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Natural fibers combined with bio-derived epoxy resins provide sustainable options for Industrial markets (c) Hexcel
Hexcel HexPly® Nature Range
11.05.2022

Hexcel Launches HexPly® Nature Range

  • Natural fibers combined with bio-derived epoxy resins provide sustainable options for Industrial markets

Hexcel has developed a new product range that combines Hexcel resin systems made with bio-derived resin content with natural fiber reinforcements to create material solutions for Automotive, Winter Sports, Marine and Wind Energy applications.

HexPly Nature Range includes proven resins such as HexPly M49, M78.1-LT and M79 but with bio-derived epoxy resin content. The excellent resin characteristics remain unchanged in the new Nature Range products, maintaining high mechanical performance and consistent processing properties.
In addition, the HexPly Nature Range provides prepreg options with natural fiber reinforcements that can be seamlessly integrated into existing production processes.

Hexcel worked with TÜV Austria to provide independent, high-quality measurement and assessment of the bio-content of HexPly Nature Range products. TÜV Austria’s OK biobased certification uses a standardized measurement of the biobased carbon content enabling transparency and easy like-for-like comparison between products.

  • Natural fibers combined with bio-derived epoxy resins provide sustainable options for Industrial markets

Hexcel has developed a new product range that combines Hexcel resin systems made with bio-derived resin content with natural fiber reinforcements to create material solutions for Automotive, Winter Sports, Marine and Wind Energy applications.

HexPly Nature Range includes proven resins such as HexPly M49, M78.1-LT and M79 but with bio-derived epoxy resin content. The excellent resin characteristics remain unchanged in the new Nature Range products, maintaining high mechanical performance and consistent processing properties.
In addition, the HexPly Nature Range provides prepreg options with natural fiber reinforcements that can be seamlessly integrated into existing production processes.

Hexcel worked with TÜV Austria to provide independent, high-quality measurement and assessment of the bio-content of HexPly Nature Range products. TÜV Austria’s OK biobased certification uses a standardized measurement of the biobased carbon content enabling transparency and easy like-for-like comparison between products.

At JEC World in Paris on May 3-5, Hexcel presented an alpine ski produced by the Tecnica Group Ski Excellence Center which produces skis for Blizzard and for Nordica using HexPly Nature Range M78.1-LT UD flax fiber prepreg. In addition to providing a bio-based material solution, the natural fiber-reinforced prepreg also offers the potential to improve impact performance and vibration damping in the ski.

Claude Despierres, VP of Sales and Marketing – Industrial at Hexcel, said, “Our new HexPly Nature Range forms an important part of providing customers with biobased, TÜV-certified material options based on our established prepreg resin systems. Marine, winter sports, wind energy and automotive manufacturers can now have the choice to switch from petroleum-based material solutions to Hexcel HexPly Nature Range with no compromise in performance or process efficiency.”

More information:
Hexcel’s HexPly® JEC World
Source:

Hexcel

(c) Hexcel Corporation
29.04.2022

Hexcel Composite Solutions for the Automotive, Marine, Wind Energy and Recreation Markets at JEC World 2022

Hexcel will present a wide range of high-performance composite innovations for the Automotive, Marine, Wind Energy and Recreation markets during JEC World 2022 in Paris on May 3 – 5.

Hexcel will present a wide range of high-performance composite innovations for the Automotive, Marine, Wind Energy and Recreation markets during JEC World 2022 in Paris on May 3 – 5.

G-Vent Technology for Marine Structures
Hexcel has developed a new technology for out-of-autoclave (OoA) processing that delivers a game-changing reduction in process time and cost for marine manufacturers without compromising mechanical performance. Hexcel has leveraged its experience in aerospace and wind energy to develop its new G-Vent technology for OoA processing of highly loaded, thick section marine structures such as masts, foils, and wind-assisted ship propulsion (WASP) components. A full range of Hexcel marine prepregs are now available with integrated G-Vent technology, reducing the requirement for debulking steps and ensuring extremely low porosity (<1%) regardless of the laminate thickness. Leading marine non-destructive testing specialists Q.I. Composites recently confirmed that the thick section G-Vent panels they had evaluated had void contents and laminate quality in line with state-of-the-art autoclaved prepreg components. Visitors to the Hexcel stand will see a unique 400mm carbon cube cured in a single stage using 695 layers of HexPly M79 carbon fiber UD600 prepreg with G-Vent technology.

New HexPly® Nature Range Sustainable Prepregs
HexPly® Nature Range prepregs feature proven resins such as HexPly M49, M78 and M79 with bio-derived epoxy resin content. Created for use in all industrial markets, HexPly Nature Range materials can be seamlessly integrated into existing production processes, maintaining consistent mechanical performance and processing properties. A dedicated sustainability corner of the Hexcel stand will detail Nature Range products optimized for automotive, marine, wind energy and winter sport applications. The display will include an alpine ski produced by leading manufacturer Tecnica Group Ski Excellence Center which produces skis for Blizzard and for Nordica using HexPly Nature M78.1 UD flax prepreg material. In addition to the reduced environmental impact of the sustainably grown reinforcement, the flax fiber laminates also improve impact resistance and vibration damping in the ski.

HexPly® XF Surface Technology for Improved Part Surface Finish Quality
HexPly XF is a lightweight, semi-preg material that replaces traditional in-mold gel coat. It eliminates time-consuming refinishing work typically required to obtain a paint-ready surface and produces lighter, more consistent parts with shorter cycle times and a cleaner working environment. Visitors to the stand will see a composite panel illustrating a high-quality painted surface enabled with XF technology in a diverse range of industrial applications such as super yacht roof parts, Class A surface automotive panels, and both prepreg and infused wind turbine blades.

HexPly® M49 Prepreg for Automotive Visual Carbon Parts
HexPly M49 is easy to process and is especially suitable for visual carbon fiber-look applications such as the Brabus hood scoop on display on the Hexcel stand at JEC.

HexPly® Prepregs and HiMax® Reinforcements for Performance Marine Structures
Using a scale model of a Gunboat 68 performance sailing catamaran, Hexcel will illustrate how its HexPly and HiMax materials provide manufacturers with a complete set of lightweight composite solutions for high-performance marine structures. HexPly prepreg was selected for critical structural parts of the Gunboat 68 and provides very high mechanical performance including high dry and wet Tg.

Heavyweight HiMax reinforcements offer high deposition rates and remain easy to handle after cutting, making them highly suitable for industrial applications. In combination with a lightweight PrimeTex® woven fabric, the package of carbon fiber HiMax materials developed for the Gunboat 68 enabled consistent resin flow during infusion with reduced surface print-through.

Hexcel Fibers and Reinforcements for Lightweight Sporting Equipment
Sporting equipment manufacturers rely on Hexcel composite materials to deliver the ultimate performance at the lowest possible weight. Hexcel will exhibit a number of the latest high-performance sporting equipment applications such as a Bauer hockey stick featuring PrimeTex 98 gsm AS4C 3K fabric and a Corima tri-spoke cycling wheel made with lightweight Hexcel carbon fiber UD tape. Hexcel will also demonstrate how its HexTow® carbon fibers are used in key leisure and marine applications by displaying an AEROrazr solid carbon rigging component manufactured by spar and rigging manufacturer Future Fibres for the 36th America’s Cup.

 

Source:

Hexcel Corporation / 100% Marketing

(c) Cobra International
26.04.2022

COBRA International: Highlights Diversification into New Market Sectors at JEC World 2022

Cobra International, a leading manufacturer of advanced composite products for the watersports, automotive, marine, and industrial sectors, will highlight recent diversification into new composite markets at JEC World 2022, with exhibits ranging from VTOL drones to carbon fibre prosthetics.  Cobra will also demonstrate how it is working alongside automotive and water sports customers to further enhance the sustainability of products in these sectors.

High Volume Production Capacity for the UAV sector
Cobra will display a wing from the 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 survey, monitoring and search and rescue operations. Cobra manufactured the 32kg 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.  

Cobra International, a leading manufacturer of advanced composite products for the watersports, automotive, marine, and industrial sectors, will highlight recent diversification into new composite markets at JEC World 2022, with exhibits ranging from VTOL drones to carbon fibre prosthetics.  Cobra will also demonstrate how it is working alongside automotive and water sports customers to further enhance the sustainability of products in these sectors.

High Volume Production Capacity for the UAV sector
Cobra will display a wing from the 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 survey, monitoring and search and rescue operations. Cobra manufactured the 32kg 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.  

Sustainability Options for Automotive and Watersports
Sustainability has a been a key focus for the Cobra Waterports division and CAC, the Cobra automotive business unit. At JEC World 2022, Cobra will showcase the increasing material and process options it has developed with both bio-resin and natural fibre reinforcements variants presented alongside more traditional carbon fibre parts.

Visitors will be able to get up close to a new Bio SUP Wingfoil board featuring a basalt, flax, bamboo and GreenPoxy bio-epoxy construction created for partners NSP, as well as state-of-the-art compression moulded prepreg foils. Cobra’s first fully recyclable surfboard incorporating the Recyclamine® resin technology that Cobra was recognised for in the 2020 JEC Innovation Awards will also be on display alongside a new Audi e-tron foil by Aerofoils – the world’s safest electric hydrofoil board.

The CAC team (Automotive Business Unit of Cobra) will present a set of OEM mirror cap parts that showcase a range of carbon SMC, woven visual carbon, pure woven visual flax, hybrid flax-carbon and painted flax construction options for the same component.  Clear carbon aesthetic and structural parts including CAC made M-carbon components for the BMW S 1000 RR Motorcycle will furthermore underline the high quality and eye-for-detail for which CAC is renowned.

Carbon Prosthetics
An entirely new composite application for the company, Cobra will also show two composite prosthetic devices at JEC which were productionised by the in-house design and development team. Working alongside a leading Thai university and a medical device OEM, Cobra created a rapid and cost effective series production process for a lightweight carbon fibre prosthetic foot. In another example of lightweight composites creating major quality of life improvements, Cobra has also designed and manufactured a carbon and glass fibre prepreg foot support for Elysium Industries.

More information:
COBRA Composites UAV
Source:

Cobra International

 Hexcel’s innovative surface technology yields parts with paint-ready surfaces for builder of luxury yachts (c) Hexcel
Sunseeker 90 Ocean Luxury Yacht
26.01.2022

Hexcel Selected for Sunseeker 90 Ocean Luxury Yacht

  • Hexcel HexPly® XF Selected for High-Quality, Paint-Ready Parts for Sunseeker 90 Ocean Luxury Yacht
  • Hexcel’s innovative surface technology yields parts with paint-ready surfaces for builder of luxury yachts

Yacht builder Sunseeker has chosen Hexcel’s HexPly® XF surface technology to produce prepreg parts with high-quality, paint-ready surfaces quickly and efficiently for its 90 Ocean luxury yacht, one of its newest models.

The lightweight composite hardtop for the Sunseeker 90 Ocean yacht is manufactured from a combination of HexPly® XF and Hexcel's HexPly® SuperFIT® semi-preg. The hardtop is lighter in weight than versions made using resin-infusion processes, and it de-molds with a pinhole-free surface that needs minimal preparation to be ready for paint. Sunseeker has recorded an overall reduction in process time of around 30%, saving three days of manufacturing time per hardtop.

  • Hexcel HexPly® XF Selected for High-Quality, Paint-Ready Parts for Sunseeker 90 Ocean Luxury Yacht
  • Hexcel’s innovative surface technology yields parts with paint-ready surfaces for builder of luxury yachts

Yacht builder Sunseeker has chosen Hexcel’s HexPly® XF surface technology to produce prepreg parts with high-quality, paint-ready surfaces quickly and efficiently for its 90 Ocean luxury yacht, one of its newest models.

The lightweight composite hardtop for the Sunseeker 90 Ocean yacht is manufactured from a combination of HexPly® XF and Hexcel's HexPly® SuperFIT® semi-preg. The hardtop is lighter in weight than versions made using resin-infusion processes, and it de-molds with a pinhole-free surface that needs minimal preparation to be ready for paint. Sunseeker has recorded an overall reduction in process time of around 30%, saving three days of manufacturing time per hardtop.

The hardtop provides shade and protection for the yacht’s uppermost deck space. Its reduced weight helps to ensure the stability of the vessel, and the paint-ready finish with HexPly XF provides Sunseeker with more options for customizing its color to the individual needs of its clients.
 
HexPly XF is a lightweight, non-woven semi-preg that eliminates the need to use a traditional in-mold gel coat. The innovative surface technology significantly reduces the costly and time-consuming refinishing work typically required to impart a paint-ready finish to prepreg or semi-preg parts, and yields lightweight, consistent components in short cycle times.

Working with Sunseeker, Hexcel developed a material format, a laminate ply sequence, and a production process that satisfied the structural requirements for the hardtop and enabled the yacht builder’s production team to lay up and cure the part in a single shot – slashing cycle times.

Hexcel supplies Sunseeker with a HexPly XF product that comprises both the surface layer and the first structural reinforcement ply, eliminating the need for a cosmetic barrier coat. Neither the HexPly XF surface layer nor the following layers of HexPly SuperFIT require time-consuming debulking steps – significantly reducing lay-up time – and both are based on Hexcel's rapid-curing M79 epoxy resin system. Adhesive resin films are not needed to bond the hardtop’s foam core, as the resin content of the SuperFIT plies has been adjusted to further reduce overall process time.

Once de-molded, the cured hardtops are inspected before they are passed to Sunseeker’s finishing and painting technicians for final preparation and painting. The HexPly XF resin surface allows the yacht builder’s quality technicians to inspect the laminate below quickly and easily, ensuring the quality and consistency of the structural reinforcement plies.

“Composite materials that improve our production processes, as well as great technical support, are what makes working with Hexcel such a success story," said Stuart Vaughan-Jones, Composite Development Manager, Sunseeker. "With the switch from gel coat and resin infusion to HexPly XF and SuperFIT in the new hardtops, we are now building lighter, more consistent parts, more quickly than before, with a higher quality surface finish. XF really has ticked all the boxes.”  

Garth Thomas, Account Manager – Marine, Hexcel, said: "With the HexPly XF surface technology now well established, XF will soon be used in other large moldings where minimizing weight is critical, as well as additional hardtops across the Sunseeker model range."

(c) AVK - Industrievereinigung Verstärkte Kunststoffe e. V.
24.11.2021

The AVK – Industrievereinigung Verstärkte Kunststoffe – presents its Innovation Awards 2021

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

Category “Research and Science”
First place in the “Research and Science” category was awarded to the German Aerospace Center (DLR) for its Bondline Control Technology (BCT). This innovative process is used for quality control and assurance of bonded joints. The core element is a porous fabric which is applied to a joining surface using an epoxy adhesive or matrix resin. Peeling away the fabric creates a chemically reactive and undercut surface and can also be used as a test to check adhesion to the substrate. BCT has potential in a variety of possible applications. For example, peel ply can be replaced by BCT fabric to produce composite components with an optimised joining surface. The cost-effective BCT peel test is suitable for coupon testing and process control. In addition, the combined adhesion test and surface pre-treatment can be used for quality assurance of bonded repairs on fibre composite structures.

Second place was taken by the Institute of Textile Technology (ITA) at RWTH Aachen University and its partners AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR with “StoneBlade – Lightweight construction with granite for the wind industry”. This innovation enables manufacturers to reduce the amount of non-recyclable materials used in rotor blade construction. At the same time, it reduces the weight of these components and improves the mechanical properties relating to the stability of wind turbines. The innovative approach replaces glass-fibre reinforced plastic in the blade components with hard rock – a natural, cost-effective and recyclable lightweight material. The slabs of rock are cut and ground to a thickness of just a few millimetres and embedded in a fibre composite laminate with carbon fibre, which stabilises them for alternating load cases. The pre-stressed material is pressure-stable in the composite and can absorb tensile forces in the event of continuously alternating loads without any loss of stiffness.

Third place went to the Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK) with its partner Mercedes Benz AG for the interdisciplinary development of a highly integrated inductive charging module for electric vehicles. The ultra-thin charging module was designed to make optimum use of space in the vehicle underbody without reducing ground clearance. An interdisciplinary approach was adopted for the development process. This involved the electrical, mechanical and process characterisation of high-frequency Litz wires, ferromagnetic foil and metal wire cloth as well as the creation of a simulation model. The result is a demonstrator for a charging system with a structural height of 15 mm and a total weight of 8 kg. It achieves a transmission efficiency of up to 92 percent at 7.2 kW nominal power and active air cooling. The hardware demonstrator was fabricated in a 3-step process using RTM and VARI techniques.

Overview of all the winners in the three categories:
Category “Innovative Products/Applications”
1st Place: “Traffic signs from Nabasco (N-BMC)” – Nabasco Products BV and Lorenz Kunststofftechnik GmbH, partners: Pol Heteren BV and NPSP BV
2nd Place: “Novel, ultratough vinyl ester resin for the construction of large marine vessels” Evonik Operations GmbH
3rd Place: “Air intake housing with a multi-material design for gas turbines” – MAN Energy Solutions SE, Leichtbau-Zentrum Sachsen GmbH and Leichtbau-Systemtechnologien KORROPOL GmbH.
Category “Innovative Processes”
1st Place: “In-mould wrapping” off-tool, film-coated, fibre composite components for exterior applications – BMW Group, Partner: Renolit SE
2nd Place: “Adaptive automated repair of composite structural components in the aviation sector” – Lufthansa Technik AG, Partner: iSAM AG
3rd Place: “Automated surface pre-treatment using VUV excimer lamps” – CTC GmbH
Category “Research and Science”
1st Place: “Bondline Control Technology (BCT)” – German Aerospace Center (DLR)
2nd Place: “StoneBlade – Lightweight construction with granite for the wind industry” – Institute of Textile Technology at RWTH Aachen University, Partners: AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR
3rd Place: “Interdisciplinary development of a highly integrated inductive charging module for electric vehicles” – Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK), Partner: Mercedes Benz AG

Submissions for the next Innovation Award can be made from the end of January 2022.

Source:

AVK - Industrievereinigung Verstärkte Kunststoffe e. V.

08.11.2021

Composites Evolution showcased prepregs and new thermoplastic unidirectional tapes

Composites Evolution exhibited at the Advanced Engineering 2021 show on 3rd - 4th November highlighting its range of prepreg and introducing a new thermoplastic tape manufacturing capability.

Composites Evolution is a developer, manufacturer and supplier of prepregs for the production of lightweight structures from composite materials. A flexible approach allows Composites Evolution to offer short lead times and low minimum order quantities, while decades of combined expertise ensure that in-depth technical support is on-hand when customers need it.

Showcased was a battery box from a high-performance luxury electric vehicle manufactured from Evopreg® PFC bio-based, fire-resistant prepreg, a rear wing from a Ginetta G56 GTA GT4 race car utilising Evopreg® ampliTex™ natural fibre prepreg, and parts fabricated from the company’s newly-launched Evopreg® PA thermoplastic tape range.

Composites Evolution exhibited at the Advanced Engineering 2021 show on 3rd - 4th November highlighting its range of prepreg and introducing a new thermoplastic tape manufacturing capability.

Composites Evolution is a developer, manufacturer and supplier of prepregs for the production of lightweight structures from composite materials. A flexible approach allows Composites Evolution to offer short lead times and low minimum order quantities, while decades of combined expertise ensure that in-depth technical support is on-hand when customers need it.

Showcased was a battery box from a high-performance luxury electric vehicle manufactured from Evopreg® PFC bio-based, fire-resistant prepreg, a rear wing from a Ginetta G56 GTA GT4 race car utilising Evopreg® ampliTex™ natural fibre prepreg, and parts fabricated from the company’s newly-launched Evopreg® PA thermoplastic tape range.

Composites Evolution has a family of specialist prepregs for various applications, including Evopreg® EPC epoxy component prepregs which are a range of pre-impregnated fabrics suitable for moulding into high-performance, lightweight, structural components; Evopreg® EPT epoxy tooling prepregs which have been designed to help composite tooling manufacturers improve the flexibility and efficiency of their tooling manufacturing processes; and Evopreg® PFC fire-retardant prepregs a 100% bio-derived alternative to phenolics for applications where fire performance is a critical requirement.

Evopreg® ampliTex™ combines Composite Evolution’s high-performance Evopreg® epoxy resin systems with Bcomp’s award-winning ampliTex™ flax reinforcements, to deliver a family of materials which offer outstanding performance for component applications.

Composites Evolution launched their new range of Evopreg® PA Thermoplastic Tapes at Advanced Engineering; these are manufactured from polyamide-6 (PA6) polymer with unidirectional carbon fibre and are suitable for automated tape laying, winding and compression moulding into high-performance, lightweight components.

Source:

Composites Evolution Ltd

Hexcel and HP Composites Collaborate to Develop Class A Body Panels (c) Hexcel
2020-Alfa-Giulia-GTAm
29.09.2021

Hexcel and HP Composites Collaborate to Develop Class A Body Panels

Hexcel has collaborated with HP Composites S.p.A (HP Composites), a world leader in the production of carbon fiber components for automotive and motorsports, to develop carbon fiber Class A body panels. Hexcel HexPly® XF surfacing technology is being extensively used by the Italian component producer to manufacture external body panels and other components for supercars such as Alfa Romeo’s stunning new supersport sedans, the Giulia GTA, and GTAm.

With five production plants in Italy, HP Composites has built an impressive track record of high-performance composite successes on both road and racetrack. HP has combined this processing expertise with Hexcel HexPly® XF3 surfacing material, HexPly® M47, and HexPly® M49 prepregs, working to the highest standards set by the most prestigious supercar OEMs and leading motorsport teams.

Hexcel has collaborated with HP Composites S.p.A (HP Composites), a world leader in the production of carbon fiber components for automotive and motorsports, to develop carbon fiber Class A body panels. Hexcel HexPly® XF surfacing technology is being extensively used by the Italian component producer to manufacture external body panels and other components for supercars such as Alfa Romeo’s stunning new supersport sedans, the Giulia GTA, and GTAm.

With five production plants in Italy, HP Composites has built an impressive track record of high-performance composite successes on both road and racetrack. HP has combined this processing expertise with Hexcel HexPly® XF3 surfacing material, HexPly® M47, and HexPly® M49 prepregs, working to the highest standards set by the most prestigious supercar OEMs and leading motorsport teams.

Hexcel’s automotive composites portfolio is the result of decades of industry experience and the creation of strategic partnerships to develop and optimize leading-edge technologies. HexPly XF3 is an epoxy prepreg surface material, developed with processing input from the HP Composites team to address the challenges of producing high-quality Class A automotive body panel surfaces with excellent resistance to aging tests.

Applied as the first ply in the mold and after curing at 120-180˚C in an autoclave, HexPly XF3 produces a smooth part surface with no porosity, that requires minimal preparation for painting.

HexPly XF3 is supplied in an easy-to-handle roll format with good tack and drapability. After curing, it can be easily prepared for painting with a rapid sanding process. HP Composites has incorporated automated robotic sanding techniques for this finishing stage with the paint-ready HexPly XF3 surface providing excellent paint adhesion according to EN ISO 2409.

HP Composites typically uses autoclave processing for HexPly XF3 parts, maximizing weight savings and structural performance of the final components. In addition, HP has also developed its own proprietary press and compression molding processes, including Air Press Moulding® technology, compatible with HexPly XF3 and other HexPly prepregs for higher volume production series that require increased production rates.

“Our long-term experience has given us a detailed understanding of the critical features that influence how prepregs and surfacing technologies interact with different production processes,” said Abramo Levato, General Manager, HP Composites S.p.A. “The relationship we have with Hexcel is both highly technical and highly supportive. As a result we have a complete material package for high-quality Class A body panels that are formulated specifically with our requirements in mind.”

“Combining the expertise of HP with a strong technical interaction and collaborative dialogue, Hexcel and HP were together able to develop the optimum HexPly XF surfacing technology,” said Claude Despierres, VP Sales and Marketing, Hexcel. “With HexPly XF3 we satisfy the toughest industry standards.”

(c) Notus Composites. Notus NE7 low temperature curing prepreg
15.09.2021

Notus Composites Launches New Low Temperature Curing NE7 Epoxy Prepreg

Notus Composites (UAE), the award-winning producer of epoxy prepreg materials, announces the latest addition to its high-performance epoxy range with the launch of its new NE7 low temperature curing prepreg system. The Notus NE7 formulation allows composite manufacturers to cure components at temperatures as low as 70˚C, reducing energy consumption and enabling more cost-effective tooling options.

Notus Composites has developed the new NE7 prepreg systems for applications across the Marine, Architecture, Industrial and Wind Energy sectors, with the novel low temperature curing chemistry delivery significant cost benefits. Existing prepreg manufacturers can now use more cost-effective composite tooling, with new prepreg users able to switch easily from existing infusion or wet laminating processes without creating expensive new high temperature tooling.

Notus Composites (UAE), the award-winning producer of epoxy prepreg materials, announces the latest addition to its high-performance epoxy range with the launch of its new NE7 low temperature curing prepreg system. The Notus NE7 formulation allows composite manufacturers to cure components at temperatures as low as 70˚C, reducing energy consumption and enabling more cost-effective tooling options.

Notus Composites has developed the new NE7 prepreg systems for applications across the Marine, Architecture, Industrial and Wind Energy sectors, with the novel low temperature curing chemistry delivery significant cost benefits. Existing prepreg manufacturers can now use more cost-effective composite tooling, with new prepreg users able to switch easily from existing infusion or wet laminating processes without creating expensive new high temperature tooling.

NE7 prepregs can be cured at temperatures as low as 70˚C, with the standard cure cycle being 12 hours at 70˚C, matching the typical cycle time for an infused part with a component Tg of 85˚C. NE7 materials have a good outlife of 30 days at 20˚C and are available in all prepreg and Notus single sided N1-Preg formats with unidirectional, multiaxial, and woven reinforcements. NE7 can also be supplied as a resin film.

Notus has recently supplied NE7 low temperature prepregs to Dubai based Aeolos Composites for the production of their new Aeolos P30 racing yacht. The P30 is a futuristic new craft created by top German sailor and designer, Hans Genthe, with a super light carbon fibre construction and large sail area that promises spectacular on the water performance for a thirty foot yacht. Notus delivered a range NE7 prepregs for the build, including woven, multiaxial, and unidirectional carbon fibre reinforcements as well as adhesive films for core bonding.

More information:
Notus prepreg material
Source:

Notus Composites.

powerribs with inset bonnet (c) Composites Evolution
04.08.2021

Composites Evolution: New range of flax-epoxy prepreg materials

Composites Evolution Ltd has teamed up with leading natural fibre reinforcement specialists Bcomp to launch a new range of flax-epoxy prepreg materials, designed to offer enhanced sustainability without compromising on performance.

Evopreg ampliTex™ prepregs combine Composites Evolution’s high-performance Evopreg epoxy resin systems with Bcomp’s award-winning ampliTex™ flax reinforcements, to deliver a family of materials which offer outstanding performance for component applications.

To reach the full performance of natural fibres, Evopreg ampliTex™ prepregs have been tailored to be compatible with Bcomp’s powerRibs™ reinforcement grid, enabling the same stiffness and weight as thin-walled monolithic carbon fibre parts while decreasing the CO2 footprint by 85% and improving safety thanks to a blunt braking behaviour without dangerous debris or sharp edges.

Composites Evolution Ltd has teamed up with leading natural fibre reinforcement specialists Bcomp to launch a new range of flax-epoxy prepreg materials, designed to offer enhanced sustainability without compromising on performance.

Evopreg ampliTex™ prepregs combine Composites Evolution’s high-performance Evopreg epoxy resin systems with Bcomp’s award-winning ampliTex™ flax reinforcements, to deliver a family of materials which offer outstanding performance for component applications.

To reach the full performance of natural fibres, Evopreg ampliTex™ prepregs have been tailored to be compatible with Bcomp’s powerRibs™ reinforcement grid, enabling the same stiffness and weight as thin-walled monolithic carbon fibre parts while decreasing the CO2 footprint by 85% and improving safety thanks to a blunt braking behaviour without dangerous debris or sharp edges.

Composites Evolution’s Sales & Marketing Director, Ben Hargreaves, explains further.
“Sustainability is an increasingly important factor for many of our customers - particularly those involved in motorsports and high-performance automotive applications. As you’d expect in these sectors though, sustainability can’t come at the expense of performance the two must go hand-in-hand. This is something that other prepreggers can struggle with, as natural fibres behave very differently to carbon or glass, for example.”

Customers would be able to understand the strengths and weaknesses of natural fibre composites, and to show where and how they can be adopted without the need for significant changes to existing composite component production processes.

One such customer is Retrac Group, whose composites division is one of the UK’s most experienced composites engineering companies across motorsports, automotive and aerospace. It recently used Evopreg ampliTex™ + powerRibs™ to produce a demonstrator bonnet panel for a race-bred supercar. Project Manager Alan Purves explains.


“We’re seeing a growing interest in flax fibre composites, particularly in the motorsports and niche vehicle sectors. It is therefore essential that we have developed an in-depth understanding of the processing requirements and performance capabilities of these materials, and are ready to respond to our customers' requirements. Being able to tap into the combined expertise and experience of both Composites Evolution and Bcomp is proving invaluable.”

Source:

Composites Evolution

20.07.2021

Hexcel: Speeding up new Product Development Cycles for Rassini

Hexcel, a global leader in advanced composites technologies, confirms that its HexPly® M901 prepreg system has been selected by Rassini, a Mexico-based technology leader in composite vehicle suspension systems, to speed up prototype and new product development cycles, reducing overall time to market with an easy to process material solution that enables effective early-stage design screening and cost-effective production.  

As a specialist in the mass production of composite helper leaf springs for various leading OEMs, Rassini continuously develops innovative new suspension component designs. Due to cost and timing, however, these new products cannot easily be prototyped using conventional high-pressure resin transfer molding (HP-RTM) technology.

Hexcel, a global leader in advanced composites technologies, confirms that its HexPly® M901 prepreg system has been selected by Rassini, a Mexico-based technology leader in composite vehicle suspension systems, to speed up prototype and new product development cycles, reducing overall time to market with an easy to process material solution that enables effective early-stage design screening and cost-effective production.  

As a specialist in the mass production of composite helper leaf springs for various leading OEMs, Rassini continuously develops innovative new suspension component designs. Due to cost and timing, however, these new products cannot easily be prototyped using conventional high-pressure resin transfer molding (HP-RTM) technology.

With more than 15 years of experience in delivering glass fiber prepregs for the serial production of composite leaf springs, Hexcel developed its high-performance HexPly M901 prepreg system specifically for this type of application. HexPly M901 combines the right level of structural performance required with simple processing, providing Rassini with a reliable material solution optimized for rapid development and fine-tuning iterations.

HexPly M901 is a high Tg epoxy resin prepreg system specifically developed for structural components that will be exposed to harsh thermal and environmental conditions.  With short cure cycles of 10 minutes and below producing excellent green, or handling, strength of the composite part for demolding and unidirectional glass fiber aerial weights up to 1,600gsm, HexPly M901 delivers a powerful combination of benefits for suspension component applications.

More information:
Hexcel’s HexPly® Hexcel
Source:

Hexcel Corporation

02.06.2021

Teijin: Tenax™ Carbon Fiber Prepreg Adopted for Next-Generation Aircraft Engine Nacelle

Teijin Limited announced today that its Tenax™ carbon fiber prepreg has been adopted for a part of nacelle, or streamlined housing, for next-generation aircraft engine to be used by Airbus. A prototype of the nacelle part, which Nikkiso Co., Ltd. is developing for Airbus’s Propulsion of Tomorrow project, will be delivered to Airbus by the end of 2021.

The Tenax™ prepreg used for the nacelle part was developed especially for aircraft applications using high-performance and rapid-curing epoxy resin. Notably, the Tenax™ prepreg can be molded at a lower temperature and in a shorter time than conventional prepregs for aircraft applications. In addition to general autoclave molding, the Tenax™ prepreg also is suited to press molding for mass production, achieving excellent quality required for aircraft applications. Furthermore, it is compatible with automated fiber placement (AFP) therefore can be combined with automatic laminating technology and short-time molding to maximize production efficiency. The excellent productivity and cost efficiency of the Tenax™ prepreg were key reasons why it was adopted for Nikkiso’s nacelle.

Teijin Limited announced today that its Tenax™ carbon fiber prepreg has been adopted for a part of nacelle, or streamlined housing, for next-generation aircraft engine to be used by Airbus. A prototype of the nacelle part, which Nikkiso Co., Ltd. is developing for Airbus’s Propulsion of Tomorrow project, will be delivered to Airbus by the end of 2021.

The Tenax™ prepreg used for the nacelle part was developed especially for aircraft applications using high-performance and rapid-curing epoxy resin. Notably, the Tenax™ prepreg can be molded at a lower temperature and in a shorter time than conventional prepregs for aircraft applications. In addition to general autoclave molding, the Tenax™ prepreg also is suited to press molding for mass production, achieving excellent quality required for aircraft applications. Furthermore, it is compatible with automated fiber placement (AFP) therefore can be combined with automatic laminating technology and short-time molding to maximize production efficiency. The excellent productivity and cost efficiency of the Tenax™ prepreg were key reasons why it was adopted for Nikkiso’s nacelle.

Teijin is intensively accelerating its development of mid- to downstream applications for aircraft, one of the strategic focuses of its medium-term management plan for 2020-2022. Going forward, Teijin intends to further strengthen its carbon fiber and intermediate material businesses to contribute to increasing global sustainability, aiming to become a company that supports the society of the future.

Source:

Teijin

15.02.2021

Hexcel’s HexPly® XF Surface Technology for Blade Surface Finishing Process

Hexcel announces its latest HexPly® XF surface technology that reduces shell manufacturing time within the wind blade surface finishing process. HexPly XF increases overall blade manufacturing efficiency by reducing time in the mold by up to two hours and by banishing surface defects that require rework before painting.

Hexcel’s HexPly XF surface technology has been formulated to address the limitations of current blade shell surfacing techniques whereby pinholes and other surface defects have to be repaired by hand to achieve the perfectly smooth surface required for painting.

HexPly XF surface technology introduces a new material format as the surface finishing layer, eliminating the need for a traditional in-mold gel coating process. HexPly® XF for infused rotor blades, is a lightweight non-woven semi-preg construction, comprising an epoxy resin matrix, that co-cures with standard epoxy infusion systems. The product has a successful track record in prepreg blades and has now been adapted for infusion processes.

Hexcel announces its latest HexPly® XF surface technology that reduces shell manufacturing time within the wind blade surface finishing process. HexPly XF increases overall blade manufacturing efficiency by reducing time in the mold by up to two hours and by banishing surface defects that require rework before painting.

Hexcel’s HexPly XF surface technology has been formulated to address the limitations of current blade shell surfacing techniques whereby pinholes and other surface defects have to be repaired by hand to achieve the perfectly smooth surface required for painting.

HexPly XF surface technology introduces a new material format as the surface finishing layer, eliminating the need for a traditional in-mold gel coating process. HexPly® XF for infused rotor blades, is a lightweight non-woven semi-preg construction, comprising an epoxy resin matrix, that co-cures with standard epoxy infusion systems. The product has a successful track record in prepreg blades and has now been adapted for infusion processes.

Easy to handle and supplied in a ready to use roll form, HexPly XF can be quickly applied by hand or with semi-automated layup equipment. It features one self-adhesive, surface finishing side - indicated by a removable protective foil. This side of the prepreg is placed against a release agent treated mold surface. Once the material has been positioned, the lay-up of the blade shell structure can start immediately, and the laminate can be infused. After curing, the blade is de-molded with the manufacturer benefitting from a pinhole-free surface that needs minimal preparation before painting.

HexPly XF material is less than half the weight of a typical gel coat per square meter, reducing the overall weight of the blade. Additionally, the consistent areal weight and thickness of the prepreg film provide a completely uniform surface coating, ensuring blade weight distribution and balance are maintained, which is critical as rotor diameters continue to increase. With no need to handle or mix liquid chemicals as in the gel coat process, HexPly® XF also improves the health and safety working conditions on the shop floor.

The material has a shelf life of six weeks at ambient temperature, which also minimizes cold storage requirements and helps to reduce scrap.

Source:

100% Marketing

09.02.2021

Sicomin: Collaboration with GREENBOATS® for natural fibre composite

Sicomin announces its latest collaboration with GREENBOATS® as they deliver the first ever natural fibre composite (NFC) nacelle for an offshore wind turbine.  

With more than 2.5 million tons of composite materials in use in the wind industry globally, and the first generation of wind turbines now approaching end of life, there is still a lack of well-established recycling options. GREENBOATS’ mission is to demonstrate how large-scale NFC structures in wind energy can lower energy consumption in manufacturing and significantly improve the sustainability of the composite materials used in the turbine.

In 2020, GREENBOATS was commissioned by a leading wind energy technology developer to design and manufacture a sustainable NFC nacelle. The resulting 7.3m long structure has a surface area of approximately 100m2 and was engineered by GREENBOATS to satisfy all DNV-GL load cases required for an offshore turbine nacelle, including 200km/h max wind loads and 2KN loads on the guard rails.

Sicomin announces its latest collaboration with GREENBOATS® as they deliver the first ever natural fibre composite (NFC) nacelle for an offshore wind turbine.  

With more than 2.5 million tons of composite materials in use in the wind industry globally, and the first generation of wind turbines now approaching end of life, there is still a lack of well-established recycling options. GREENBOATS’ mission is to demonstrate how large-scale NFC structures in wind energy can lower energy consumption in manufacturing and significantly improve the sustainability of the composite materials used in the turbine.

In 2020, GREENBOATS was commissioned by a leading wind energy technology developer to design and manufacture a sustainable NFC nacelle. The resulting 7.3m long structure has a surface area of approximately 100m2 and was engineered by GREENBOATS to satisfy all DNV-GL load cases required for an offshore turbine nacelle, including 200km/h max wind loads and 2KN loads on the guard rails.

Sicomin’s market leading GreenPoxy® range met these challenging engineering requirements, with the company’s recently expanded manufacturing capability also matching the potential supply volumes required by wind turbine manufacturers.  

Sicomin’s DNV-GL type approved bio-based epoxy was used to infuse BComp flax fibre reinforcements and balsa cores, with Sicomins’ intumescent weatherproof gelcoat applied on the outer surface. Cured panels were cut to shape, formed over a male plug and bonded together, before flax reinforcement plies, hand laminated with GreenPoxy resins and vacuum bagged, were added along all the panel joints lines.  Finally, Sicomin’s highly UV resistant clear coating products were used to protect and enhance the finish of the flax fibre feature stripe details.

Source:

100% Marketing

COBRA provides high-quality mass production for ARE Tahiti’s new composite canoes (c) COBRA
23.11.2020

COBRA provides high-quality mass production for ARE Tahiti’s new composite canoes

Cobra International, Chonburi, Thailand: COBRA International, one of the world’s largest OEM manufacturers of composite goods for Water Sports, Automotive, Marine and Civil Engineering, is pleased to confirm the shipment of its first 36 composite canoes to ARE Tahiti.

COBRA has collaborated with leading outrigger canoe brand ARE Tahiti to mass produce its new OC-1 canoe, ‘Mana’. Designed by former professional windsurfer Baptiste Gossein  (JP Australia and Neil Pryde), ‘Mana’ features a closed deck on which the paddler sits on top of the hull. Available in two models; a hybrid version weighing 12kg, using an 80:20 mix of E-glass and carbon fibre reinforcement fabrics, and the PRO model – a weight optimized, ultra-light, full carbon version that weighs as little as 9kg.   

“We required the best in composite construction for both models, a stunning final finish and a build rate that could keep up with our growing order book”, comments Baptiste Gossein.

Cobra International, Chonburi, Thailand: COBRA International, one of the world’s largest OEM manufacturers of composite goods for Water Sports, Automotive, Marine and Civil Engineering, is pleased to confirm the shipment of its first 36 composite canoes to ARE Tahiti.

COBRA has collaborated with leading outrigger canoe brand ARE Tahiti to mass produce its new OC-1 canoe, ‘Mana’. Designed by former professional windsurfer Baptiste Gossein  (JP Australia and Neil Pryde), ‘Mana’ features a closed deck on which the paddler sits on top of the hull. Available in two models; a hybrid version weighing 12kg, using an 80:20 mix of E-glass and carbon fibre reinforcement fabrics, and the PRO model – a weight optimized, ultra-light, full carbon version that weighs as little as 9kg.   

“We required the best in composite construction for both models, a stunning final finish and a build rate that could keep up with our growing order book”, comments Baptiste Gossein.

As with all of COBRA’s watersports’ projects, a perfect master model formed the basis of the mass production tooling and two sets of composite hull tooling were taken from the master plug allowing a build rate of up to 50 OC-1 canoes per month.

For the lay-up and construction process, COBRA’s high-performance PVC foam sandwich windsurf board construction provided a solid starting point.  Having selected vacuum consolidated epoxy wet layup for the mix of woven and stitched biaxial reinforcements, COBRA was able to build down to the customer’s weight target with the absolute minimum of waste and additional consumables.  Top and bottom sections of the hull were moulded separately then bonded together, with the smaller outrigger hull – known as the ‘ama’ – produced in the same way.  Prepreg carbon fibre and in-house split mould tooling was also used for the two ‘Iakos’ - the two cross beams that join the ama to the main hull. 

An in-mould applied finish coat was then used for the hybrid OC-1 while the PRO carbon fibre model benefits from COBRA’s ultra-light paint system.

“COBRA is able to provide mass production capability and rapid new model turnaround, as well as delivering consistently high quality. We are delighted with the first COBRA built OC-1s and have received exceptionally positive feedback from both customers and racers” comments Baptiste Gossein.

The next ARE project to enter mass production at COBRA will be the V-1 canoe. Similar to the OC-1 but an open boat that the paddler sits inside, the V-1 will have no rudder or steering system, requiring more finesse to manage underway.

“The OC-1 outrigger canoe is a superb example of our customer focused approach to production process development.  By working closely with Baptiste and the ARE team, COBRA is able to provide mass production capability and a rapid new model turnaround, as well as delivering consistently high quality.  This is a sector in which we expect to see significant expansion over the next few years”, comments Danu Chotikapanich, CEO, COBRA International.

Composite car seat back (c) NaCa Systems
Composite car seat back
05.02.2020

Hexcel and NaCa Systems develop hybrid carbon and wood fiber

Hexcel is collaborating with NaCa Systems, a Tier 1 supplier of natural fiber composite automotive interior parts, on the development of a lightweight carbon fiber prepreg and wood fiber composite sportscar seat back using a rapid press molding process. This innovation validates a short cycle time production process for CFRP and wood fiber composite parts and offers a host of benefits to automotive manufacturers.

Hexcel supplies NaCa Systems with an optimized version of its HexPly® M77CS epoxy prepreg material. HexPly® M77CS is a fast curing hotmelt, thermosetting epoxy matrix, specifically designed for prepreg applications for which short cure cycles and clear surfaces with perfect aesthetics are required.

The lightweight seat back demonstrates a 40% weight saving compared to a typical injection molded plastic component whilst also featuring a significantly improved CO2 footprint vs a full carbon part. The prepreg and wood fiber structure doesn’t produce sharp edged pieces when damaged. In addition, wood fiber composites also increase sound absorption, contributing to improved NVH damping within the vehicle interior.

Hexcel is collaborating with NaCa Systems, a Tier 1 supplier of natural fiber composite automotive interior parts, on the development of a lightweight carbon fiber prepreg and wood fiber composite sportscar seat back using a rapid press molding process. This innovation validates a short cycle time production process for CFRP and wood fiber composite parts and offers a host of benefits to automotive manufacturers.

Hexcel supplies NaCa Systems with an optimized version of its HexPly® M77CS epoxy prepreg material. HexPly® M77CS is a fast curing hotmelt, thermosetting epoxy matrix, specifically designed for prepreg applications for which short cure cycles and clear surfaces with perfect aesthetics are required.

The lightweight seat back demonstrates a 40% weight saving compared to a typical injection molded plastic component whilst also featuring a significantly improved CO2 footprint vs a full carbon part. The prepreg and wood fiber structure doesn’t produce sharp edged pieces when damaged. In addition, wood fiber composites also increase sound absorption, contributing to improved NVH damping within the vehicle interior.

The NaCa Systems seat back will be on display on the Hexcel stand at JEC World 2020.

More information:
Hexel NaCa
Source:

100percentmarketing 

(c) Chomarat
09.10.2019

Chomarat fabrics at the KraussMaffei booth during K Messe 2019

Chomarat Group’s composite reinforcements will be featured at the KraussMaffei stand during the next K Messe in Düsseldorf. Chomarat has created a glass reinforcement adapted to the mass production of automotive parts, helping to lighten leaf springs by 60% compared to metal.

Automotive: Producing 60% lighter leaf springs for car's underbody
The new leaf springs made of composites are 60% lighter than their pendants made of steel thanks to KraussMaffei process and the involvement of a network of partners, including Chomarat with G-PLY™ glass reinforcement. Their strength can be deliberately increased in sections where it is required and the corrosion resistance offers further added value.

Chomarat Group’s composite reinforcements will be featured at the KraussMaffei stand during the next K Messe in Düsseldorf. Chomarat has created a glass reinforcement adapted to the mass production of automotive parts, helping to lighten leaf springs by 60% compared to metal.

Automotive: Producing 60% lighter leaf springs for car's underbody
The new leaf springs made of composites are 60% lighter than their pendants made of steel thanks to KraussMaffei process and the involvement of a network of partners, including Chomarat with G-PLY™ glass reinforcement. Their strength can be deliberately increased in sections where it is required and the corrosion resistance offers further added value.

“We created the fabrics, when Engenuity developed the component, Huntsman supplied the matrix system made of epoxy resin, Johns Manville supplied the glass fibers, Schmidt & Heinzmann manufactured the preforms, Alpex designed the RTM mold and Hufschmied (Bobingen, Germany) took charge of post-mold processing of the component by milling. KraussMaffei has taken over the project management for Hengrui and coordinates the project with the partners.” Francisco De Oliveira at Chomarat explains.

More information:
CHOMARAT K 2019
Source:

AGENCE APOCOPE

Tiger Drone (c) COBRA International / HG Robotics
19.09.2019

COBRA delivers first 100 composite fuselage covers for cutting-edge drones

COBRA International is collaborating with HG Robotics, a leading drone manufacturer that specializes in unmanned aerial vehicles (UAVs) for the agricultural market, on a composite fuselage cover for the cutting-edge Tiger Drones.

Undertaking a full range of services with HG Robotics and having been involved from the outset: from the design and engineering through to the prototyping of the composite drone fuselage cover, COBRA has now delivered nearly 100 sets and will produce approximately 500 units throughout 2019.

COBRA International is collaborating with HG Robotics, a leading drone manufacturer that specializes in unmanned aerial vehicles (UAVs) for the agricultural market, on a composite fuselage cover for the cutting-edge Tiger Drones.

Undertaking a full range of services with HG Robotics and having been involved from the outset: from the design and engineering through to the prototyping of the composite drone fuselage cover, COBRA has now delivered nearly 100 sets and will produce approximately 500 units throughout 2019.

The multi-rotor Tiger Drones typically carry spraying equipment and can also carry high definition cameras that provide a wide range of field information. Farmers can measure land profiles, identify any problem plants or areas and manage their cultivation in the most efficient way. The 420 mm square shaped fuselage cover protects the drone’s electronic controls and forms an aerodynamic fairing between the central fuselage and the craft’s 4 rotor arms.
 
The COBRA Design and Development team selected a composite laminate of glass fibre reinforcements for the cover – which don’t interfere with GPS signals used by the drone - and combined these with epoxy laminating resins in a hand laminated, vacuum bag consolidated production process.

COBRA also designed all of the mould tools for the project. The 2-piece aluminium mould was produced by one of COBRA’s long-term tooling partners. This metallic tooling provides an excellent surface finish to the part with absolutely minimal trimming and finishing required.   Moulded parts can go swiftly through a painting and clear coating process before final inspection and delivery to the client.

Danu Chotikapanich, CEO of COBRA International comments: “Our collaboration with HG Robotics is going well, and we are hoping to collaborate further with them on other multi-rotor and fixed wing VTOL (vertical take-off and landing) drone models in the future. These are COBRA’s first parts for the agricultural industry, and they provide an exciting vision as to just a few of the possibilities for lightweight composites in this area and also in the wider commercial UAV market as a whole.”

More information:
glass fibers COBRA
Source:

COBRA International Ltd,

(c) Hexcel
04.03.2019

Hexcel at JEC World 2019

  • Hexcel’s Composite Innovations For Aerospace, Automotive, Energy And Marine Applications At JEC World 2019 Hall 5 - Stand J41

STAMFORD, Conn. – At this year’s JEC World taking place in Paris on March 12-14, Hexcel will promote a wide range of composite innovations for customer applications in aerospace, automotive, energy and marine markets.

Aerospace Innovations

Hexcel’s HiTape® and HiMax™ dry carbon reinforcements were developed to complement a new generation of HiFlow™ resin systems, producing high quality aerospace structures using the resin infusion process. HiTape® was developed for the automated lay-up of preforms and HiMax™ is a range of optimized non-crimp fabrics (NCF). Both products incorporate a toughening veil to enhance mechanical properties, meeting the structural requirements for aerospace parts.

  • Hexcel’s Composite Innovations For Aerospace, Automotive, Energy And Marine Applications At JEC World 2019 Hall 5 - Stand J41

STAMFORD, Conn. – At this year’s JEC World taking place in Paris on March 12-14, Hexcel will promote a wide range of composite innovations for customer applications in aerospace, automotive, energy and marine markets.

Aerospace Innovations

Hexcel’s HiTape® and HiMax™ dry carbon reinforcements were developed to complement a new generation of HiFlow™ resin systems, producing high quality aerospace structures using the resin infusion process. HiTape® was developed for the automated lay-up of preforms and HiMax™ is a range of optimized non-crimp fabrics (NCF). Both products incorporate a toughening veil to enhance mechanical properties, meeting the structural requirements for aerospace parts.

Visitors to JEC will see an Integrated Wing Panel demonstrator and an I-beam, both made with HiTape® reinforcements, and an Opticoms rib made with HiMax™ NCF. The Opticoms rib and I Beam were both manufactured using C-RTM (Compression Resin Transfer Molding). They were injected with Hexcel’s RTM6 resin in a process taking less than 5 minutes. The total manufacturing cycle for both parts was just 4.5 hours.

Also among the Aerospace exhibits, Hexcel will display a composite petal for a satellite antenna, manufactured by Thales Alenia Space Italia. The petal is part of a set of 24 deployable structural elements that form the large area reflector assembly used on board Low Earth Orbit (LEO) observation satellites. Thales Alenia Space Italia selected Hexcel’s HexPly® M18 prepreg for this application, acknowledging the superior mechanical and outgassing properties provided.

Another Hexcel prepreg application on show is a “zero” frame, manufactured by Aerofonctions for the engine area of Daher’s TBM 910/930 single-engine turboprop aircraft. Hexcel’s HexPly® M56 prepreg was selected by Daher for the “zero” frame – a product developed for Out of Autoclave applications that provides the same high quality and performance as autoclave-cured prepregs, from a simple vacuum bag cure in an oven.

With 50 years of experience behind its comprehensive range of high-strength, high-strain PAN-based carbon fibers, Hexcel continues to innovate, and is introducing two new fibers to its portfolio. HexTow® HM50 combines high modulus and high tensile strength, making it ideal for commercial and defense aircraft and engines. HexTow® 85 was developed specifically to replace rayon-based carbon fiber for ablative applications.

HexTow® carbon fiber holds the most qualified carbon fiber positions on aerospace programs in the industry and is the best unsized fiber available on the market. It provides excellent bonding interfacial properties with thermoplastic matrices and is the best-performing fiber for 3D printing applications.

Additive manufacturing is another area of expertise for Hexcel, using PEKK ultra-high performance polymers and HexAM™ technology to manufacture carbon-reinforced 3D printed parts. This
innovative process provides a weight-saving solution for intricate parts in highly demanding aerospace, satellite and defense applications. HexPEKK™ structures offer significant weight, cost and time-to-market reductions, replacing traditional cast or machined metallic parts with a new technology.

Hexcel is well known for its range of weight-saving, stiffness-enhancing honeycombs and the company adds value by providing a range of engineered core solutions to customers from facilities in the USA, Belgium and the newly opened Casablanca plant in Morocco. Hexcel’s engineered core capabilities enable highly contoured parts with precision profiling to be produced to exacting customer specifications. An example of such a part will be on display at JEC. Made from Aluminum FlexCore®, the part is CNC machined on both sides, and formed and stabilized with both peel ply and flyaway layers of stabilization. Aircraft engines benefit from a number of Hexcel core technologies including HexShield™ honeycomb that provides high temperature resistance in aircraft engine nacelles. By inserting a thermally resistant material into honeycomb cells, Hexcel provides a core product with unique heat-shielding capabilities that allows for the potential re-use of material after a fire event.

Hexcel’s Acousti-Cap® broadband noise-reducing honeycomb significantly improves acoustic absorption in aircraft engine nacelles. The acoustic treatment may be positioned at a consistent depth and resistance within the core, or can be placed in a pattern of varying depths and/or resistances (Multi-Degrees of Freedom and 3 Degrees Of Freedom), offering an acoustic liner that is precisely tuned to the engine operating conditions. These technologies have been tested at NASA on a full engine test rig and meet all 16 design conditions without trade-offs.

HexBond™ – the new name in Adhesives

Hexcel’s range of high performance adhesives has expanded considerably following the company’s acquisition of Structil. The company has now decided to unite the range by marketing all of its adhesive products using HexBond™ branding. The comprehensive range of HexBond™ structural film adhesives, foaming adhesive films, paste adhesives, liquid shims, epoxy fillets and Chromium free liquid primers is suitable for a wide range of applications in combination with Hexcel’s prepreg and honeycomb products.

Automotive Innovations

Hexcel’s carbon prepreg patch technology provides an innovative way of locally stiffening and reinforcing metal parts, providing noise and vibration management functionality. HexPly® prepreg patches consist of unidirectional carbon fiber impregnated with a fast curing epoxy matrix that has self-adhesive properties, enabling it to bond to metal in a highly efficient one-step process. These key technology properties are demonstrated in an 18.5kg aluminum subframe (that is 50% lighter than steel equivalents), which was reinforced with 500 grams of HexPly® prepreg and tested by Saint Jean Industries. The part demonstrates a significant reduction in noise, vibration and harshness (NVH). Other benefits include lower production costs, energy savings, increased driver comfort, production flexibility and part count reduction. With this technology Hexcel is a finalist in the JEC Innovation Awards 2019 in the Automotive Applications category.

HexPly® prepreg patch technology was also applied to a hybrid side sill demonstrator developed with Volkswagen and Dresden University to address future crash test requirements, specifically for electric cars. Combining fiber-reinforced plastic (FRP) with metal, the hybrid construction allows for optimum performance including weight savings, enhanced safety, increased energy absorption, battery protection in a crash situation and production flexibility.

Hexcel will also display a lightweight CFRP transmission crossmember produced from Hexcel’s high performance HexMC®-i 2000 molding compound. The transmission crossmember was developed in partnership with the Institute of Polymer Product Engineering (at Linz University), Engel and Alpex. As the part connects the chassis together and supports transmission it has to be stiff and strong, resisting fatigue and corrosion. Hexcel’s HexMC®-i 2000 was selected as the best-performing molding compound on the market, curing in as little as two minutes to produce lightweight, strong and stiff parts.
To produce the transmission crossmember HexMC®-i 2000 preforms are laid up in Alpex molds and compression-molded in a v-duo press that was tailored for the application by Engel. Ribs, aluminum inserts and other functions can be molded into the part using the single-stage process, reducing component-count. Any offcuts from the preforms can be interleaved between the plies of material to provide additional reinforcement in key areas - meaning that the process generates no waste.

Other Automotive promotions on Hexcel’s stand at JEC World include a composite leaf spring manufactured by ZF using HexPly® M901 prepreg. In contrast to steel leaf springs, composite versions offer many advantages including weight savings of up to 70%, high corrosion resistance, optimized system integration and superior performance. HexPly® M901 prepreg reduces the cure cycle to below 15 minutes and provides 15% higher mechanical performance, with enhanced fatigue properties. It also operates at high temperatures, providing a Tg of up to 200°C following a post cure.

Marine Innovations

Hexcel has a comprehensive range of products aimed at racing yacht and luxury boat builders that include America’s Cup, IMOCA class and DNV GL-approved prepregs, woven reinforcements and multiaxial fabrics for hull and deck structures, masts and appendages.

At JEC World Hexcel will display an IMOCA yacht mast manufactured by Lorima using HexPly® high modulus and high strength carbon fiber prepreg from Hexcel Vert-Le-Petit. Lorima is the exclusive official supplier of masts for IMOCA 60 class racing boats.

Hexcel’s HexTow® IM8 carbon fiber has been selected as the highest performing industrial carbon fiber on the market and will be used by spar and rigging manufacturer Future Fibres to manufacture their AEROrazr solid carbon rigging for all the teams in the 36th America’s Cup.

Hexcel’s HiMax™ DPA (Dot Pattern Adhesive) reinforcements are non-crimp fabrics supplied pre-tacked, allowing multiple fabrics to be laid-up more easily in preparation for resin infusion. Providing an optimal, consistent level of adhesion, they allow a faster and more consistent resin flow, as well as eliminating the use of spray adhesive for a healthier working environment and lower risk of contamination. Simply unrolled and applied to the mold or core layer before the introduction of resin, HiMax™ DPA fabrics are widely used in boat building, where lay-up times can be reduced by up to 50%.

Wind Energy Innovations

Hexcel has developed a range of HexPly® surface finishing prepregs and semi-pregs for wind turbine blades and marine applications. Providing a tough, durable and ready-to-paint surface without using in-mold coats, these products shorten the manufacturing cycle and reduce material costs. HexPly® XF2(P) prepreg is optimized for wind blades and has a ready-to-paint surface, straight from the mold, saving at least 2 hours of takt time.

Polyspeed® pultruded carbon laminates were developed for load-carrying elements in a blade structure and are manufactured with a polyurethane matrix that provides outstanding mechanical performance in terms of stiffness and durability. The blade manufacturing process is optimized, with increased throughput. The pultruded laminates are supplied in coils as continuous cross section profiles.
HiMax™ non-crimp fabrics using E-glass, high modulus glass and carbon fibers are also available in a wide range of unidirectional, biaxial and triaxial constructions. HiMax™ fabrics have applications throughout the turbine, from the stitched carbon fiber UDs used in the main structural elements, to glass fabrics and hybrids for blade shells and nacelles. There are also specialist applications such as lightweight fabrics for heated leading edge de-icing zones.

Source:

AGENCE APOCOPE

(c) AGENCE APOCOPE
22.10.2018

12 Composites Innovators to receive a JEC Innovation Award in Seoul next November 15, 2018

Twelve companies from eight different countries will receive a JEC Innovation Award at JEC Asia 2018. Asia-Pacific is an innovative region that sets the tone for all other regions of the globe. Once again, the JEC Innovation Awards highlight how composites bring solutions considering the new challenges in terms of efficiency, sustainability and life-cycle analysis.

This year, JEC Group awards innovations in the following categories: aerospace (structural and tooling), automotive, commercial vehicles, e-mobility, marine, railway, sports & leisure, infrastructure & civil engineering, industrial equipment, sustainability and additive manufacturing.

The ceremony will take place on Thursday November 15, 2018 at the COEX Center of Seoul (South Korea). Ida DAUSSY (Seo Hye-na), will host the ceremony in front of officials, manufacturers, scientists and composites professionals.

Twelve companies from eight different countries will receive a JEC Innovation Award at JEC Asia 2018. Asia-Pacific is an innovative region that sets the tone for all other regions of the globe. Once again, the JEC Innovation Awards highlight how composites bring solutions considering the new challenges in terms of efficiency, sustainability and life-cycle analysis.

This year, JEC Group awards innovations in the following categories: aerospace (structural and tooling), automotive, commercial vehicles, e-mobility, marine, railway, sports & leisure, infrastructure & civil engineering, industrial equipment, sustainability and additive manufacturing.

The ceremony will take place on Thursday November 15, 2018 at the COEX Center of Seoul (South Korea). Ida DAUSSY (Seo Hye-na), will host the ceremony in front of officials, manufacturers, scientists and composites professionals.

Category: AEROSPACE – STRUCTURAL
Winner: CSIR National Aerospace Laboratories (India)

Most of the composite structures for aircraft are made of carbon-epoxy composites, which can withstand a maximum service temperature of 130°C. As a consequence, carbon-epoxy materials cannot be used in hot zones like engine vicinity areas. The Aeronautical Development Agency (ADA) and CSIR-NAL took up the challenge of developing high temperature resistant composites for use in hot zones of light combat aircraft, which would result in significant weight and cost savings, as well as a considerable reduction in the meantime between failures (MTBF) due to thermal ageing.

The first task was to choose a material system with a service temperature of about ~ 200°C. During the material selection process, it was found that BMI resins are a relatively young class of thermosetting polymers. Hence, a carbon-BMI prepreg was selected due to a number of unique features including excellent physical property retention at elevated temperatures and in wet environments.

It was realized that weight savings and performance can be maximized using co-curing technology. This results in a large reduction of fabrication cycle times, costs and weight. Co-cured structures have fewer fasteners, which results in shorter assembly cycle times and also reduces sealing issues.

A prototype engine bay door assembly was built and tested at 180°C for flight certification. The engine bay door consists of an inner skin and co-cured outer skin assembly with eight transverse stiffeners. The stiffeners were designed with ‘J’ sections. The door size was 1.5 m length, 1 m width and 0.4 m overall depth. The co-cured door was developed using autoclave moulding. Two doors were installed in prototype aircraft and successfully flown.

26.02.2018

Hexcel’s Product Innovations for Aerospace, Automotive, Wind Energy and Marine at JEC WORLD 2018

STAMFORD, February 26, 2018 - at JEC World 2018, taking place in Paris March 6-8, Hexcel will display an array of product innovations for customer applications in aerospace, automotive, wind energy and marine markets.
Hexcel’s banner at the exhibit hall entrance features the Airbus H160 helicopter and A350 XWB aircraft, both with carbon fiber livery to acknowledge the high Hexcel composites content in both programs. Hexcel’s reinforcements, prepregs, adhesives and honeycomb materials were selected for the H160’s composite fuselage structures and main rotor blades, contributing to the lightweight fuel-saving design and performance optimization. Airbus has loaned Hexcel an H160 BLUE EDGE blade to display on the booth.

STAMFORD, February 26, 2018 - at JEC World 2018, taking place in Paris March 6-8, Hexcel will display an array of product innovations for customer applications in aerospace, automotive, wind energy and marine markets.
Hexcel’s banner at the exhibit hall entrance features the Airbus H160 helicopter and A350 XWB aircraft, both with carbon fiber livery to acknowledge the high Hexcel composites content in both programs. Hexcel’s reinforcements, prepregs, adhesives and honeycomb materials were selected for the H160’s composite fuselage structures and main rotor blades, contributing to the lightweight fuel-saving design and performance optimization. Airbus has loaned Hexcel an H160 BLUE EDGE blade to display on the booth.

Among the Aerospace promotions at Hexcel’s booth are carbon-reinforced 3D printed parts, made from Hexcel’s HexAM™ additive manufacturing technology that uses PEKK ultra-high performance polymers. Hexcel acquired this technology from Oxford Performance Materials in December 2017 to provide a weight-saving solution for intricate parts in highly demanding aerospace, satellite and defense applications. HexPEKK™ structures offer significant weight, cost and time-to-market reductions, replacing traditional cast or machined metallic parts with a new technology.

Aircraft engines benefit from a number of Hexcel technologies that will be promoted at JEC 2018, including HexShield™ honeycomb that provides high temperature resistance in aircraft engine nacelles. By inserting a thermally resistant material into honeycomb cells, Hexcel provides a core product with unique heat-shielding capabilities that allows for the potential re-use of material after a fire event.
Another honeycomb innovation from Hexcel is Acousti-Cap® broadband noise-reducing honeycomb that significantly improves acoustic absorption in aircraft engine nacelles. The acoustic treatment may be positioned at a consistent depth and resistance within the core, or can be placed in a pattern of varying depths and/or resistances (Multi-Degrees of Freedom and 3 Degrees Of Freedom), offering an acoustic liner that is precisely tuned to the engine operating conditions. These technologies have been tested at NASA on a full engine test rig and meet all 16 design conditions without trade-offs. An example of this technology will be on display at JEC 2018.

Rounding off the aircraft engine exhibits is a CTi fan blade for new generation lightweight turbofan engines from Rolls-Royce, manufactured from Hexcel’s HexPly® M91 high toughness and impact-resistant epoxy prepreg. Hexcel supplies HexPly® M91 as slit tape for the automated lay-up of the complex aerodynamic shape, with a constantly changing thickness across the blade length. The blade which is thinner and lighter than titanium fan blades is currently undergoing flight tests.
Hexcel’s HiTape® and HiMax™ dry carbon reinforcements that were developed for the automated lay-up of preforms for resin-infused aerospace structures will be promoted at the show. Two demonstrator parts, one made with HiMax™ and one with HiTape®, were both infused with HexFlow® RTM6 resin to demonstrate the potential benefits of an integrated design for aircraft skins, spars and stiffeners that meets OEM requirements for production rate increases and cost effectiveness.

Hexcel is also introducing its new range of HiFlow™ advanced liquid resins for aerospace structures manufactured by liquid molding technologies. Based on novel proprietary chemistry, the new resin family will enhance the performance of composites and ease processing when combined with HiTape® and HiMax™ dry carbon reinforcements. HiFlow™ HF610 is the first resin in the range.
Hexcel’s range of high performance adhesives has expanded considerably following the company’s acquisition of Structil last October. Hexcel is relaunching the acquired products under the new HexBond™ brand name at JEC World. This fast-growing range of pastes, liquid shim and film adhesives has a wide spectrum of operating temperatures and is in qualification with a large number of aerospace and industrial OEMs.
In the Planet Aerospace area at JEC, Daher and Hexcel will jointly display an aircraft spar manufactured from HexPly® M56 prepreg. Hexcel’s Neil Parker and Daher R&T Director Dominique Bailly will give a joint presentation focusing on the materials used and the benefits for the finished part. The aircraft spar was designed and manufactured by Daher using Hexcel’s HexPly® M56 prepreg, in slit tape format, that was developed for automated deposition and out-of-autoclave curing. The spar was manufactured using only the vacuum bag process and demonstrates very low porosity levels. It is currently undergoing testing and validation through CORAC funding.

Hexcel’s Automotive promotions at JEC World 2018 include a new prepreg for composite leaf springs, HexPly® M901. In contrast to steel leaf springs used for suspension on vans, trucks and SUVs, newer composite versions offer many advantages including weight savings of up to 70%, high corrosion resistance, optimized system integration and superior performance. Hexcel’s HexPly® M901 prepreg raises the bar further, reducing mold cure time below 15 minutes, a 50% reduction compared to standard industrial prepregs. HexPly® M901 provides 15% higher mechanical performance, with enhanced fatigue properties. It also operates at high temperatures, providing a Tg of up to 200°C following a post cure. Hexcel’s expertise in manufacturing heavy weight glass UD prepregs, with fiber areal weights of up to 1600gsm, allows the company to offer a highly cost-competitive solution for the rapid manufacture of these safety critical components.

Hexcel is constantly seeking ways to ensure that customers obtain the maximum benefit from composites and has recently acquired state-of-the-art simulation technology that accurately predicts how HiMax™ non-crimp fabrics will drape in a mold. Working in collaboration with Nottingham University Hexcel has created a car seat shell, for which the material selection was optimized using this new drape simulation technology. Visitors to Hexcel’s stand at JEC will see an on-screen demonstration that illustrates how the simulation tool operates, predicting process and performance and ensuring that the optimum fabric architecture is quickly identified, reducing the need for expensive trial programs.
Hexcel’s HexMC®-i 2000 carbon fiber/epoxy molding compound has been successfully used by Audi to manufacture a high-performance engine cross brace. HexMC®-i is a fast curing high-performance molding material, suitable for the series production of complex shaped parts and providing excellent mechanical properties. The Audi cross brace covers the engine, providing torsional stiffness for enhanced drive dynamics.

Hexcel’s product offering for customers in the Marine industry has expanded following the acquisition of Formax in 2016 and Structil in 2017. At JEC World, Hexcel will promote its enhanced portfolio of carbon fibers, prepregs, woven reinforcements and multiaxial fabrics for builders of racing catamarans and luxury yachts.
Marine customers have supplied a number of parts for display to illustrate their expertise in manufacturing composite structures from Hexcel materials. These include part of a Diam 24 yacht mast made by ADH Inotec from Hexcel’s HexPly® M79 fast curing, low temperature cure prepreg. ADH Inotec purchased the prepreg from Composites Distribution, a Hexcel Official Distributor that also supplied HexPly® M9.6 prepreg to Lorima for the Outremer 5X catamaran mast section on display. Part of Lorima’s 42m wing mast for a multihull racing boat made with HexPly® prepreg from Vert-Le-Petit (formerly Structil) will complete the marine display.

Hexcel’s innovations for Wind Energy include Polyspeed® pultruded laminates for load-carrying elements in wind blades. These continuous cross-section profiles, made from a polyurethane matrix reinforced with unidirectional carbon fiber, provide consistently high mechanical properties, including high stiffness, fracture toughness and shear strength, combined with low weight and durability. Visitors to Hexcel’s stand will see a 2m diameter coil of pultruded carbon laminate that contains 255m of material in a single roll. This technology offers an economical way of reinforcing large-scale composite structures such as wind turbine blades. Hexcel will also launch its surface finishing prepreg for wind turbine blades and components. This provides a tough, durable and ready-to-paint blade surface without the use of gel coat and results in faster blade manufacture, saving time in production and reducing material costs. The benefits of the new surfacing prepreg will be demonstrated via a wind blade exhibit that has been given four different treatments across the blade surface. These include a section with gel coat, a section of standard prepreg without gel coat, and a section where a fleece has been added to improve surface quality but still requires preparation before painting due to pin holes. The final section made with new HexPly® XF2P surfacing prepreg has a ready-to-paint surface, straight from the mold, without any requirement for gel coat, fleece or finishing operations.

More information:
Hexcel JEC World 2018 Aircraft
Source:

Dorothée DAVID & Marion RISCH, AGENCE APOCOPE