From the Sector

Adaptable insulation elements can ensure that the heat transfer through the building envelope can be adjusted as required. This saves heating or cooling energy and therefore costs. Intelligent systems can regulate heat transfer according to the outside temperature and the need for heating or cooling in the interior. In the ReVaD project, the German Institutes of Textile and Fiber Research Denkendorf (DITF) and their partners are developing adaptive building envelopes that can also use concrete components as structural thermal energy storage units for temperature control in buildings.

The research project is developing adaptable insulation elements based on the Knudsen effect. The Knudsen effect describes the change in the thermal conductivity of porous structures with the prevailing gas pressure in the pore space. If there is a vacuum in the pore space, the thermal conductivity is low; if the pressure increases, the thermal conductivity also increases. In order to use the principle in an adjustable insulation element, the highest possible switching factor between the two states is required. To achieve this, the pore system and gas pressure range must be optimally matched. In the adaptable insulation panel, the pore system consists of a spacer fabric that is being developed at the DITF. A key challenge here is the compressive strength of the filling core, which must only allow minimal deformation at a surface pressure of 10 N/cm2 imprinted by a fine vacuum.

The research team at the Technology Center Knitting Technique at DITF has developed the corresponding pressure-resistant structures. Their pore size will be optimized in the next steps by inserting textured yarns into the pole thread space. The basic thermal conductivity of the structure should be increased as little as possible. With the knitted structures in the panel, a switching factor, i.e. the ratio of maximum to minimum thermal conductivity achieved, of 5 has already been demonstrated. Current work involves optimizing the spacer structures and setting up a demonstrator.

In the joint project, the Institute of Technical Thermodynamics at the German Aerospace Center (DLR) in Stuttgart is developing a thermochemical reactor component that enables precise and energy-efficient gas pressure adjustment in the vacuum insulation panel. Metal hydride-hydrogen reaction systems are used, which allow the gas pressure in the insulation panel to be set through temperature control.

The Institute for Building Energetics, Thermal Engineering and Energy Storage (IGTE) at the University of Stuttgart is investigating the integration possibilities of the panels in the wall composite using simulations and experiments. The thermal-energetic simulations make it possible to assess the energy-saving potential of the technology in different scenarios and under different boundary conditions. A demonstrator is used to test the adaptable thermal insulation in an application-oriented manner.

The ReVaD project (development of adaptable vacuum insulation elements for the needs-based adaptation of heat transfer in building envelopes and structures as well as the thermal activation of storage masses) is funded by the Federal Ministry of Economics and Energy as part of joint industrial research (IGF) (FKZ: 22617 N).

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.”

One of the automotive industry’s first hydrogen-powered spray booths has been installed by AkzoNobel at a new training center in Belgium.

Located near Brussels, the facility is part of a multi-million euro program to expand and upgrade the company’s network of more than 40 Automotive Training Centers (ATCs), which are located across the globe.  

Designed to go beyond local and legislative requirements, the new spray booth highlights how embracing the latest technologies can contribute to more sustainable operations. The site itself – which is 30% larger than the one it’s replacing – has been constructed to be BREEAM certified, further demonstrating AkzoNobel’s commitment to reducing carbon emissions across the full value chain by 2030.

“The industry of the future requires painters of the future who are fully conversant with the latest technologies and techniques,” says Patrick Bourguignon, Director of the company’s Automotive and Specialty Coatings business. “By increasing the size of our Belgian facility by almost a third, we can accommodate more technology – such as the new spray booth – and train more people.

The hydrogen-powered combi spray booth is fully equipped for traditional repairs and includes an all-in-one repairs workstation. It also has a special air filtration system which uses “active carbon” to filter any volatile organic compounds (VOCs) generated during the painting process. An extra high efficiency particulate air filter (HEPA) produces clean air (up to 99%), which is filtered back out into the atmosphere.

“By further upskilling painters, bodyshop managers and OEM engineers on a new generation of coatings and technologies, we can help them improve operational efficiency and reduce their own carbon emissions,” adds Bourguignon. “The investments we’re making in our ATCs will therefore address a growing global skills shortage, while also helping us set a new benchmark for sustainable practices in our industry.”

The company’s ATCs are part of a broader global network of training facilities that AkzoNobel operates across its businesses. They support customers and partners across key industries including aerospace coatings, decorative paints and yacht coatings.

Stratasys Ltd. is announcing updates to several Industrial and Healthcare Business Unit products and Stratasys Direct. These include a new open platform for the F900™ 3D printer, more on-demand 3D printing capabilities and a new high-performance material for its Fused Deposition Modeling line.

OpenAM comes to the F900
Stratasys OpenAM™ is a software application that enables the user to modify machine controls to achieve results beyond standard print settings. Already available for the Fortus 450®mc printer, Stratasys is now making its OpenAM software available for the F900 printer. This will allow for expanded functionality and capabilities and will unlock new materials for F900 users.

New VICTREX AM 200 material for FDM
A new material offering that opens the application potential for demanding industries like aerospace and medical, where material properties are critical components of a 3D-printed solutions. This new high-performance, high-strength, validated material, VICTREX AM™ 200, will be available for the Fortus 450mc and the F900. VICTREX AM 200 is a PEEK-based polymer that is temperature, corrosion, and chemical resistant, with excellent mechanical properties which can be utilized with soluble and breakaway support material.

Carbon Fiber Visual Print Option for the F-Series
Carbon Fiber Visual Print Option is a new 5-slice (0.005”) layer height across the F-123 Series™ line of printers that is coming later this month for FDM®ABS-CF10. It produces a smoother surface finish, to provide the perfect finish when a part’s visual appearance is important to the application. It is built for applications that demand the durability of a carbon-filled polymer, but also requires a visually appealing result without additional post-processing.

F770 adds New Colors
The F770® printer can now print in multiple colors, in addition to its original single ivory color. Six new ASA colors, including red, white, light gray, black, blue, and yellow, will allow for more application versatility with FDM® ASA and ABS-M30 tried-and-true engineering plastics. The new colors enable printing without painting or other post-production marking, allowing parts to be available much faster, increasing productivity.

Somos NeXt Validated for SLA
Somos® NeXt™ is now a validated material for Stratasys NEO® stereolithography 3D printers. Somos NeXt is a resin with superior strength and can be used in automotive and consumer products, along with other applications, including prototyping, to produce durable, accurate and detailed parts.

New GrabCAD Software Print Integration Enhances On-Demand 3D Printing Capabilities
Stratasys has introduced Parts on Demand by GrabCAD, a new integration that synchronizes the company's software platform with Stratasys Direct. This addition allows GrabCAD Print™ customers to access Stratasys Direct’s fleet of 3D printers, allowing for larger and more intricate designs, a selection of more than 50 engineered materials, and the assurance of stringent quality inspections.

Felix Pohlkemper and Tim Röding from Institut für Textiltechnik (ITA) of RWTH Aachen University are developing a technology with their start-up CarboScreen GmbH that makes complex carbon fibre production controllable through sensor monitoring. With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 m/min to 30 m/min in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year and production plant. Felix Pohlkemper and Tim Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for this ground-breaking development. The award ceremony took place during the JEC Roof Forum in Salzburg, Austria.

The production of carbon fibres is highly complex. In the current state of the art, however, the manufacturing process is only monitored manually by semi-skilled workers. However, even minimal fibre damage during production leads to a reduction in the quality of the carbon fibre. In extreme cases, it can also lead to plant fires. To ensure production quality, the production speed is currently limited to a maximum of 15 m/min. In fact, the production speed of the systems could be higher. The sensor-based online monitoring of Carbo-Screen makes it possible to increase the production speed to 30 m/min in the medium term. As a result of the increased production volume per system, the specific production costs of the carbon fibre are reduced, which can result in lower prices.

A reduced sales price would make it possible to use carbon fibres and their composite materials even more widely in traditional markets such as aerospace technology and wind energy, as well as for mass production in the automotive industry.

The CarboScreen online monitoring system is currently being developed for industrial use. It is to be validated at an industrial plant in 2024. CarboScreen GmbH was founded as part of EXIST funding and offers AI-supported sensor systems for carbon fibre production. The sensor technology continuously monitors the fibre throughout the entire production process. Deviations are detected automatically.

The winners of the AVK Innovation Award are honoured annually by the AVK Industrievereinigung Verstärkte Kunststoffe. Companies, institutes and their partners are honoured in three categories: products and applications, processes and procedures, and research and science.

• Positive business development in all four business units
• Sales increases by 14.8% to €853.9 million
• Adjusted EBITDA improves by 25.4% to €136.1 million
• Successful refinancing of the 2018 convertible bonds

After €270.9 million in Q1 2022 and €278.9 million in Q2, SGL Carbon increased its consolidated sales to €304.1 million in Q3 2022. After nine months, this corresponds to a significant sales growth of 14.8% to a total of €853.9 million (9M 2021: €743.5 million). The positive business development is also reflected in the company's adjusted EBITDA, which improved by 25.4% year-on-year to €136.1 million (9M 2021: €108.5 million). All four business units contributed to the operating success.

Outlook
Due to the positive business development, the management increased the forecast for the full year on 6 September 2022. For the financial year 2022, Group sales of approx. €1.2 billion (previously: approx. €1.1 billion) and adjusted EBITDA of €170 to 190 million (previously: €130 to 150 million) are expected.

Consequently, an adjusted EBIT of €110 to 130 million (previously: €70 to 90 million) is forecasted. The expectations for return on capital employed (ROCE) of originally 7% to 9% are raised to 10% to 12% in line with the development of earnings. The estimate for free cash flow (significantly below the previous year's level of €111.5 million) remains unchanged.

Monforts will highlight its technologies for special technical textile applications at this year’s ITMA ASIA + CITME which takes place at the National Exhibition and Convention Center in Shanghai, China, from November 20-24.

One of Monforts' developments is the Montex 8500 XXL stenter system for the production of technical fabrics in widths of up to 6.8 metres. Among the products made on this system are treated nonwovens for the geotextiles and filter media markets, tarpaulins, advertising banners, black-out curtains, membranes and many more.

On Montex©Coat coating lines, meanwhile, the possibilities range from the single-sided application of finishing agents for outdoor clothing and adding functionality to home textiles, to the creation of materials for sophisticated lightweight construction and automotive and aerospace components.

“Many more applications are possible, such as the overdyeing of denim, the creation of double-face coated materials, fabrics awnings, tents and medical drapes and the pre-treatment of substrates for digital printing”, explains Gunnar Meyer, Monforts area sales manager for China. “A range of different doctor blades and their combinations can be supplied to meet individual requirements, including air knife, roller knife, foam, screen and magnetic roller coating. The latter option is recommended for lines with working widths of over 2.4 metres.”

In addition, Monforts can provide the necessary explosion-proof ranges for solvent-based coatings and high temperature processes up to 320°C, such as the PTFE coating of nonwoven filter material. These lines are equipped with special burners, stenter chains, and insulation.

• Hexcel Composite Innovations for Aerospace Applications on Display at JEC World 2022: Hall 5, Stand J41

In late 2021, Hexcel announced an agreement with Fairmat, a deep technology startup, to build the capability to recycle carbon fiber prepreg from Hexcel European operations for reuse in composite panels sold into commercial markets, giving a second life to recovered carbon fiber. To do so, Fairmat has developed a virtuous recycling process, and a sample of its newly recycled material will be available to view at JEC World 2022. Hexcel will present an array of product innovations for aerospace and urban air mobility customer applications during JEC World 2022 in Paris on May3-5. These latest innovations demonstrate the company’s leadership in developing advanced composites technology for the aerospace market.

• Sustainability Focus on Recycling and Reuse
• HiTape® and HiMax® Reinforcements for OoA Processing
• Innovative HiFlow™ Resins for Continuous and Shorter Cycle Injection Processes
• HexPly® Prepregs for Primary Structure and Engine Applications
• HexTow® High Modulus Fibers HM63 and HM54
• Thermoplastics and Processing Innovations for Primary and Secondary Structures
• Lightweight PrimeTex® Reinforcements Solutions for Urban Air Mobility (UAM)

Each year, since its creation more than 20 years ago, the JEC Composites Innovation Awards celebrate successful projects and cooperation between players of the composites industry. The competition has especially shined a light on some 203 companies and 499 partners, awarding them for the excellence of their composite innovations.

The ceremony took place on April 26th in Paris. Highlighted by the presence of jury members, finalists and winners but most importantly, as it was livestreamed, the gathering of many people all around the world to watch the awaited results.

The enthusiasm for the Innovation Awards, exactly 7 days prior to JEC World, is a good sign of the industry’s eagerness to get back together and ensure the future of composites innovation.

• Aerospace Application
  Diab (Sweden): 100% thermoplastic panel for cabin interiors
• Aerospace – Process
  MTorres Disenos Industriales S.A.U. (Spain): Innovative Infusion Airframe Manufacturing System
• Automotive & road transportation – Structural
  Jaguar Land Rover Limited (UK): TUCANA
• Automotive & road transportation – Surfaces
  AUDI AG (Germany): Seamless Integration of Flexible Solar Film in FRP
• Building & Civil Engineering
  Windesheim (Netherlands): Structural Re-Use of Thermoset Composites
• Design, Furniture and Home
  Kairos (France): Kairlin®, a new recyclable & compostable material
• Equipment and Machinery
  Fibraworks GmbH (Germany): Winding the future – fibraforce technology
• Maritime Transportation & Shipbuilding
  Voith Composites SE & Co. KG (Germany): Marine Rotor Blades made of Voith ‘Carbon4Stack’
• Renewable Energy
  Siemens Gamesa Renewable Energy (Denmark): RecyclableBlade
• Sports, Leisure & Recreation
  Bcomp Ltd. (Switzerland): Eco-joint from thermoset race and thermoplast road

Cobra International will showcase its portfolio of design and manufacturing solutions for the unmanned vehicle systems sector when the company exhibits alongside long-term partner HiveGround at the AUVSI XPONENTIAL 2022 conference.

Taking centre stage on the Cobra stand will be a fully assembled Swiftlet UAV. This compact tactical fixed wing UAV platform has a 5.5m wingspan and was developed by the Royal Thai Air Force and National Science and Technology Development Agency (NSTDA) for a broad range of survey, monitoring and search and rescue (SAR) operations. Cobra manufactured the 30kg Swiftlet composite airframe using a combination of CNC cut carbon sandwich internal structure and PVC foam sandwich skins using both high grade glass fibre and carbon fibre reinforcements.

Visitors to the Cobra stand will also see the VETAL, a twin rotor vertical take-off and landing (VTOL) drone with a composite airframe manufactured by Cobra for HiveGround, the Thailand based developer of UAV surveying and robotics systems.

At AUVSI XPONENTIAL, Cobra will also illustrate how the company leverages innovation and expertise developed in its water sports and automotive business to enhance its product offering to the UAV sector. Products on display include a Fliteboard electric foiling surfboard, pre-preg hydrofoil parts, lightweight medical prosthetics, flax and forged carbon parts, as well as a full set of visual carbon and painted automotive trims, each demonstrating the company’s high volume production capacity for ultra-light carbon composite structures.

The show will take place from the 25 to 28 April at the Orange County Convention Center, Orlando, Florida.