From the Sector

• Interfilière Paris, 6th-8th July 2019, booth D60

Able to offer an alchemy of design and sustainable innovation, Iluna Group with ROICA™ by Asahi Kasei join the latest edition of the Parisian tradeshow for lingerie with a range of innovations capable of combining innovation, aesthetics and quality. "Ethical" lace and stockings, where quality standards go hand in hand with fashion content, respecting both the environment and humans, an offer already selected among the protagonists of the Sustainable Thinking Exhibition of the Salvatore Ferragamo Museum, for its value in the field of responsible innovation.

Experts in the production of stretch lace since 1985, ILUNA today represents the largest European laces’producer. Thanks to the effectiveness of their responsible innovation strategy, Iluna Group has been the very first lace producer to have gained the GRS (Global Recycled Standard) for their transformed products, together with the company certification STeP (Sustainable Textile Production by Oeko –Tex®).
A relevant achievement for the firm that, thanks to the Green Label collection, now even richer, make responsible innovation an asset for production that focuses on smart ingredients as ROICA Eco-Smart™ family and Q-Nova® by Fulgar.

A range that culminates today in the launch of an athleisure and sporty-chic capsule collection that perfectly fit the contemporary modern wardrobe, result of a qualified and totally traceable supply chain, from yarn up to garment, based on design, sustainability and performance.

Of major interest is the fact that the Iluna fashion R&D based its strategic choice for the AI2020/2021 on the extension of the offer with new Black label’s developments between lace and embroidery, the premium R&D line.

The range of new Ultralight multicolor laces offers jacquardtronic and textronic 4 or 5 colours galloons with a 3D effect. The change of the color of thread in the background as well as in the design gives life to unique coordinated solutions for creatives. The match between expectations of brands and retailers are met always keeping as a priority the contemporary design, that is integrated to unique strategy committed to responsibility both at corporate and product level.

To ILUNA smart innovation is not just a project, its space at Interfilière where visitors will have the chance to discover the new collection and above all to experience and touch latest boundaries of lace smart innovations pursued staying true to the values the brand. Iluna team is pleased to welcome you with a special cadeaux created in collaboration with ROICA™ by Asahi Kasei.

Market and technology analysis confirms big potential for tape inserts in the injection molding process. Following the finalization of a major consortial project led by the Aachen Center for Integrative Lightweight Production (AZL) and the Institute for Plastics Processing at RWTH Aachen University (IKV), the result is clear: tape inserts offer enormous potential for injection molding parts. For suitable components, product costs and component properties can be positively influenced.

In cooperation with 20 industrial partners, the two renowned Aachen research institutes AZL and IKV carried out a detailed analysis of tape inserts in injection molded components over a period of eight months. The tapes, which are a few tenths of a millimeter thick, are continuous fibers, typically made of glass or carbon, completely impregnated and embedded in a thermoplastic matrix. The tapes can be precisely aligned to the loads in a component and are used primarily in high-performance applications with the aim of weight reduction. The aim of the conducted analysis was the identification of potential applications and the estimation of a wider range of applications.

The project was divided into several phases: Phase I was used to identify the current status. In 20 interviews with representative companies of the injection molding industry, the researchers gathered why tape inserts have rarely been taken into account so far, when defining the material concepts to be analyzed. The lack of information about the material class, the procedure and tools for the development process and the necessary production technologies were cited as major challenges. This is where the consortium will take action and provide comprehensive information during the “Technology Information Day” on the extensively prepared state of the art and the high degree of maturity of the supply chain. Based on the status quo, they developed a methodology for analyzing the technological and economic potential of tape inserts in injection molding applications.

Both the previous results and the planned follow-up projects are the subject of the “Technology Information Day" at K 2019, to which the companies involved in the study, the AZL and IKV, invite all companies along the value chain, from raw material manufacturers to injection molders to OEMs. (Date: 18th October 2019, 10:00 am to 1:30 pm, Trade Fair Düsseldorf CCD South, Room 002).

The consortium, amongst others consisting of Asahi Kasei Europe GmbH, BASF SE, Borealis AG, BÜFA Thermoplastic Composites GmbH & Co. KG, ENGEL AUSTRIA GmbH, Huesker Synthetic GmbH, LG Hausys R&D Center, Mitsui Chemicals, Nippon Electric Glass, Polyscope Polymers BV, POLYTEC GROUP, Simcon kunststofftechnische Software GmbH, SABIC and Toray International Europe GmbH, is inviting to the “Technology Information Day” at K 2019. The goal is to inform about the technology and to identify topics for future collaboration.

Re.VerSo™ will be on hand at Première Vision to present refined and innovative materials that inspire creativity and infuse technology. Worth to highlight, the fact that, at the beginning of 2019, Re.VerSo™ has been selected as one of the protagonists of the Sustainable Thinking project of the Museo Salvatore Ferragamo, thanks to the value it bears in the field of responsible innovation. Representing excellence as the result of a culture of Made in Italy traditions, combined with a new vision of Smart Innovation, Re.VerSo™, the advanced supply chain, integrated, transparent and traceable, 100% Made in Italy, covers the woven textiles market through the unique offer of A. Stelloni Collection by Mapel.

For next season, A.Stelloni Collection by Mapel offers even more Re.VerSo™ solutions with strong focus on noble fibres such as Re.VerSo™ Baby Camel and Re.VerSo™ Cashmere for coats and jackets. New finishes, draps, streaks, velours and, mostly, Re.VerSo™ Baby Camel developments, as the company is becoming leader for the sustainable Camel market.

Sappi to present its innovative papers and packaging solutions at FachPack 2019

Environmentally friendly packaging is a hot topic worldwide. Sappi has been a pioneer in the field of innovative and sustainable packaging solutions for years. The company will present its latest innovations at Stand 9-260 at FachPack in Nuremberg. Alongside barrier papers, these include the heat-sealable Sappi Seal paper. This is notable for being completely recyclable and can replace existing PE-coated packaging. The recently launched Atelier paperboard will be another focus of the trade fair presentation. This offers brilliant colour reproduction and a silky touch and feel.

Able to offer an alchemy of design and sustainable innovation, Iluna Group with ROICA™ by Asahi Kasei join the latest edition of the Milano Unica fair with a range of innovations capable of combining innovation, aesthetics and quality. "Ethical" lace and stockings, where quality standards go hand in hand with fashion content, respecting both the environment and humans, an offer already selected among the protagonists of the Sustainable Thinking Exhibition of the Salvatore Ferragamo Museum, for its value in the field of responsible innovation.

Experts in the production of stretch lace since 1985, ILUNA today represents the largest European laces’producer. Thanks to the effectiveness of their responsible innovation strategy, Iluna Group has been the very first lace producer to have gained the GRS (Global Recycled Standard) for their transformed products, together with the company certification STeP (Sustainable Textile Production by Oeko – Tex®).

"Beyond Conventional Function" is the exciting special topic at the PERFORMANCE FORUM of the next PERFORMANCE DAYS. Besides the obvious beauty, which is the main topic at the upcoming trade fair, often it is the fabrics that also hide some special added benefit that are of particular interest.

THE BEAUTY OF FUNCTION is the main theme at the next PERFORMANCE DAYS trade fair for functional fabrics and accessories on May 8-9th, 2019 in Munich. Around 300 exhibitors present various interpretations of beauty across all categories in their functional fabrics. Although obviously designed for beauty, these innovative fabrics also promise many hidden benefits at the same time. At the PERFORMANCE FORUM, a special area on the PERFORMANCE WALL is devoted to the most important of these special fabrics, rather than highlighting just one of the fabrics in the context of an award.

The PERFORMANCE JURY selected fabrics from well over 1.100 manufacturer submissions; not only fabrics with an interesting look and feel with essential functions like climate regulation and weather protection for sports, but also fabrics that provide the wearer of the garment with additional benefits and special comfort. These special fabrics represent the motto: "Beyond Conventional Function."

China is the world’s undisputed front-runner in the global car market, leading the way in both production and sales. 2018 saw 27.8 million vehicles produced and domestic sales of 28.1 million, and while these numbers were down slightly year-on-year, the opportunities for global textile producers are still unrivalled given the overall size of the market. These opportunities can best be explored at this year’s biennial China International Nonwovens Expo & Forum (CINE – supported by Techtextil), which runs from 3 – 5 June in Shanghai.
While CINE features nonwovens & nonwoven products, machinery for nonwovens and raw materials & chemicals for nonwovens for a wide range of applications, it is the potential in the automotive sector that is generating a lot of talk before this June’s event. And considering only around 50% of demand for automotive textiles is met by domestic output, the opportunities for imports from overseas suppliers is high.

While new car sales in China dropped for the first time last year since 1992, production still reached 27.8 million vehicles, including 23.5 million passenger cars and 4.3 million commercial vehicles. Furthermore, strong growth is still evident in new energy vehicle (NEV) sales, as well as exports of all vehicle types. NEV production totalled 1.27 million units last year, a staggering 60% increase, while sales grew by nearly 62%. More e-vehicles are sold in China than rest of the world combined, while the government recently set a target of selling 7 million e-vehicles by 2025, ensuring growth in this sector will remain robust for some time. Exports of all vehicle types in 2018 did not grow as fast as NEVs, but the 1.04 million vehicles produced for overseas markets last year still represented growth of 16.8%.

Premium automotive industry buyers attend CINE
Given CINE’s strong reputation in the Chinese nonwovens sector, a number of leading automobile brands, and textile suppliers to these companies, source at the fair. Previous buyers have included Autoliv, Honeywell, Johnson Controls, Lear Corporation, Lydall, Toyota Boshoku, Volkswagen, Wangbo Co Ltd and more.

This edition, buyers such as these can source from a range of automotive nonwovens suppliers. This includes Shanghai Shenda, one of the country’s largest producer of automotive textiles, who will group together a number of automotive interior suppliers.

This year the fair will take place in a new venue, the Shanghai Convention & Exhibition Center of International Sourcing, located conveniently between Hongqiao airport and downtown Shanghai. Visitor registration for the fair is now open and can be accessed here: http://vis.eastfair.com/CINEPCEN/reg.aspx.

JEC WORLD 2019 closed successfully on Thursday, March 14, after three intense days of innovation, networking and knowledge sharing. "With more than 112 participating countries and 27 national pavilions, JEC World – the place where the world of Composites meets – gathered the key players of the industry and their representatives, as illustrated by the premiere meeting of the global and European industry associations. On top of that, the show highlighted the dynamic ecosystems of composite materials in France, Turkey as well as in the Netherlands, thanks to the special visit in Paris and an active participation of their companies, officials and government bodies,” Adeline Larroque, Show director JEC World explains.
JEC World organizers created special tracks, displays and conference programs dedicated to the specific audience of Aerospace, Automotive and Construction sectors, for everyone to better understand the benefits offered by Composites in these applications.

• 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.

At the joint stand of the Aachen Centre for Integrative Lightweight Construction (AZL) in Hall 5A, booth D17, the Institut für Textiltechnik of RWTH Aachen University (ITA) will demonstrate its expertise in the field of glass fibres, preforms and textile concrete 12-14 March 2019 in Paris.
The exhibits come from various fields of application and address the automotive, aerospace and mechanical engineering sectors.

1. Innovative glass fibre research at ITA
   The newly constructed induction heated glass fibre production line enables increased flexibility in research. For the first time, glass fibres will be produced live at the ITA booth at JEC World. One of the innovations of the system is the inductively heated bushing. It features a flexible design and consists of a platinum/rhodium alloy (Pt/Rh20) for use in high-temperature glasses.
   The glass fibre production line was designed in such a way that new concepts and ideas can be tested quickly. The modular design allows a high flexibility, the induction system a significantly faster operability.
   Research and development projects can therefore be carried out faster and more cost-effectively.
    
2. DrapeCube - Forming of textile semi-finished products
   The DrapeCube offers a cost-effective design for the production of fibre preforms from textile semi-finished products. It is used in the production of preforms for prototypes and in small series and is suit-able for companies active in the production of fibre-reinforced plas-tics (FRP).
   In the production of FRP components, the preforming process de-fines a large part of the subsequent component costs. In small- and medium-sized enterprises, this process step is often still carried out manually. This results in high quality fluctuations and component prices. Especially in the case of highly stressed structural components, the fluctuation in quality leads to oversizing of the components.
   Thus, the lightweight construction potential of fiber-reinforced plastics is underused. One solution is offered by the stamp forming process adapted from the sheet metal forming industry for shaping rein-forcing textiles. The textile is inserted between two mould halves (male and female) and automatically formed. Due to high plant and tooling costs, this process is used almost exclusively in large-scale production.
   The ITA has developed the DrapeCube forming station which offers a cost-effective alternative and is able to completely reproduce the current state of the art for forming textile half branches. The process steps will be demonstrated in a video at the booth.
    
3. Carbon fibre reinforced plastic (CFRP) preform
   The CFRP preform consists of carbon multiaxial fabrics formed by expanded polystyrene (EPS) to optimise draping quality. Preforms of increased quality can be produced by gentle, textile-compatible forming with foam expansion. For the first time, foam expansion was used to form preforms in such a way that the draping quality is improved compared to classic stamp forming.
   The advantages of the CFRP preform lie in the savings in plant costs, as the investment is much lower. In addition, the proportion of waste is reduced because near-net-shape production is possible. In addition, rejects are reduced, as fewer faults occur in the textile.
    
4. Embroidered preform with integrated metal insert
   The 12k carbon fibre rovings are shaped into a preform using Tai-lored Fibre Placement (TFP) which is a technical embroidery pro-cess. For the further layer build-up, a fastener is not only integrated under the roving layers but also fixed by additional loops. The highly integrative preforming approach offers the possibility of reducing weight and process steps as well as increasing mechanical perfor-mance.
   Until now, inserts were glued or holes had to be drilled in the com-ponent. Bonded fasteners are limited by the adhesive surface. The bonding of fasteners into drilled holes results in high drill abrasion and thus high tool wear.
   The advantages of the embroidered preform with integrated metal fasteners are the reduction of scrap due to TFP preforming and the increase in the specific pull-out force. In addition, it is possible to automatize the production of integrative preforms. This makes the preform with integrated metal fasteners interesting for the automotive and aerospace industries.