From the Sector

With its latest Joint Partner Project titled “Thermoplastic Pressure Vessel Production – Benchmarking of Design-for-Manufacturing Strategies to Optimize Material Efficiency and Cost,” AZL Aachen GmbH invites companies from across the pressure vessel and composite value chains to collaborate on the next step in sustainable high-pressure storage solutions.

Unlocking the Full Potential of Thermoplastic Composites
Thermoplastic composites are widely recognized for their potential to reduce processing times, offer alternative recycling routes, and improve design flexibility. Yet, when traditional thermoset vessel designs are simply transferred to thermoplastic manufacturing, cost and efficiency often fall short of competitiveness. The aim of this project is to rethink vessel design and production holistically – aligning thermoplastic material properties with optimized design- and manufacturing strategies to unlock their full economic and technological potential.

Collaborative Engineering for Scalable Solutions
Conducted as a Joint Partner Project, the initiative brings together companies with shared interests to co-finance and co-shape the project. The AZL Engineering Team will analyse current technologies, develop new design concepts for hydrogen and CNG vessels, and benchmark the resulting configurations in terms of weight, cost, recyclability and production KPIs. The consortium of participating companies will get access to simulation results, concept layouts, and comparative evaluations based on a unified framework.

Experience and Exchange Built In
The JPP format provides a platform not only for technical development, but also for strategic networking. Each partner can contribute input, benefit from consolidated expertise, and gain early access to the results. With more than a decade of experience managing such initiatives, AZL ensures a structured and result-driven collaboration.
The project will start on July 16th, 2025. All participants are invited to engage in an interactive Kick-off Meeting to define key priorities and present their internal perspectives. 

The European Defence Agency (EDA) has selected the REGEN project as one of three groundbreaking initiatives to integrate circularity into the defence sector. Uplift360, a pioneer in advanced material recycling technologies, will play a critical role in this effort, leveraging its specialist expertise in the recycling and regeneration of aramid fibres to advance sustainable material solutions for high-performance defence applications.

Uplift360 is a cleantech innovator specializing in the recycling of advanced materials, including carbon fibre and aramid. With a focus on circular economy solutions, Uplift360 provides technologies that reduce waste, lower emissions, and support a more sustainable future.

Driving Circularity in Defence
As part of the REGEN project, Uplift360 will focus on the recovery and reuse of continuous aramid fibres, a critical component in defence applications. This effort includes overcoming the complex challenge of PFAS coating removal, a significant barrier to scaling up advanced material recycling. By developing innovative technologies to increase the quality and characteristics of recycled spun aramids, Uplift360 aims to directly engage with material users for ongoing product evolution and development.

The REGEN project brings together a powerful consortium, including FECSA and AITEX from Spain, Uplift360 and the Luxembourg Institute of Science and Technology (LIST). This collaboration aims to accelerate the transition to a circular economy within the defence sector by fostering knowledge sharing, technical innovation, and sustainable resource management.
 
Uplift360’s Role in REGEN
•    Advanced Fibre Recovery: Expertise in recycling and regeneration of aramid fibres.
•    PFAS Coatings Removal Technology: Developing solutions to overcome this critical scaling challenge.
•    Direct Industry Collaboration: Engaging with material users to refine and evolve product performance.
•    Circular Economy Leadership: Contributing to the long-term sustainability of defence materials.
•    Techno-economic analysis (TEA): To optimise the process accordingly.
 
Partners’ Roles in REGEN
•    FECSA: Coordinator of the REGEN project, FECSA leads the consortium and communication strategy, contributing its expertise in advanced protective textiles and sustainable innovation for the defence sector.
•    AITEX: As a partner in the REGEN project consortium, AITEX is leading the development of the fabric and characterisation testing. It is also supporting Uplift360 by contributing its expertise in optimising the wet-spinning process.
•    LIST: As a partner in the REGEN project consortium, LIST is responsible for the life cycle assessment (LCA).

Kongsberg Defence & Aerospace AS (KONGSBERG) and HEXCEL Corporation (HEXCEL) have signed a long-term partnership agreement at the Paris Air Show for the supply of HexWeb® engineered honeycombs and HexPly® prepregs for KONGSBERG’s strategic production programs over a five-year period.

HEXCEL is a leading global manufacturer of advanced composite materials and lightweighting solutions for the aerospace sector and offers a broad and evolving product portfolio, including materials designed for Defence and Space, commercial aerospace and industrial applications.

“This partnership agreement is a reflection of HEXCEL and KONGSBERG’s strong relationship over many years and the company’s joint commitment to partnering for the future. The agreement provides a solid base for Kongberg’s production program for several years to come.” says Terje Bråthen, EVP Aerostructures & MRO at Kongsberg.

Thierry Merlot, HEXCEL President, Europe Middle East Africa Asia Pacific, adds “We are delighted that Kongsberg has placed their trust in Hexcel as their advanced composites solutions partner. This partnership agreement secures business on key programs in the defence market for years to come”.

KONGSBERG Defence & Aerospace, a subsidiary of KONGSBERG, is Norway’s premier supplier of defence and aerospace-related systems and solutions. The company’s portfolio comprises products and systems for command and control, information, data handling and surveillance, communications solutions, space technology, missiles and remotely controlled systems. KONGSBERG Defence & Aerospace also has extensive capabilities within advanced composite manufacturing and maintenance, repair and overhaul within the aircraft and helicopter market.

Technically and economically viable lightweight production based on fiber-reinforced plastics and multi-material systems requires an integrated approach. Due to the almost unlimited combination possibilities of different materials and the very complex interactions between materials, component design, manufacturing processes and the machine and system components, an optimal production process requires a direct link between materials science, process engineering and production technology.

As the official center for “Composite-based Lightweight Production” of the RWTH Aachen Campus, AZL Aachen GmbH uses its strong network to provide these capacities and possibilities on an interdisciplinary basis. Within walking distance, researchers and students are working on the latest technologies for the cost-efficient development and production of lightweight components on one of the largest research landscapes in Europe - the RWTH Aachen Campus: Aachen Center for Integrative Lightweight Production of RWTH Aachen University, Fraunhofer Institute for Production Technology IPT, Fraunhofer Institute for Laser Technology ILT, Institute for Automotive Engineering (ika) of RWTH Aachen University, Institute for Plastic Processing in Industry and Craft at RWTH Aachen University, Institute of Structural Mechanics and Lightweight Design (SLA) of RWTH Aachen University, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University, Welding and Joining Institute (isf) of RWTH Aachen University.

Exklusive insights into the latest lightweight technologies

Once a year, the AZL Open Day offers an exclusive and unique insight into the R&D capacities of the institutes in the field of lightweight construction and sustainable mobility. This year, nine AZL partner institutes opened their machine halls and research laboratories on April 9, 2025 to provide interested industrial players with comprehensive insights into their current focus areas along the value chain. Among other things, the institutes presented high-precision laser processes for plastics processing, new joining processes for thermoplastic composites, 5-axis CNC machining with real-time quality management, large-format 3D printing and their own tape lines & tape integration. Design, prototyping and testing of products & solutions such as crash-optimized vehicle structures, thermoplastic pressure vessels, digital twins for structural-mechanical monitoring as well as prototyping and recycling approaches for battery systems were also demonstrated. The range of topics, key activities & infrastructure, seen at the Open Day, enables new technologies to be tested under real production conditions and efficiently brought to market maturity.

“The AZL Open Day is a great opportunity to discover the numerous technology centers, labs, prototyping and testing facilities that are available on the Aachen campus, that makes it unique in its kind. The AZL organization and teams located there are a true catalyst for new projects and development for the Composites industry: they are creating the link between Market analysis & technology scouting, academic research resources and business opportunities with their industrial partners. They are currently working on several topics that are at the forefront of Composites” reports Éric Pierrejean, CEO of the JEC Group. Apart from being there as an interested participant, he also gave the audience an insight into the key topics and trends in the composites industry as seen at this year's JEC World Show.

Efficient use of established infrastructures & know-how

As a one-stop shop for lightweight solutions, AZL offers an interface for successful cooperation between research and industry. In close coordination between scientific developments and specific customer requirements, solutions are developed in a targeted and tailor-made manner: as part of the AZL partnership, consortial projects or individual projects. In addition to the know-how of the institutes, cooperation with the AZL's industrial partner network also enables direct access to the necessary infrastructure of components, materials, tools and machine and system parts, which can be tested, developed or newly constructed in integrated process chains on a large scale.

Thanks to the close networking between science, industry and the AZL team of experts, companies can access an established infrastructure and utilize synergies for their projects.
The date for the next AZL Open Day will be announced in the second half of the year.

Fibre and fabric production technologies – especially in the area of composite reinforcements – have played an as-yet largely unheralded role in the development of the UK’s Formula One industry, but the British Textile Machinery Association (BTMA) aims to change that.

Motorsport Valley
“If there’s one thing the UK does well, it’s Formula One, with seven of the ten F1 teams located within just an hour of each other in the midlands region known as Motorsport Valley,” explains BTMA CEO Jason Kent. “They are all linked to a national network of around 4,500 companies involved in a motorsport and high-performance engineering industry worth around £9 billion annually and employing 40,000 people. This network draws on the services of a significant number of our member companies.”

“With the exception of the engine, virtually every part of a Formula One racing car now starts from a textile, including the bodywork, the tyres and many of the latest fuel systems,” says Richard Kirkbright, project manager at Leeds-based Roaches International. “This has influenced developments in the broader automotive sector, in addition to the aerospace industry.”

Show cars and memorabilia
While best known as the developer of textile testing systems, Roaches has over the years also supplied advanced autoclaves to the UK’s composites industry, including a recent delivery to Northampton-based Memento Exclusives, a specialist in the production of show cars working directly with F1 and its leading teams.

Each major F1 team sponsor is supplied with one or two show cars for use at exhibitions and a wide range of other promotional activities arranged around the racing event calendar. These cars have no engine and their bodies may be made of fewer carbon fibre plies, but they are otherwise identical to the latest cars being raced by the F1 teams.

Memento Exclusives has its own in-house carbon fibre parts manufacturing facility and the integration of the Roaches autoclave has significantly expanded its capabilities in show car production.

Master bakers
“Composite materials undergo a metamorphosis in the autoclave which subjects them to both mechanical and chemical processes,” explains Richard Kirkbright. “Trapped air and volatiles are expelled and plies are consolidated under precise pressure. Heat cycles are then introduced, curing the resin systems and yielding flawlessly crafted components. Autoclave specialists are a little like master bakers, knowing exactly how to treat their ingredients at every stage of the process, to achieve the desired final product.”

“The Roaches autoclave now enables us to cure large components with full control and achieve a swift turnover of parts while ensuring the highest quality finish,” adds Terry Wasyliw, Head of Build for Memento Exclusives.

McLaren’s influence
Woking, UK-headquartered McLaren was the very first F1 team to introduce a car chassis manufactured entirely from carbon fibre composites back in 1981, setting the ball rolling for the creation of a completely new and global supply chain.

McLaren has this year unveiled a world-first in supercar engineering – aerospace-derived Automated Rapid Tape (ART) carbon fibre, developed at the dedicated McLaren Composites Technology Centre (MCTC) facility in Sheffield. This is being employed to create the active front wings of the W1 hypercar which has a starting price of $2.1 million.

A rear floor component was also developed for McLaren as part of the recently-completed £39.6 million ASCEND programme involving a range of UK partners, including BTMA member Cygnet Texkimp.

Handling, converting and decarbonisation
A wide range of handling and converting machines are supplied to the composites industry by Cygnet Texkimp, including bespoke creels, prepreg, coating, slitting and filament winding machines.

Its technologies are employed in the construction of composite components for aerospace and automotive, as well as in the production of tyre cord and more recently in the advanced construction of hydrogen storage vessels which are largely viewed as the future of F1 propulsion, along with advanced batteries for electric vehicles.

Cygnet Texkimp has been involved in the F1 supply chain for over 20 years and most carbon fibre used in the industry has been processed on one of its VHD creels. The company is also the largest independent manufacturer of prepreg machines in the world and is currently leading the design and build of the UK’s first carbon fibre research lines for a project led by NCC (National Composites Centre) to accelerate the development of more sustainable carbon fibres.

In addition, Cygnet is licensed to design and build the DEECOM® composite recycling system developed by new BTMA member Longworth Sustainable Recycling Technologies, the first of which was recently commissioned by the Henry Royce Institute in Manchester. DEECOM® is a zero emission, low carbon pressolysis solution using pressure and steam to reclaim pristine condition fibres and resin polymers frocm production waste and end of life composites.

“Decarbonisation is a major priority for manufacturers globally,” says Cygnet CEO Luke Vardy. “At Cygnet Texkimp, we’re developing the capability to process technical fibres in ways that enable lightweighting, hydrogen power and electrification, reduce waste and revolutionise the end-of-life management of composite materials and parts. In collaboration with our industry partners, we’re bringing to market some of the most innovative new fibre processing technologies ever developed to deliver real-world benefits that support the sustainability agenda.”

Prepregging
Another new BTMA member, Emerson & Renwick (E+R), a specialist in print, forming, vacuum and coating technologies, also supplies technology for the production of carbon fibre prepregs, which are integrated rolls of fabrics and resins.

Its most recent 1.7-metre-wide line supplied to a customer in Italy operates at speeds of 40+ metres per minute for web coatings or prepreg fibre and resin consolidation, or a combination of both processes. It is distinguished by an ultra precise three-roll reverse roll coater for the processing of high viscosity thermo-activated resins and enables the automatic changeover of sensitive woven fabric materials at zero tension, with three high precision calendaring nips with hot/cool plates. Multiple unwind and rewind systems for intermediate lamination steps include side loading and reliable lap splicing and zero speed splicing with a web accumulator for the main product rewind.
 
 E+R has also been part of a consortium working on the development of lithium-sulphur (Li-S) batteries within the £540 million UK Faraday Battery Challenge. Once commercially viable, Li-S batteries promise to provide relatively high energy density at low cost for sustainable electric vehicles of the future – inevitably starting with F1.

Strong links
“In addition to our powerful base of textile testing and control companies, many other BTMA members are working on further F1 and advanced composite projects,” says Jason Kent in conclusion. “We are also forging strong links with the UK’s key research hubs such as Sheffield University’s Advanced Manufacturing Research Centre, the Northwest Composites Centre in Manchester, the National Centre for Motorsport Engineering in Bolton and the National Composites Centre in Bristol.

“The BTMA recently became an associate member of Composites UK too, because this sector is the crucible of innovation for tomorrow’s textiles.”

Beaulieu Fibres International is exhibiting its next-generation sustainable fibre solutions for high performance nonwovens in various industries at IDEA25 in Miami Beach end of April.

“IDEA25 is at the intersection of nonwoven materials and sustainability, with a focus on innovation and research to address environmental challenges and new opportunities. With our Sustainable Fibres Program, we offer low carbon, recyclable and circular solutions where performance and sustainability go hand in hand, bringing value in co-design and TCO performance,” said Maria Teresa Tomaselli, General Manager, Beaulieu Fibres International.

Self-reinforced PP fibres for fully recyclable automotive composites
The company will be presenting its comprehensive range of polypropylene (PP) bonding fibres designed for thermoplastic lightweight composites and automotive interior fabrics. These fibres assist car manufacturers and OEMs in meeting stringent performance, cost-efficiency, and sustainability standards. Beaulieu’s PP fibres are engineered to enhance the mechanical, thermal, and functional properties of composites while reducing vehicle weight.

Fibres for high performance liquid and air filtration
Beaulieu has set new performance standards for the fast-growing air and liquid filtration industry rolling out its full range of MONO and BICO fine-medium count fibres, as an outcome of its investment into R&D efforts to promote staple fibres in the field of high efficiency filtration.

In addition to its existing portfolio of PP fibres for liquid filtration, compliant with FDA and European food contact regulations, Beaulieu is launching a new bicomponent fibre range in PET/PE, PP/PE for high loft filtration media and fine count mono PP fibres for tribo-electric charged air filter media.

The fine count mono fibres are customized according to the line specifics of the nonwoven producer and guarantee up to 20% higher filtration efficiencies for nonwovens in combination with state-of-the-art acrylic counter fibre compared to standard PP fibres used in this application. Typical applications are air handling units in larger buildings and residential furnaces.

Premium outdoor PP fibres for resilient, weather-resistant crop protection solutions
Engineered for superior mechanical strength and resistance to environmental stress factors, these fibres enhance durability in needle-punched fabrics, ensuring long-lasting protection in the field. Their advanced UV stabilization prevents degradation from prolonged sun exposure, extending the lifespan of crop covers, while their hydrophobic properties repel water, reducing moisture-related damage and maintaining breathability.

Ultrabond, design for recycling
Discover UltraBond innovative bonding staple fibres that replace the need for chemical binders. They open a path to create 100% polypropylene (PP) needlepunched fabrics which meet the same performance requirements as traditional constructions, while reducing end-of-life environmental impact.

The 100% polyolefin-based needlepunched fabrics are fully recyclable, reducing waste generation and creating high value PP recycled products as new materials. Furthermore, the sustainable fabrics are produced with an improved Total Cost of Ownership and with a significant ecological footprint reduction.

Beaulieu strengthening its position in the hygiene market
With a full portfolio already serving the hygiene sector, Beaulieu is focusing on next-generation speciality bicomponent solutions designed to enhance softness, processability, and sustainability in absorbent hygiene products.

Hypersoft fibres are specifically engineered for topsheet applications in direct contact with the skin: 25% improvement in softness compared to standard reference fibres while maintaining optimal processability has been achieved.

Meralux is a bicomponent trilobal fibre that improves nonwoven materials by providing better opacity, comfort, and absorption. It also promotes sustainability by saving raw materials and reducing carbon emissions by up to 60%.

Freudenberg Performance Materials (Freudenberg) will be showcasing its high-performance textile and nonwoven solutions for the composites industry at JEC World, the leading international composites show, in Paris, France. These include Enka®Solutions flow media and spacers for composites manufacturing and surfacing veils.

Composite manufacturers will have the opportunity to discuss solutions for optimizing resin infusion and foam injection molding processes with the experts, focusing on Enka®’s unique 3D polymeric filament structures used in Enka®Solutions flow media and spacers. With this technology, manufacturers benefit from a marked improvement in both quality and efficiency, ensuring their products meet the highest standards.

In vacuum-assisted resin transfer molding (VARTM) and resin transfer molding (RTM) processes, composites manufactured using Enka®Solutions flow media have a superior bond and enhanced mechanical properties, which significantly decreases the risk of wrinkling and defects in the final products. Enka®Solutions flow media ensure rapid and reliable resin distribution. This guarantees full wet-out of the internal structure whilst keeping glass fiber reinforcement nettings and component surfaces precisely in place.

Freudenberg will also be presenting Enka®Solutions spacers, which contribute to faster production cycles and reproducible high-quality finished products.

Nonwoven surfacing veils for anti-corrosive coatings in piping and tank construction, UV-resistant facade panels, and other FRP end products.

Freudenberg’s surfacing veils are an essential part of FRP components and provide abrasion resistance, corrosion protection, smooth surfaces, and enhanced mechanical strength. As one of the world’s leading nonwoven manufacturers, Freudenberg’ portfolio of technologies is well suited to meeting the different needs of FRP part manufacturers. At JEC, the company’s experts will highlight the wide variety of technical capabilities for combining glass, PAN, and PET, in the shape of fibers or filaments, using their unique nonwoven expertise in wetlaid, drylaid, and spunbond processes.

Bcomp, a company in high-performance, natural fibre composites for the mobility-, recreational-, and mass transportation sectors, has been awarded the 2024 Altair Enlighten Award with BMW M GmbH, a renowned performance car subsidiary of BMW Group, for the BMW M Visionary Materials Seat, alongside other BMW M GmbH partners in the project. Manufactured with Bcomp’s ampliTex™ bio-based materials, the seat won in the Sustainable Process category.

The award-winning seat design re-envisions the manufacture and component materials to introduce a lighter, circular product that meets the demands of large-scale vehicle production. The seatback features a fully bio-based, high-performance natural fibre layup with ampliTex™-PP composite. By combining the structural and aesthetically pleasing visual properties of the material in one manufacturing step, production is both more efficient and dematerialised.

The accent has been on Design for Circularity, meaning that in addition to using natural and recycled materials, the BMW M Visionary Materials Seat’s recyclability has been taken into account right from the start of development. Less complex assemblies and monomaterials that can be separated by type enable the recyclability of the seat at the end of its life. Flax fibre composites are CO₂e-neutral from cradle to gate, and can reduce manufacturing-related emissions of high-performance composite parts by up to 85% compared to carbon fibre, depending on the application. Compared to current large-scale automotive plastic parts, Bcomp’s material solutions can reduce component weights by up to 50%, thanks to their low density and high stiffness.

The seat is a development project designed and engineered by long-time collaborators, BMW M GmbH and Bcomp, along with BMW Designworks, Automotive Management Consulting GmbH, Gradel Lightweight Sàrl and Lasso Ingenieurgesellschaft mbH. BMW M GmbH and Bcomp have already delivered innovations in previous development projects for high-end road cars and series application for race cars, such as interior and bodywork components for the BMW M4 GT4, bodywork for the BMW M4 DTM, and cooling shafts for the BMW iFE.20 in Formula E.

The annual Enlighten Awards are sponsored by Altair, a global leader in computational science and intelligence. They celebrate lightweighting innovations that reduce emissions, materials and energy consumption, while advancing material reuse and recyclability. The winning technologies are of significant interest to automotive engineers, manufacturers, policymakers and consumers.

AZL Aachen GmbH announces the launch of a new Joint Partner Project focusing on the further growth potential and technology developments for composite propellers in the field of air mobility and for composite rotors for small to medium-sized wind energy systems.

The nine-month consortial industry project will investigate current and future composite applications for propellers and rotors and their requirements, provide technological insights and develop new product concepts and evaluate them in terms of economic efficiency.

The project aims to address the growing demand for efficient, powerful and compact composite propellers and rotors for the growing markets of air mobility and decentralised power generation. Although the application, manufacturing and material technologies for propellers and rotors made of composite materials have proven to be technically mature, they have so far mainly been used in the high-performance sector for large propeller aircrafts and large wind turbines. Due to the increasing interest in efficient electric propulsion system in the field of air mobility, e.g. air taxis or parcel delivery drones, as well as for decentralised energy generation with the help of small/medium-sized wind energy systems, a rising demand for these components and their production volumes are expected.

AZL will bring together experts along the entire value chain in the project to analyse current and future product concepts. During the project, the participating companies will gain a comprehensive understanding of composite propeller and rotor technology. The project team will carry out a detailed screening of current and future technologies, investigate different materials and processes for the production of propellers and rotors and elaborate design options as well as analyse and evaluate them in terms of technological and cost-effective criteria.

Interested companies can join the project consortium until the Kick-Off on September 18th, 2024.

With the MAX GLASS ECO, the KARL MAYER Technical Textiles Business Unit offers a production machine for the economical manufacture of standard reinforcement textiles made from glass fibers, in particular non-crimp fabrics for the wind power industry. The newcomer can be adapted to the requirements of different application areas thanks to various optional functions and combines short amortization times. At a maximum speed of 1,800 min-1, it produces up to 410 m/h at a working width of 101". This performance is very well received on the composite market. Since the launch of the MAX GLASS ECO at JEC World in March this year, several purchase agreements have already been signed.

Some machines are going to India, and a larger number has been ordered by Chinese customers. Even the demonstration models in the KARL MAYER GROUP customer centers in Changzhou and Chemnitz have already been sold. However, the MAX GLASS ECO at KARL MAYER Technische Textilien in Saxony can still be used for processing trials and performance tests until September.

There is also great interest in Eastern Europe. At Techtextil 2024 in Frankfurt, for example, the new composite machine was a topic of numerous meetings with Ralf Schramm, Sales Manager at KARL MAYER Technische Textilien for this region. "I held many orientation discussions about the machine's performance. But there were also customers with specific purchase requests, including the Polish manufacturer of high-quality, professional solutions for the composites industry, Rymatex," says the sales professional.