade fair premiere at this year's ISPO Munich at the end of January, a newcomer in the sportswear and outdoor market has achieved a well-received appearance: For the first time in Europe, the Japanese company I.S.T Corporation presented its new high-tech fiber and a spinning technology with amazing possibilities at their booth with extensive augmented reality technology. In the sports industry, I.S.T is only known to a few, although there have been first cooperations with well-known manufacturers such as Patagonia in the last seasons.

NEW HIGH-TECH FIBERS AND YARNS FOR THE SPORTS AND LEISURE MARKET 

With its trade fair premiere at this year's ISPO Munich at the end of January, a newcomer in the sportswear and outdoor market has achieved a well-received appearance: For the first time in Europe, the Japanese company I.S.T Corporation presented its new high-tech fiber and a spinning technology with amazing possibilities at their booth with extensive augmented reality technology. In the sports industry, I.S.T is only known to a few, although there have been first cooperations with well-known manufacturers such as Patagonia in the last seasons.

The CEO and president, Ms. Toshiko “Toko” Sakane, answered Textination's questions. She has been running the company - founded by her father - since November 2016. After completing her bachelor's degree in sociology / human sciences, she worked in the office of the House of Representatives of the Japanese Parliament and the former Japanese Minister of Health and Social Affairs. Later she was managing director of the I.S.T Corporation in Parlin, New Jersey, USA, founded in 2000 - a manufacturer of unique, high-temperature resistant resin materials.

I.S.T is a Japanese company with a comparatively young history. Originally founded in 1983 as an R&D company, you are now also based in the United States and in China. If you had to introduce yourself in 100 words to someone who doesn't know the company: What makes you unique?
I.S.T Corporation is an R&D-oriented Japanese material company with the claim to "invent technologies that no one can imitate". What makes us uniquely competent is our integrated process of material development, innovating our own in-house production methodologies and advancing production technologies. Through this end-to-end cycle, we can achieve various advantages including developing complete original products, securing best quality assurance, and, most importantly, letting us discover new innovations. I.S.T is committed to keep innovating new technologies so they can contribute to enriching people’s lives more.   

Your slogan is: make the impossible possible. In which markets and from which industries do you feel particularly challenged? And with which product innovations for the textile industry do you think you can move the most?
I.S.T’s focus is sporting goods and apparel industry because materials used in this industry demand a wide variety of functionalities and are likely used in extreme conditions. We find it challenging and exciting to offer our advanced innovations. As for the textile industry, we believe our KARL KARL™ spinning technology offers a new great solution for winter active inner wears because it offers all the functions they want, such as warmness, being light-weighted, and easy-care.

A central guideline of the company is the motto "Inventing technologies no-one can copy". Patent protection and a consistent brand policy characterize your activities in the market. But patents can expire and brands can be copied, what makes you uncopiable?
A patent or brand can be copied. However, what makes it impossible to copy us is that our core technologies are embedded throughout our integrated process of material development, in-house production methodologies and advancing production technologies. For example, our KARL KARL™ technology is spinning technology that offers multiple functionalities in one yarn and also can be applied to all different types of and hybrid yarns.
There are some other companies that claim their yarns having a similar function with ours, but those are single function and in a particular type of yarn. This is the most fundamental and significant difference between technologies and competitors. Other companies may be able to copy a single function from us, but it will never be the same as our products that are the results of layers and layers of our integrated innovations.
          
Initially focused on selling technology, you are now a major fiber producer yourself. In addition, you have expanded your portfolio in the past 15 years - for example in the wool market - through acquisitions in Japan and China. Where do you see I.S.T as a player in the textile sector in 2030?
Just as you see a GORE-TEX tag on any outerwear, I would like to see brand names produced by I.S.T on every sports and fashion apparel and people instantly recognize it as the sign of most advanced functional materials.

For the first time you attended ISPO Munich 2020 in January as an exhibitor to present the high-tech fiber IMIDETEX® and new KARL KARL™ yarns to the sporting goods and outdoor industry. What is so special about these two products and what makes them so suitable for use in these markets?  
IMIDETEX®, made of 100% polyimide resin and commonly used in outer space, has possess various advantageous characteristics that other existing super fibers couldn’t overcome, including it being high UV resistant, heat resistant, low water absorption, and has a high tensile strength.
Examples of possible applications for the outdoor market as in composites, would include highly resistive but also durable golf shafts or tennis rackets that can minimize the impact sent to players, and a bicycle that can absorb the shock from the ground throughout a long and competitive race. As for textile, it makes an incredibly durable sail that endures an unforgiving sun. Finally, as yarns IMIDETEX® makes a light-weighted but super strong ropes that people can trust their lives with. IMIDETEX® can provide great performances in extreme natural conditions.
KARL KARL™ is the patented spinning technology that multiplies one core thread with another thread. By expanding the yarn structure itself, it achieves lightness and warmness, which are two seemingly opposite characters to coexist. This technology can be applied to wool, cotton, silk, polyester, nylon … plus there are endless possibilities of developing new yarns by combining different characteristic yarns.
These materials by I.S.T are unrivaled and present infinite possibilities for richer designs in sports fashion scenes.

In a world in which great value is placed on nature and natural materials, man-made fibers are not always welcome. On your website you postulate, I.S.T contributes to the people around the world through chemistry for a better life style. Which aspects make a good case for that?
Our brand-new product, faux-fur, made with KARL KARL™ technology is a good example of our contribution to keep the good balance of natural and synthetic.
The real fur is fashionable but it’s a symbol of animal abuse nowadays. To conserve the nature, our KARL KARL™ faux-fur offers an alternative to fashion, while preventing polluting the ocean from using micro fibers.    

In which socially relevant subject areas do you see a particularly great need for innovation and action during the next 5 years? What is your assessment that your company will be able to offer solutions for this with its products?
We believe that light-weight is a major key factor for better lives and the planet because it allows to save energies and expand the performances.
As the first step, we are bringing in our light-weight technologies, such as IMIDETEX® composites and KARL KARL™ technology, to sporting gears and apparels to support our active lifestyle before extending those technologies to all other markets that can benefit from them.

There are various definitions for sustainability. Customers expect everything under this term - from climate protection to ecology, from local on-site production to the exclusion of child labor etc. What do you do to bring this term to life for your company and what activities or certifications do you rely on?
I.S.T's taking this subject seriously in any aspects. We aggressively approach to research and develop technologies and materials that can support human lives and planet, as well as bringing in sustainable methods and materials to our operations. For instance, we are developing a yarn making from cellulose taken out of used papers without using any harmful chemicals to humans. Also, we invested in a state-of-the-art low emission production facility to make Polyimide materials.
We are RWS (Responsible Wool Standard) certified yarn spinner as far as wool is concerned and we are using RWS certified wool fiber. As for polyester, we are using GRS (Global Recycled Standard) certified recycled polyester and as for cotton, we are using organic cotton fiber. Moreover, our company values producing materials that last forever and not to produce any wastes and/or one-time use materials.
          
Where do you get your inspiration from to research certain technologies or products? Which orders or inquiries from the textile supply chain play a decisive role?
You may think that our life is already filled with things and there isn’t a thing that we cannot get in this world. And yes, we have everything. Yet there are some functions you wish you had in addition to full of those things.
The original idea of developing KARL KARL™ technology was that we wanted to adapt functions like lightness, warmness, quick-drying and easy-care that synthetic fibers have, into natural fibers such as wool and cotton because, obviously natural fibers are much friendlier to human and the earth than petroleum-based fibers.
We believe in and keep our corporate missions: “Develop and manufacture products no others have tried before” and “Handle high-value added products”. Our inspirations for R&D come from our belief, “bringing a wish into a reality”. We do not get an inspiration from others. Our innovations inspire customers and the market.

Breaking new ground means willingness to make decisions, overcoming fears - and thus courage to fail. Not every project can succeed. In retrospect, which entrepreneurial decision are you particularly happy to have made?
Actually, for us, there is no such thing as failed projects because we never give up until each and every project becomes successful.
By carrying on our original corporate missions of “Develop and manufacture products no others have tried before” and “Confront difficulties” that my father, the founder of I.S.T, established almost forty years ago, I.S.T members including myself have learned the joy of overcoming problems and of feeling the victory.
When I took over the business, I have set my goal to “move forward to the global market to inspire the world with our technologies”.
Most recently, by making the decision to enter the sporting gears and apparel market and receiving very positive responses at the ISPO Munich 2020, I’m very pleased that we have made one step forward toward my goal.

The interview was conducted by Ines Chucholowius, CEO Textination GmbH

The new AddiTex compound comes out of the extruder as a filament for 3D printing. © Fraunhofer UMSICHT
12.11.2019

FRAUNHOFER UMSICHT: COMPOUNDS FOR ADDITIVE MANUFACTURING, GEOTEXTILES AND WEARABLES

Whether biodegradable geotextiles, wearables from thermoplastic elastomers or functional textiles from 3D printers - the scope of plastics developed at the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT is wide.

Insights into these projects were provided from October 16th - 23rd  in Düsseldorf: At the K, scientists presented their work on thermally and electrically conductive, biodegradable, bio-based compounds as well as compounds suitable for additive production.
 
Textile composites from the 3D printer
In the "AddiTex" project, plastics were developed that are applied to textiles in layers using 3D printing and give them functional properties. A special challenge in the development was the permanent adhesion: The printed plastic had to be both a strong bond with the textile and sufficiently flexible to be able to participate in movements and twists.

Whether biodegradable geotextiles, wearables from thermoplastic elastomers or functional textiles from 3D printers - the scope of plastics developed at the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT is wide.

Insights into these projects were provided from October 16th - 23rd  in Düsseldorf: At the K, scientists presented their work on thermally and electrically conductive, biodegradable, bio-based compounds as well as compounds suitable for additive production.
 
Textile composites from the 3D printer
In the "AddiTex" project, plastics were developed that are applied to textiles in layers using 3D printing and give them functional properties. A special challenge in the development was the permanent adhesion: The printed plastic had to be both a strong bond with the textile and sufficiently flexible to be able to participate in movements and twists.

A flexible and flame-retardant compound was developed, which is particularly suitable for use in the field of textile sun and sound insulation, as well as a rigid compound, which is used, among other things, for reinforcing the shape of protective and functional clothing.

Geotextile filter for technical-biological bank protection
Geotextile filters for technical-biological bank protection are the focus of the "Bioshoreline" project. It stands for gradually biodegradable nonwovens, which allow a near-natural bank design of inland waterways with plants. They consist of renewable raw materials and are intended to stabilize the soil in the shore area until the plant roots have grown sufficiently and take over both filter and retention functions. The ageing and biodegradation of the fleeces begin immediately after installation, until the fleeces are gradually completely degraded.

Prototypes of the geotextile filters are currently being tested. Female scientists evaluate the plant mass formed above and below ground with and without geotextile filters as well as the influence of the soil type on plant growth and the biological degradation of the filter.

Wearables made of thermoplastic elastomers
In addition, Fraunhofer UMSICHT is developing novel, electrically conductive and flexible compounds that can be processed into thermoplastic-based bipolar plates. These plastics are highly electrically conductive, flexible, mechanically stable, gas-tight and chemically resistant and - depending on the degree of filling of electrically conductive additives - can be used in many different ways. For example, in electrochemical storage tanks (batteries), in energy converters (fuel cells), in chemical-resistant heat exchangers or as resistance heating elements.

Another possible field of application for these plastics: Wearables. These portable materials can be produced easily and cheaply with the new compounds. It is conceivable, for example, to form garments such as a vest by means of resistance heating elements. The idea behind this is called Power-to-Heat and enables the direct conversion of energy into heat.

FUNDING NOTES

"AddiTex" is funded with a grant from the State of North Rhine-Westphalia using funds from the European Regional Development Fund (ERDF) 2014-2020 "Investments in growth and employment". Project Management Agency: LeitmarktAgentur.NRW – Projektmanagement Jülich.

The "Bioshoreline" project (funding reference: 22000815) is funded by the Federal Ministry of Food and Agriculture (BMEL) on the basis of a resolution of the German Bundestag.

More information:
Fraunhofer-Institute UMSICHT K 2019
Source:

Fraunhofer Institute for Environmental, Safety, and Energy Technology UMSICHT

DIGITALE PROZESSKETTE SICHERT ZUKUNFT DES LEICHTBAUS © Reed Exhibitions Deutschland GmbH
10.09.2019

DIGITAL PROCESS CHAIN SECURES THE FUTURE OF LIGHTWEIGHT CONSTRUCTION

  • At COMPOSITES EUROPE from 10 to 12 September
     
  • Incubator of ideas for multi-material lightweight construction
     
  • „Ultralight in Space“: Market study examines lightweight construction trends in aerospace

Whenever there’s movement, mass and weight quickly become destroyers of energy. From 10 to 12 September, the Lightweight Technologies Forum (LTF) at COMPOSITES EUROPE in Stuttgart will show how lightweight construction contributes to more efficient and better cars, airplanes and machines. The focus at the Forum will be on the commercially viable implementation of cross-material and holistic lightweight construction systems. The way to get there is through the digitalisation of the process chain.

  • At COMPOSITES EUROPE from 10 to 12 September
     
  • Incubator of ideas for multi-material lightweight construction
     
  • „Ultralight in Space“: Market study examines lightweight construction trends in aerospace

Whenever there’s movement, mass and weight quickly become destroyers of energy. From 10 to 12 September, the Lightweight Technologies Forum (LTF) at COMPOSITES EUROPE in Stuttgart will show how lightweight construction contributes to more efficient and better cars, airplanes and machines. The focus at the Forum will be on the commercially viable implementation of cross-material and holistic lightweight construction systems. The way to get there is through the digitalisation of the process chain.

From the idea to the component – that’s the path the Lightweight Technologies Forum aims to illuminate and support. To that end, the forum will gather current lightweight construction projects in Stuttgart, including from automotive engineering, aerospace and mechanical engineering – precisely those industries whose stringent material, safety and reliability demands make them idea generators for many other industries.
The commonality that runs through all the projects: a consistently digital process chain contributes significantly to the implementation of innovations. Another focus area is connecting and joining technology in multi-material lightweight construction.

"The Lightweight Technologies Forum is conceived as a cross-industry and cross-material incubator of ideas, a place where all stakeholders can consider new concepts. For that, we’re bringing successful flagship projects to Stuttgart”, says Olaf Freier, who on behalf of organiser Reed Exhibitions is responsible for the programme of the forum.

The growing significance of digitalisation and bionics
Support in putting together the forum programme comes from Automotive Management Consulting (AMC). The consulting company specialises in lightweight construction strategies, processes and structures in the automotive industry. “Lightweight construction requires comprehensive, systematic thinking”, says Rainer Kurek, the managing director of AMC. “The most important key factor, though, is the digitalisation of the process chain. Only virtual and simulation-driven design work can bring about competitive lightweight construction products, because they’re launched faster and ensure process safety while costing far less in development”, Kurek adds.

„Ultralight in Space“: Market study on lightweight construction trends in the aerospace industry
When it comes to ultra-lightweight construction, space travel has played a pioneering role since its inception, having driven many disciplines to new record performances. In cooperation with the Luxembourg-based aerospace suppliers GRADEL, AMC are currently conducting a market study to examine the latest technological trends. The results will be revealed at the LTF in Stuttgart on 10 September.
"Even though aerospace is a niche business: technical solutions that meet the stringent material demands here lead the way into the future, which in turn impacts other industries. That’s why it’s important to know the customer’s needs as well as the lightweight strategies, processes, structures and material decision-making of this market”, Rainer Kurek says assuredly.

Also underlining how important space travel is for the development of new technologies is Claude Maack, managing director of GRADEL: “All components are exposed to extreme conditions. Right from the launch of the rocket, they have to withstand enormous acceleration forces. In space, material must resist radiation exposure – and for many years. Then there are the high temperature differences from minus 185 to plus 200 degrees Celsius – alternating every couple of hours from one extreme to the other.“

The material question: Composites with biggest growth potential
Metals currently hold the largest market share among lightweight materials – but fibre-reinforced composites are said to have the biggest growth potential. More and more often they get to apply their strengths in lightweight construction. In the exhibition area, the LTF demonstrates how glass-fibre reinforced (GFRP) and carbon-fibre reinforced plastics (CFRP) play to their strengths in hybrid structural components.
On display, among other things, will be an ultra-lightweight seat by Automotive Management Consulting (AMC), Alba tooling & engineering and csi entwicklungstechnik GmbH, which was presented as a feasibility study – based on the lightweight construction innovation xFK in 3D – and virtual prototype at the 2018 LTF.

The innovative ultra-lightweight seat, which only weighs 10 kg, is based on a special winding process for fibre-composite components. The  “xFK in 3D process” uses a resin-impregnated continuous fibre from which components are wound and produced without waste to match the load. Conceivable uses for the concept seat include the so-called hypercars, sports cars and the air taxis of the future. Just a few weeks ago, the prototype was presented to the public and swiftly recognised with the German Innovation Award.

Exhibitors will be presenting additional lightweight construction solutions in the adjacent Lightweight Area. Some examples include structural components, semi-finished goods, technical textiles, adhesives and resins for automotive engineering and aerospace.

Altogether, visitors of the Lightweight Technologies Forum and COMPOSITES EUROPE will meet 300 exhibitors from 30 countries who will come to Stuttgart to showcase the entire process chain of fibre-reinforced plastics – from materials to machines for processing to concrete application examples from automotive engineering, aerospace, mechanical engineering, construction, wind power, and the sports and leisure sector. Besides new products, a special focus of the trade fair will be on advances in process technologies for large-scale series production.  
 

Textildruckerei Mayer: Innovation management in Swabian © Textildruckerei Heinrich Mayer GmbH
03.09.2019

CEO Michael Steidle (Textildruckerei Mayer): Innovation Management in Swabian

  • “Keep it up! is not an option"

The textile printing company Mayer is a family business on the Swabian Alb. As a leader in textile printing, in screen, rouleaux, rotary, sublimation and flock printing and as well as in 3D coating, the enterprise is increasingly applying its leading expertise to the field of technical textiles. An in-house quality management system ensures the traceability of all production processes, an environmental portfolio the efficient use of energy, sustainability and resources. Textination talked to Managing Director Michael Steidle.

  • “Keep it up! is not an option"

The textile printing company Mayer is a family business on the Swabian Alb. As a leader in textile printing, in screen, rouleaux, rotary, sublimation and flock printing and as well as in 3D coating, the enterprise is increasingly applying its leading expertise to the field of technical textiles. An in-house quality management system ensures the traceability of all production processes, an environmental portfolio the efficient use of energy, sustainability and resources. Textination talked to Managing Director Michael Steidle.

Textildruckerei Heinrich Mayer GmbH is a family business that has been active in textile printing and finishing for 45 years. If you had to introduce yourself in 100 words to someone who doesn't know the company, what makes you unique?
Over the past ten years or so, our family-owned company based in rural Baden-Wurttemberg has changed from a classic textile printing company into a system supplier. A central precondition for this is our knowledge of our own strengths. We rely on proven printing solutions. We do not rush into exchanging them with the latest trend. Instead, we examine whether another, innovative application can be found for them. Or whether one it is possible to combine the tried and tested with a new approach. For example, we were able to solve electronic requirements by printing technology. This area is our second focus. I am a Master of electronic engineering and completed my apprenticeship at Bizerba, a worldwide leading specialist in industrial weighing and labeling technologies. My wife brought me to the textile industry.

In which product area do market and customers challenge you in particular? And on which socially relevant areas do you see a particularly great need for innovation in the upcoming 10 years? What is your assessment that textile finishing will be able to offer solutions?
Mobility is an issue that will be of great concern to all of us in the coming years. In this area trump is what brings little weight, can be produced in a resource-saving way and is easy to shape. All these requirements are met by textile carrier materials and composites. However, textiles as a pure material are still not well-known in public and in our target industries. This understanding should be promoted.

Were fashion and clothing yesterday and do hybrid product developments like your ceramic-coated high-tech fabrics represent the future? When would the company name have to be adjusted, and how long will you keep your broad range of products and services?
In any case, it is true that the textile market, especially the clothing sector, is becoming smaller and smaller in Germany, while the market for technical textile solutions is growing. Of course, this also has an impact on our business and our priorities. Textiles are now found in so many products - we would never have dreamed about before!

As far as the company name is concerned, we have discussed it extensively. We decided to keep it because it is still right. The textiles we talk about are mostly a functional material, but they still remain textiles. And the technology with which we manufacture our high-tech coatings continues to be the printing technology ...

"Without innovation no future" - In five years time, you celebrate the company’s 50th anniversary, with which fundamental corporate decisions will you then have secured the future of your customers and employees?
You already mentioned the landmark decision: "Innovation, innovation, innovation." We can secure our future through innovation only. This means that we must constantly question ourselves and be prepared to be widely interested in attending trade fairs and exhibitions and find out what people are looking for.

Innovation manager or tinkering: What does it mean for a medium-sized family business high up on the Swabian Alb having to profile on specialties in the niche? What advantages do you see compared to large companies?
The Swabian Alb is a traditional textile region. In 1980, about 30,000 people worked here in the textile industry. In 2005 it was barely a sixth. There is not much else left to do than to look for profitable niches and to show a clear profile. Perhaps the special thing about it is that we are not alone in this. Basically, all successful textile companies in our region have undergone a similar process.

As a small - and owner-managed - company, we have the shortest and fastest decision-making channels. That makes us more flexible than a big company. A budget is not questioned five times, but it is decided. If we make a trial, we can evaluate it in the evening and react the very next day. If something doesn't work, we don't need a meeting – then that's it.

At the same time, we do not automatically have a budget for research and development. We first have to carve this out elsewhere. And we do so in the knowledge that it can also be for the trash can. Within the framework of this budget, entrepreneurs have the greatest possible freedom.

To break new ground means decisiveness, overcoming fears - and thus the courage to fail. Not every project can succeed. Which entrepreneurial decision are you particularly glad to have made in retrospect? What makes you proud?
That's easy (Michael Steidle laughs)! We have realized a company’s request that has driven us for months, which in the end has also awakened personal ambition. That was the introduction to these technical coatings, the key and door opener for technical textiles in general. In doing so, I revived old resources, almost by chance. Meaning: my knowledge in electronics. That's when I realized that with a textile you can do completely different things. When you see the finished product on sale after two or three years, it makes the whole team proud!

Every man for himself, God for us all: With which sectors in the textile industry and from neighboring sectors do you want to get closer cooperation beyond competitive borders? For which higher-level problems do you consider this to be indispensable?
Actually, it is not so much a matter of competitive boundaries - cooperation with innovative competitors would always be good for the end product, but that is the case in every industry!

For us, cooperation with other companies in the textile chain is important, i.e. the upstream company. Let’s assume that I am looking for a special fabric for my coating, which in turn has to be made from a special yarn. Then I am already dependent on two companies. Fortunately, we have innovative companies right on our doorstep. But sometimes we have to go further to find the right partner. Characteristics such as willingness to take risks, a common entrepreneurial interest and a passion for the final product are enormously important in a successful cooperation.

Together with your customers, universities, specialist institutes and research institutes, porject-related you work on market-ready solutions. Do you think Germany is a good breeding ground for innovative entrepreneurs? What should happen to stay successful in international competition?
The cooperation with the institutes makes perfect sense; after all, it is their task to carry out research for companies that cannot shoulder such assignments on their own. This includes testing facilities as well as applying for funding, which is only possible in cooperation with research institutes. However, they are public institutions and therefore per se have a different objective than a company: We need to bring a promising idea to market as soon as possible so that it generates a return. A research institute does not have this pressure.

And Germany as a location? Germany is a brilliant location! But we have an infrastructure bottleneck: I mean roads and internet connections as well as access to funding or venture capital. That does not exist in Germany in the true sense anyway. Finding investors for an idea is therefore extremely difficult.

Let me give you an example: Over the years, I have received around 14,000 euros in subsidies for a coating innovation. An American entrepreneur had a very similar idea. He was able to raise about $ 35 million within three years through venture capital, crowd funding, and grants. In the end, he did not even know what he should spend the whole money on!

In addition, for us as a company in Germany, the large, open economic area of Europe is important!

You are the first textile printing company to be certified for screen printing as well as for rotary and rouleaux printing according to the GOTS standard. How important do you consider such certification as a unique selling point in the competition?
Such certifications are important because we work with clients in the upper and premium segments. Especially in times in which - undoubtedly justified - ever greater demands are placed on sustainable business and also the external presentation receives a steadily growing attention, we can support our clients this way. We therefore offer different printing methods, all of which are certified. One thing we have to be aware of is, that if we - and all the other members of the textile chain – charge the additional costs, the price mark-up would be so enormous that nobody would accept it anymore.

How do you feel about the willingness to perform of the succeeding generation? And who would you recommend to join the textile industry and to whom would you dissuade from it?
We work a lot with students and interns. Every year we give two students the opportunity to work and research in our company for their master's thesis. With these young talents, we often experience great commitment and the ambition to bring their own project to a meaningful completion. At the same time, it is difficult for us to fill our apprenticeships; the idea of working eight hours daily, five days a week seems daunting.

And who would I recommend to join the textile industry? For decades, we vehemently discouraged our offspring from working in the textile industry, because one said it has no future ... As a true high-tech industry, it is interesting for engineers, process engineers, chemists or electronic engenieers. Very important: for people with visions! If you are looking for the classic textile industry you have to be prepared to work worldwide and you will not be unemployed. Many companies are desperately looking for plant managers or managing directors for their non-European branches.

 

Composites Europe 2019 (c) Photos: Reed Exhibitions/ Oliver Wachenfeld
30.07.2019

COMPOSITES EUROPE 2019: Digital Process Chain makes Fibre Composites Competitive

  • Strong Triple: COMPOSITES EUROPE, International Composites Conference and Lightweight Technologies Forum
  • “Process live” special areas showcase technological progress
  • Co-located event: Foam Expo Europe

The composites industry provides important impetus – for lightweight construction and material innovations in automotive, aviation, mechanical engineering, construction, wind power as well as in the sports and leisure sectors. So in international competition it is solutions with a high degree of automation that are in demand. COMPOSITES EUROPE from 10 to 12 September will present the trends and advances in the production and processing of fibre-reinforced plastics in Stuttgart. The trade fair will be accompanied by the International Composites Conference and the Lightweight Technologies Forum. Also held in parallel at the Messe Stuttgart premises will be Foam Expo Europe.

  • Strong Triple: COMPOSITES EUROPE, International Composites Conference and Lightweight Technologies Forum
  • “Process live” special areas showcase technological progress
  • Co-located event: Foam Expo Europe

The composites industry provides important impetus – for lightweight construction and material innovations in automotive, aviation, mechanical engineering, construction, wind power as well as in the sports and leisure sectors. So in international competition it is solutions with a high degree of automation that are in demand. COMPOSITES EUROPE from 10 to 12 September will present the trends and advances in the production and processing of fibre-reinforced plastics in Stuttgart. The trade fair will be accompanied by the International Composites Conference and the Lightweight Technologies Forum. Also held in parallel at the Messe Stuttgart premises will be Foam Expo Europe.

Trade fair visitors will meet with over 300 exhibitors from 30 nations who will be displaying materials, technical solutions and innovative application examples in Stuttgart. Apart from novel products the trade fair will place special emphasis on innovative process engineering. Visitors will learn about the state of play in serial production and new applications in the composites industry in the exhibition area as well as on numerous special areas, on themed guided tours, at the accompanying International Composites Conference and at the Lightweight Technologies Forum, which is dedicated to the trends in multi-material lightweight construction.

“Process live”: Technologies in Synergy
Perfectly coordinated processing and manufacturing processes will be centre stage at the “Process live” event. On shared exhibition space machinery and equipment manufacturers will exhibit their technologies in concert and – what’s more – in operation so as to show the different individual processes in a real context.  

On display, to name but one exhibit, is VAP®, the Vacuum Assisted Process patented by Airbus, which will be in the limelight in the Trans-Textil and Composyst special area. This process permits the one-step production of large-surface and geometrically complex components without an autoclave, which is why it is particularly suitable for structural components in aviation, wind power, shipbuilding, in rail and road transport, in machinery and device manufacturing as well as in architecture and in the leisure industry.

The “Process live” special area care of cutting specialists GUNNAR from Switzerland specifically targets the DACH region (Germany, Austria, Switzerland) with its small and medium-sized companies. Jointly with laser projection expert LAP and composites engineering expert SCHEURER Swiss, GUNNAR introduces a connected overall process that fuses modern machinery and software with specialists’ manual jobs. The point of departure here is an automated manufacturing process for sorted layer placement in small and medium quantities involving a certain degree of skilled labour.

Fibre composite specialist Hacotech will present CNC-controlled cutting processes and various finishing possibilities in cooperation with Aristo Graphic Systeme and Lavesan. Alongside cutting, production preparation and customised sizing, the production of dimensionally correct templates and the cutting and custom-sizing of composite materials and prepregs will be on show.

Cutting technology is also centre stage in the special area of Rebstock Consulting, Broetje-Automation and Zünd Systemtechnik, which will be taking part in “Process live” with “Automated Sorting and Kitting”.

Composite producer Saertex and chemical company Scott Bader will demonstrate the RTM process for producing and curing a laminate that complies with the highest fire protection requirements in as little as 1 hour.   

5th International Composites Conference (ICC)
Serial production, stable processes, new markets – the International Composites Conference (ICC) is set to inject a fresh breeze for innovations into the market and to this end brings together processors and users of fibre-reinforced plastics from all over Europe. For the first time, this renowned Conference will be held in parallel with COMPOSITES EUROPE. The lecture programme put together by the trade association Composites Germany and the trade fair will also move closer in terms of content.  

One of tomorrow’s cross-cutting themes keeping the entire industry on its toes are multi-material solutions in nearly all industrial applications. In the construction sector the Conference also deals with the rising use of carbon concrete. Process engineering will focus on processing thermoplastic materials for serial production and stable processes for thermoset plastic processing.  

The partner country of the Conference is the United Kingdom. Especially against the backdrop of the current Brexit debate the ICC aims to foster exchange among all European countries. After all, the UK is among the biggest producers of composites components in Europe.

Themed Tours on Digitalisation, Fibre Glass, Thermoplastics, Automotive and Wind Power
Guided tours and hands-on demonstrations in the exhibition halls complement the conference programme. Themed guided tours revolving around composites application, materials and markets guide trade fair visitors and congress delegates right to the stands of selected exhibitors, who will share with visitors their innovations in the fields of digitalisation of composites production, automotive manufacturing, building and construction, fibreglass, new mobility, thermoplastic materials and wind power.  

New ideas on special areas and joint stands
“Material and Production Technology” is the name of the new special area set up under the guidance of the Institute of Plastics Processing (IKV) of the RWTH Aachen University. In cooperation with other institutes such as the Aachen Center for Integrative Lightweight Production (AZL) the IKV will place manufacturing technology centre stage at the trade fair. In particular, the special area will trace the path from scientific development to practical, industrial implementation.

Tomorrow’s automotive experts will also be given a separate forum: under the heading “Formula Student” students and trainees will present to visitors racing cars and bikes they have engineered.

Lightweight Technologies Forum: platform for multi-material lightweight construction
Lightweight construction remains a driver across the board for many developments in the composites sector. The Lightweight Technologies Forum (LTF) held as part of COMPOSITES EUROPE makes it clear how lightweight construction can be achieved in an economical and resource-efficient manner. This Forum views itself as a cross-industry and multi-material think tank where all parties involved can reflect on these new concepts.

To this end, the Forum in Stuttgart pools lightweight construction projects from automotive manufacturing, aviation and aerospace and mechanical engineering, to name but a few industries that serve as a driving force for many sectors with high demands made on materials, security and reliability.  

This year’s keynote speakers include Airbus Innovation Manager Peter Pirklbauer, lightweight construction expert Prof. Jörg Wellnitz (TU Ingolstadt), Dutch racing driver Jeroen Bleekemolen and lightweight construction, aviation and aerospace specialist Claus Georg Bayreuther (AMC). In their talks they will provide an overview of reference projects and novel manufacturing and joining technologies.  

Combining its own exhibition space with a lecture forum, the LTF demonstrates how glass-fibre reinforced plastics (GRP) and carbon fibre reinforced plastics (CFRP) leverage their strengths mixed with other materials in hybrid structural components. Exhibitors at the Forum and in the neighbouring Lightweight Area include “Leichtbau-Zentrum Sachsen” (Lightweight Construction Center Saxony), Chem-Trend, Gößl + Pfaff, Krempel, Mitsui Chemicals Europe, Leichtbau BW, the VDMA, Gustav Gerster, Potters Ballotini (UK), Yuho (Japan), Riba Composites (Italy) and Stamixco (Switzerland) as well as the journals Lightweight Design (Springer Fachmedien) and Automobil Industrie (Vogel Communications Group), to name but a few.

“Ultralight in Space”: market study on lightweight construction trends in the aerospace industry
The aerospace industry has always served as a pioneer for ultra-lightweight construction pushing many disciplines to their limits as a driver of innovation. The latest technical trends are currently under scrutiny via a market study carried out by consultancy Automotive Management Consulting (AMC) in cooperation with the Luxembourg-based aerospace OEM GRADEL. The results will be presented for the first time at the LTF in Stuttgart on 10 September.  

Presentation of the AVK Innovation Prize
Innovative products and applications in fibre-reinforced plastics, manufacturing processes and the latest insights from research and science, will again be recognised by the German trade association AVK – Industrievereinigung Verstärkte Kunststoffe e. V. with its renowned Innovation Prize. The winners will be announced as part of the trade fair on 10 September and the award-winning products and projects will be on display in a special area.

Presentation of the SMB-BMC Design Award
The European Alliance for SMC BMC will announce the winners of the SMC BMC Design Award 2019 – also on 10 September. The contest already held for the second time now, honours and promotes the design excellence of students or young design professionals who use SMC and BMC components (sheet and bulk moulding compounds) in their designs. This year saw sustainable mobility take centre stage as a theme.

COMPOSITES Night
The event to celebrate the midway point of the trade fair: the COMPOSITES Night at the end of the second trade fair day offers visitors and exhibitors additional opportunities for networking. Participants are in for buffets and live music at the Stage Palladium Theater in Stuttgart.

Matchmaking programme makes trade fair visit more efficient
Thanks to the complimentary networking & meeting platform “matchmaking” visitors and exhibitors can already reach out to contacts in the run-up to COMPOSITES EUROPE. Who is at the trade fair? Who has answers to your specific questions? Who can you team up with to turn new ideas into practice? The matchmaking platform allows you to “filter” and make direct appointments with potential cooperation partners by product category, industry, country, or company.

Career & Composites
With its career&composites stand COMPOSITES EUROPE targets students and graduates who can come here to establish contact with potential employers. On the special area the exhibitors present their companies to interested junior employees and attract attention to vacancies and career opportunities via a Job Wall.

Co-located with Foam Expo Europe
COMPOSITES EUROPE will be co-located with Foam Expo Europe for the first time. This trade fair covers the supply chain of technical foam production and presents moulded, rigid and soft foam solutions – from raw materials to equipment and machinery. The parallel exhibition dates generate special synergies for gaining an overview of lightweight construction materials for such shared applications as the automotive, aviation, construction and sports & leisure industries.

Show Preview COMPOSITES EUROPE 2018: Focus on process technologies (c) COMPOSITES EUROPE
09.10.2018

SHOW PREVIEW COMPOSITES EUROPE 2018: FOCUS ON PROCESS TECHNOLOGIES

  • Premiere: “Process live” format
  • Lightweight Technologies Forum to present hybrid lightweight construction
  • Trade fair kick-off event: International Composites Congress (ICC)

In the competition of lightweight construction and design materials, composites are among the winners – automotive engineering, aerospace, wind energy, boatbuilding and construction can no longer do without glass- and carbon-fibre reinforced plastics (GFRP & CFRP). Nevertheless, the greatest impetus right now is coming from the composites industry itself: technological advancements in the process chain. From 6 to 8 November, COMPOSITES EUROPE in Stuttgart will drive home that point.

  • Premiere: “Process live” format
  • Lightweight Technologies Forum to present hybrid lightweight construction
  • Trade fair kick-off event: International Composites Congress (ICC)

In the competition of lightweight construction and design materials, composites are among the winners – automotive engineering, aerospace, wind energy, boatbuilding and construction can no longer do without glass- and carbon-fibre reinforced plastics (GFRP & CFRP). Nevertheless, the greatest impetus right now is coming from the composites industry itself: technological advancements in the process chain. From 6 to 8 November, COMPOSITES EUROPE in Stuttgart will drive home that point.

Trade fair visitors will meet more than 350 exhibitors from 30 countries who in Stuttgart will present state-of-the-art technology and the potential of fibre-reinforced composites – in the exhibition area as well as in numerous event areas, lecture forums and themed tours.

With the new “Process live” format, coordinated processing and manufacturing processes will become the visible focus of this year’s COMPOSITES EUROPE. Mechanical and plant engineering companies will get together in group exhibits to showcase their technologies in live interactions – thus enabling visitors to experience sub-processes presented in a larger context.

Partnerships in the process chain accelerate growth in the industry
Among others, the cutting specialists Gunnar (Switzerland), the composites automation experts Airborne (Netherlands) and the gripping systems providers Schmalz (Germany) will join forces to create a combined production cell in a process-safe depiction of the entire value chain from roller materials to the finished layer structure of a composite component. In this setup, interlocking hardware components are fully connected with each other via software. “Cooperation among processors is getting closer and closer. These partnerships within the process chain are accelerating the growth of the composites industry; that’s what we want to show with the new ‘Process live’ format”, says Olaf Freier, event director of COMPOSITES EUROPE.

Lightweight Technologies Forum: Platform for multi-material lightweight construction
Besides the optimisation of the process chain, industry research today is heavily focused on the use of GFRP and CFRP in multi-material systems. The Lightweight Technologies Forum will once again demonstrate how composites play to their strengths alongside other materials in the material mix for hybrid structural components. A total of 16 exhibitors will present materials, tools and exhibits here – from fillers to bonding agents and presses for laminating different materials to semi-finished hybrid products.

In various presentations, experts will provide an overview of new products in manufacturing and joining technology as well as applications and lightweight engineering references from the automotive, aerospace and construction sectors. Support for the Lightweight Technologies Forum is provided by the German Federal Ministry for Economic Affairs and Energy.

From digitalisation to recycling: Know-how in the supporting programme
A presentation programme, themed tours and special areas complete the COMPOSITES EUROPE lineup. Manufacturing technology, recycling, digitalisation and thermoplastics will be central themes in the programme of the COMPOSITES Forum, which will also feature exhibitors presenting application examples from automotive engineering, aerospace, construction, mechanical engineering, wind energy and shipbuilding.

Themed guided tours, meanwhile, will lead visitors straight to the stands of selected exhibitors ready to explain the latest innovations in fibreglass, thermoplastics, automotive engineering, wind energy and construction.

Special areas and group stands to highlight new ideas
Hosting the special area “Industry meets Science”, the Institute of Plastics Processing (IKV), the leading European research institute for plastics technology based in Aachen, will showcase developments in process technology, design, quality assurance and repair.

The exhibitors at the “Bio-Based Composites Pavilion”, which will again be set up in cooperation with the nova-Institute, will reflect the development of the market for green composites. The focus will be on application options of wood-polymer composites (WPC), natural fibre composites (NFC), bio-based thermoplastics and thermosets for composites, and bio-based plastics.

Moreover, numerous young companies will thrill visitors with fresh ideas: the industry newcomers will present themselves at a group stand funded by the Federal Ministry for Economic Affairs and Energy (BMWi). They will cover a wide range of topics from semi-finished carbon-fibre products to metal foams to production lines for multi-material 3D fibre laminates.

Even the automotive experts of tomorrow will have their own forum at the trade fair: under the banner of “Formula Student”, students and apprentices will show visitors racecars they themselves have designed.

Kick-off event: 4th International Composites Congress (ICC)
The International Composites Congress (ICC) will once again kick off COMPOSITES EUROPE. In a series of presentations starting the day before the trade fair (5 and 6 November), international experts at the event with the headline topic “Composites – On the Path to Becoming a Key Industry?” will speak about and discuss applications, materials, process technologies and market prospects.

More information:
Composites Composites Europe
Source:

Reed Exhibitions Deutschland GmbH

Composites Europe © COMPOSITES EUROPE
05.09.2017

COMPOSITES EUROPE 2017: Lightweight automotive construction propels use of fibre-reinforced plastics

  • Market study “Lightweight Construction as Innovation Factor”: Presentation at COMPOSITES EUROPE
  • 21 September: Focus Day Automotive

No other industry has drawn more public attention to glass- and carbon-fibre reinforced plastics (GFRP/CFRP) than the automotive indus-
try. Next to the aerospace industry, it’s one of the innovation and growth drivers for composites. The great significance of composites for the automotive industry must be credited to the continuing lightweight construction trend. From 19 to 21 September, COMPOSITES EUROPE in Stuttgart will show how the composites industry can support automakers and their suppliers in this area. Programme highlights include the Focus Day Automotive and the Lightweight Technologies Forum.

  • Market study “Lightweight Construction as Innovation Factor”: Presentation at COMPOSITES EUROPE
  • 21 September: Focus Day Automotive

No other industry has drawn more public attention to glass- and carbon-fibre reinforced plastics (GFRP/CFRP) than the automotive indus-
try. Next to the aerospace industry, it’s one of the innovation and growth drivers for composites. The great significance of composites for the automotive industry must be credited to the continuing lightweight construction trend. From 19 to 21 September, COMPOSITES EUROPE in Stuttgart will show how the composites industry can support automakers and their suppliers in this area. Programme highlights include the Focus Day Automotive and the Lightweight Technologies Forum.

Presentation of the study “Lightweight Construction as Innovation Factor”
When it comes to composites in the automotive sector, modern lightweight construction is the No. 1 topic, according to industry expert Rainer Kurek, CEO of AUTOMOTIVE MANAGEMENT CONSULTING GmbH (AMC) from Penzberg near Munich. After all, he says, it comprises all the aspects of lightweight automotive construction – from concept, functions and joining technologies to materials. The training and consulting company specialises in auto-industry strategies, processes and structures; together with COMPOSITES EUROPE organiser Reed Exhibitions, they will, on 21 September, present the study “Lightweight Construction as Innovation Factor” (“Leichtbau als Innovationsfaktor” in the original German), which takes a holistic and detailed look at the issue. “Created in cooperation with Reed Exhibitions, the market study ‘Lightweight Construction as Innovation Factor’ synthesises the German automotive industry’s knowledge from nearly 150 years of experience”, explains Kurek. “Against the backdrop of increasing environmental and climate-protection requirements, a fragile energy supply and the resulting more stringent resource-conservation targets, it serves to sustainably enhance and strengthen Germany’s role as a centre of innovation.” The developer says he used to think in terms of materials first, but “design engineers today approach lightweight construction with an integrative mindset – with other joining and production technologies as well as with new materials. These days, the typical tasks we get from OEMs are almost always based on integrative lightweight construction.”
 
Positive Outlook
With about a third of the GFRP materials produced in Europe being used in the transport sector, innovations and the current development status of composites for the automotive market will be emphasised in the exhibition halls of COMPOSITES EUROPE 2017, as well. The future looks bright, according to Composites Germany’s latest market survey. No fewer than 46 per cent of responding companies expect this segment to grow. Only 15 per cent anticipate a downturn. The automotive industry isn’t just one of the biggest buyers of thermoplastic composites, it’s also a major purchaser of thermoset materials like SMC. Exhibitors such as Saint Gobain Performance Plastics, capricorn COMPOSITE, Lange+Ritter, SGL TECHNOLOGIES GmbH, ARKEMA France, Cevotec and EMS will be onsite to address the automotive industry’s composites requirements.

Theme day for “motorists”: Focus Day Automotive
What’s more, the entire third day of the trade fair – dubbed the Focus Day Automotive – will be dedicated to visitors predominantly interested in composites for the vehicle industry. A free one-hour guided tour at 11 am on 21 September, for example, will give visitors a comprehensive overview. Stops include the stands of industry-leading companies such as Evonik Industries, Huntsman, the Institute of Aircraft Design at the University of Stuttgart, PHP Fibers, Toho Tenax Europe and Vosschemie. Since the number of participants is limited, it would be advisable to register in a timely manner by visiting: www.composites-europe.com/guided-tours.

The subsequent Automotive Business Lunch taking place at the stand of sponsor Hexion (Hall C2, BO6) at 12 pm will provide an excellent networking opportunity. In addition, expert lectures at the COMPOSITES Forum in Hall 6, Stand B76, will cover automotive basics, trends and innovations. Admission is free of charge for trade fair visitors.
 
Hybrid lightweight construction: The best from different material worlds
Hybrid lightweight construction, which combines metallic materials with composites, is another trend in automotive engineering, as Kurek confirms. In his estimation, it’s imperative to intelligently leverage the strengths of each respective material. “We need to think very carefully about how the different materials can be used in line with the required strength.” Composites, for instance, are great at absorbing tensile forces, while metallic materials are better suited for compressive forces.” This is exactly the issue Kurek sees as COMPOSITES EUROPE’s most critical task: “Even with composites, we long ago moved from ‘either-or’ to ‘both’. Metallic materials have a right to exist just as composites do.”
That’s why the Lightweight Technologies Forum at COMPOSITES EUROPE will provide answers to questions revolving around lightweight construction with other materials like aluminium or steel. The combined exhibition and presentation forum featuring exhibitors such as Kunststoffwerk AG Buchs, Linn High Therm, Schütze, OCSiAL Group, Hexcel Composites and ar engineers will serve as the cross-material interface between metal and composite technologies in structural components.

Trade fair opening event: 3rd International Composites Congress (ICC)
Kicking off COMPOSITES EUROPE 2017 on 18 and 19 September 2017 will be the “3rd International Composites Congress (ICC)” hosted by the trade association Composites Germany in Stuttgart. Current trends, new applications and technologies, and a comprehensive overview of market developments in Europe and worldwide will be the centre of attention at the 3rd ICC. This year’s partner country, South Korea, will be represented with several exclusive speakers.

 

Wind energy plant © Timo Klostermeier / pixelio.de
11.10.2016

WIND POWER INDUSTRY AT COMPOSITES EUROPE 2016

Offshore expansion and onshore repowering ensure growth

  • Wind theme day with guided tour November 29th
  • Lectures about material trends

With an investment volume of EUR 14 billion in the offshore sector alone, the European wind power industry has set a new record high in the first half of 2016. This figure and the view on the still open approval procedures in this segment as well as the onshore upcoming generational change from existing to modern facilities (repowering) show that the potential for growth is far from being exploited. Also in America as well as in Asia and the Pacific area a new emerging wind energy sector is also driving demand for fiber composites. The COMPOSITES EUROPE exhibition will be showing in Dusseldorf from November 29th to December 1st 2016 the latest trends and developments.

Theme Day: Wind meets Composites

Offshore expansion and onshore repowering ensure growth

  • Wind theme day with guided tour November 29th
  • Lectures about material trends

With an investment volume of EUR 14 billion in the offshore sector alone, the European wind power industry has set a new record high in the first half of 2016. This figure and the view on the still open approval procedures in this segment as well as the onshore upcoming generational change from existing to modern facilities (repowering) show that the potential for growth is far from being exploited. Also in America as well as in Asia and the Pacific area a new emerging wind energy sector is also driving demand for fiber composites. The COMPOSITES EUROPE exhibition will be showing in Dusseldorf from November 29th to December 1st 2016 the latest trends and developments.

Theme Day: Wind meets Composites

Sector specialists such as Gaugler & Lutz, DD Compound, 3D Core, LAP and Power & Composite Technology will be showing current technologies at the COMPOSITES EUROPE, latest machine tools and manufacturing processes for the wind power industry. A highlight for all wind experts: On November 29th will be the theme day „Wind meets Composites" at the fair. This day will be sponsored by GUNNAR International, Weissenberger, Hexion and SAERTEX. Engineers of aerodynamics, materials science, lightweight construction and production technology will be able to exchange ideas with purchasers, exhibitors and wind energy specialists in the composite sector. The focus will be, among other things, on topics such as the influence of material selection, on design, weight, stability, processing or production processes as well as on certification, standardization and automation in rotor blade construction.
 
Guided theme walks

An optimal overview of exhibitors' offer on the topic wind is given to visitors by the opportunity of taking part at guided tours. Here they will specifically directed to various exhibitors from the wind segment, where they can get within 10 minutes information about their products and innovations. There will be two guided tours on November 29th: tour 1 will take place between 12:00 AM and 01.00 PM and tour 2 in the afternoon between 02:00 and 03:00 PM. Participating exhibitors include Airtech, GUNNAR International, Agilent Technologies, RH Cutting Technology, Granta Design, DD Compound and Armacell Benelux. The lecture is in English. Participation is free, but the number of participants is limited. Between the two round trips the participants have the opportunity to strengthen themselves at the "Wind Lunch" at the booth of Hexion (Hall 8a / booth G31).
Click here to register for the guided tours: www.composites-europe.com/guided-tours

 
Lectures at COMPOSITES Forum

On the afternoon of the wind theme day the COMPOSITES Forum provides an overview of the latest challenges in research, design, quality management, transportation and production of rotor blades. Starting at 3:00 PM Sinoi will discuss "Challenges and approaches in the construction of large onshore blades". Euros will hold a lecture on "Potentials and limits of composites in rotor blade construction" and the Fraunhofer Institute for Wind Energy and Energy System Technology will be presenting "Composite trends for wind turbine blades". Pontis Engineering also has a slot in the lecture program. From 04.00 PM it will be about "Challenges in design and manufacturing of large wind turbine blades". Access to the lecture area is free of charge for visitors. The COMPOSITES Forum is located in Hall 8, Booth B45.

Click here for a complete overview on the topic wind:
https://www.composites-europe.com/windenergie_527.html

About COMPOSITES EUROPE:
350 exhibitors from 30 countries will attend the COMPOSITES EUROPE, European Trade Fair and Forum for Composite Materials, Technology and Applications from November 29th to December 1st in Dusseldorf. The exhibition shows the entire range of fiber-reinforced plastics, from raw materials to manufacturing processes, to lightweight construction innovations in automotive engineering, aviation, boat building, wind power industry and construction. COMPOSITES EUROPE is organized by Reed Exhibitions in cooperation with the European sector association EuCIA and the economic association Composites Germany, a consortium of branch associations and clusters AVK, CCeV, CFK-Valley Stade and VDMA AG Hybrid Light Construction Technologies.

 

The ‘Textile Structures for New Building’ competition for students is being held for the 14th time by Techtextil © Messe Frankfurt Exhibition GmbH
27.09.2016

TECHTEXTIL AND TENSINET INVITE ENTRIES FOR THE 14TH ‘TEXTILE STRUCTURES FOR NEW BUILDING 2017’ COMPETITION FOR STUDENTS

The ‘Textile Structures for New Building’ competition for students is being held for the 14th time by Techtextil, International Trade Fair for Technical Textiles and Nonwovens, and students of civil engineering, product design and related disciplines, as well as young professionals, are invited to enter their ideas for building with textiles or textile-reinforced materials. As in the past, the competition is sponsored by the international TensiNet network with cash prizes worth a total of € 8,000. The closing date for entries is 26 February 2017.

The ‘Textile Structures for New Building’ competition for students is being held for the 14th time by Techtextil, International Trade Fair for Technical Textiles and Nonwovens, and students of civil engineering, product design and related disciplines, as well as young professionals, are invited to enter their ideas for building with textiles or textile-reinforced materials. As in the past, the competition is sponsored by the international TensiNet network with cash prizes worth a total of € 8,000. The closing date for entries is 26 February 2017.

The scientific supervision remains in the hands of Prof Werner Sobek, Director of the Institute for Lightweight Structures and Conceptual Design (ILEK) of the University of Stuttgart. For the first time, the competition is partnered by Architonic, the leading online platform for architecture and design. The award-winning works will be on show for international exhibitors and visitors during the official presentation ceremony and in a special exhibition at Techtextil 2017 from 9 to 12 May 2017. The aim of the competition is to encourage innovative and practical examples of building with textiles or textile-reinforced materials, and to promote the interests of students and young professionals.

Information about the ‘Textile Structures for New Building 2017’ competition for students

Assignment

The competition covers all aspects of building with textiles and entrants are free to choose any subject of relevance to this. An important theme is ‘Suitability for reuse and recycling’. Both supervised and unsupervised projects will be accepted.

Jury

An independent, international jury of experts comprising renowned academics, architects (building with textiles) and engineers will judge the works submitted. The Chairman of the jury is Prof Werner Sobek.

Prizes

The winners will share prize money totalling € 8,000, sponsored by the TensiNet association. Awards will be given in the following categories: macro-architecture, micro-architecture, material innovations, the environment & ecology and composites & hybrid structures.

Further information and registration at techtextil-student.com