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20.03.2025

SGL Carbon: Business development in 2024 in line, decreasing sales markets expected for 2025

Increasingly weaker demand from key sales markets over the course of 2024 is slowing SGL Carbon's sales and earnings growth. Group sales in 2024 amounted to €1,026.4 million, down slightly by 5.8% on the prior-year level (2023: €1,089.1 million). The group's adjusted EBITDA decreased by 3.3% to €162.9 million (2023: €168.4 million).

Despite the slight decline in sales, the adjusted EBITDA margin improved from 15.5 % in the previous year to 15.9 % in 2024. This is mainly due to positive price and product mix effects.

Declining demand from the key semiconductor and automotive markets, coupled with persistently unsatisfactory demand from the wind industry, led to a decrease in volume and sales in three of four business units. Only Process Technology was able to improve its sales and adjusted EBITDA.

Increasingly weaker demand from key sales markets over the course of 2024 is slowing SGL Carbon's sales and earnings growth. Group sales in 2024 amounted to €1,026.4 million, down slightly by 5.8% on the prior-year level (2023: €1,089.1 million). The group's adjusted EBITDA decreased by 3.3% to €162.9 million (2023: €168.4 million).

Despite the slight decline in sales, the adjusted EBITDA margin improved from 15.5 % in the previous year to 15.9 % in 2024. This is mainly due to positive price and product mix effects.

Declining demand from the key semiconductor and automotive markets, coupled with persistently unsatisfactory demand from the wind industry, led to a decrease in volume and sales in three of four business units. Only Process Technology was able to improve its sales and adjusted EBITDA.

Earnings performance in the past fiscal year was strongly affected by non-recurring items of minus €118.5 million (2006: minus €52.9 million). These mainly included the impairment of assets of the Carbon Fibers business unit totaling €91.2 million (previous year: €44.7 million) and expenses from restructuring measures in the Carbon Fibers and Battery Solutions business lines totaling €19.0 million. After deducting one-off effects and non-recurring items as well as depreciation and amortization of €58.7 million (2023: €58.9 million), EBIT amounted to minus €14.3 million in 2024 (2023: €56.6 million).

Taking into account the financial result of minus €32.6 million (2023: minus €34.2 million) and tax expenses of €32.5 million (2023: €19.3 million), SGL Carbon recorded a net loss of €80.3 million (2023: net profit of €41.0 million) despite the solid overall business performance.

In 2024, the Carbon Fibers (CF) business unit's sales continued to decline, decreasing by 6.7% to €209.8 million (2023: €224.9 million). The decline was due in particularly to the continued low demand from the wind industry and the increasing competitive headwind resulting from global overcapacity for textile and carbon fibers.

Adjusted EBITDA in the Carbon Fibers business unit decreased by €18.2 million year-on-year to minus €11.0 million (2023: €7.2 million). The lack of fixed cost absorption led to high idle capacity costs and combined with declining margins for our fiber products, had a negative impact on adjusted EBITDA. It should be noted that the Carbon Fibers business unit included the result of the equity accounted activities (mainly the joint venture Brembo SGL Carbon Ceramic Brakes, BSCCB) in the amount of €15.8 million (2023: €18.3 million). Excluding the contribution from the equity-accounted BSCCB, the adjusted EBITDA of Carbon Fibers would amount to minus €27.0 million (2023: minus €10.9 million).

In February 2025, as part of the review of all strategic options for the Carbon Fibers, a decision was made to extensively restructure the Carbon Fibers business unit, which also includes the closure of unprofitable business activities. A complete sale of the Carbon Fibers activities was reviewed and is currently not considered feasible.

In the reporting period, sales in the Composite Solutions (CS) business unit amounted to €124.6 million, down 19.0% (2023: €153.9 million). The decline was due in particular to the premature expiration of a significant project-related supply contract with an automotive customer.

As a result of lower volumes and product mix effects, CS's adjusted EBITDA decreased by €4.0 million or 18.0% year on year to €18.2 million (2023: €22.2 million). It should be noted that the adjusted EBITDA includes a compensation payment of €3.0 million for a prematurely terminated customer contract. The adjusted EBITDA margin remained almost constant at 14.6% compared to the previous year (2023: 14.4%).

Forecast
For the year 2025, SGL Carbon expects different but overall challenging developments in their key sales markets. For the semiconductor industry and in particular for silicon carbide-based semiconductors, the demand is expected to remain moderate. The main reasons are lower than originally forecast growth rates for electric vehicles and continued high inventories at our customers site. At the earliest, demand could pick up in the second half of 2025. The company also expects a high degree of uncertainty combined with lower momentum for the automotive market segment.

The forecast for the current fiscal year 2025 takes into account all four operating business units, as they are still in the early stages of restructuring our Carbon Fibers business. Based on their assumptions regarding the development of the key sales markets, the managers expect consolidated sales for fiscal year 2025, including all business units, to be slightly below the previous year (2024: €1,026.4 million).

Taking into account all four operating business units, an adjusted EBITDA in 2025 is expected to range between €130 million and €150 million. Furthermore, the assumption is that the free cash flow at the end of the 2025 financial year - excluding payments for the planned restructuring of the CF - will be below the previous year's level but still positive (2024: €38.7 million).

Restructuring Carbon Fibers
On February 18, 2025, the Board of Management of SGL Carbon announced a restructuring of the loss-making CF business unit. This includes a significant reduction of CF's business activities and a focus on a profitable core. SGL Carbon's group sales guidance for 2025 excluding the expected sales contribution from CF would be approximately €200 million lower. On the other hand, the adjusted EBITDA for the remaining businesses excluding the operating adjusted EBITDA of CF would be between 155 – 175 million €.

“In the coming months, our work will focus on restructuring the carbon Fibers business unit and safeguarding our profitability. This includes focusing on new sales opportunities to further utilize our production capacities and strict cost management. The major trends such as digitization, climate-friendly transportation and renewable energy sources remain intact and are the drivers for our key sales markets. SGL Carbon will benefit from these trends and the associated growth opportunities in the medium and long term,” explains Andreas Klein, CEO of SGL Carbon SE.

Source:

SGL Carbon SE

from left: Dr. Erik Frank (DITF), Britta Waschl (e5) Photo: DACCUS-Team
from left: Dr. Erik Frank (DITF), Britta Waschl (e5)
31.01.2025

Lightweight construction: JEC Composites Innovation Award 2025 for CO2-negative house walls

At this year's JEC Composites Innovation Awards ceremony, the award in the "Construction & Civil Engineering" category went to the "DACCUSS" project, coordinated by the DITF. TechnoCarbon Technologies GbR, the inventor of Carbon Fiber Stone (CFS), received the JEC Award together with its development partners. The award is for the development of house walls made of Carbon Fiber Stone (CFS), a CO2 negative composite material.

Each year, the JEC Composites Innovation Awards recognize innovative and creative projects that demonstrate the full potential of composite materials. With the help of a development team from 12 companies and research institutions, TechnoCarbon Technologies GbR successfully submitted its innovative DACCUSS building element for house walls made of Carbon Fiber Stone.

At this year's JEC Composites Innovation Awards ceremony, the award in the "Construction & Civil Engineering" category went to the "DACCUSS" project, coordinated by the DITF. TechnoCarbon Technologies GbR, the inventor of Carbon Fiber Stone (CFS), received the JEC Award together with its development partners. The award is for the development of house walls made of Carbon Fiber Stone (CFS), a CO2 negative composite material.

Each year, the JEC Composites Innovation Awards recognize innovative and creative projects that demonstrate the full potential of composite materials. With the help of a development team from 12 companies and research institutions, TechnoCarbon Technologies GbR successfully submitted its innovative DACCUSS building element for house walls made of Carbon Fiber Stone.

Carbon Fiber Stone is a building material made of natural rocks and bio-based carbon fibers. It serves as an environmentally friendly replacement for CO2-intensive concrete in the construction industry. While conventional concrete walls release large amounts of CO2 during production, the DACCUS building element binds 59 kg of CO2 per square meter and therefore has a negative carbon footprint. In addition, the panels weigh only one-third of equivalent reinforced concrete house walls.

Each DACCUS element consists of several high-strength natural stone slabs made from magmatic rock. Inside the construction are bio-based carbon fibers, which the DITF Denkendorf is working intensively to develop. They form the stiffening element that enables the high strength of the construction elements and, in turn, contribute to the negative CO2 balance. The layer between the natural rock slabs is filled with carbon-negative biochar granulate, which is responsible for the insulation of the building element. The mineral sawdust from the cut rock slabs can be used as a soil amendment and serves as a binder for free CO2 from the atmosphere. The strict focus on processes and materials that actively bind CO2 has made it possible to produce a building material with a negative CO2 balance.

Partners: Deutsche Institute für Textil- und Faserforschung Denkendorf (DITF), TechnoCarbon Technologies GbR, Universität Hamburg (UHH), Labor für Stahl- und Leichtmetallbau GmbH (LSL), AHP GmbH & Co. KG, Technische Universität München (TUM), GVU mbH, Silicon Kingdom Holding Ltd., Gallehr Sustainable Risk Management GmbH, Peer Technologies GmbH & Co. KG, GREIN srl, Convoris Group GmbH, RecyCoal GmbH, ITA, Institut für Textiltechnik der RWTH Aachen, LISD GmbH.

Source:

Deutsche Institute für Textil- und Faserforschung DITF

10.11.2024

SGL Carbon: Business Report 3Q

Weak demand in some of their customer markets is increasingly hindering SGL Carbon's sales growth. After nine months in 2024, SGL Carbon generated sales of €781.9 million, which was slightly below the prior-year level at minus 4.8% (9M 2023: €821.7 million). Adjusted for currency and structural effects, Group sales decreased by 3.6%. Adjusted EBITDA, an important key figure for the Group, remained at a comparable level of €127.6 million in the reporting period (9M 2023: €130.0 million). Despite the slight decrease in sales, the adjusted EBITDA margin improved from 15.4% in Q1 and 16.7% in Q2 to 16.9% in Q3 and amounted to 16.3% after nine months (9M 2023: 15.8%). The reasons for the improved adjusted EBITDA margin are, in particular, product mix effects in the Graphite Solutions and Process Technology business units. By contrast, the ongoing weakness in demand and the associated price pressure for carbon and textile fiber products in the Carbon Fibers business unit continued to weigh on the Group's sales and earnings development.

Weak demand in some of their customer markets is increasingly hindering SGL Carbon's sales growth. After nine months in 2024, SGL Carbon generated sales of €781.9 million, which was slightly below the prior-year level at minus 4.8% (9M 2023: €821.7 million). Adjusted for currency and structural effects, Group sales decreased by 3.6%. Adjusted EBITDA, an important key figure for the Group, remained at a comparable level of €127.6 million in the reporting period (9M 2023: €130.0 million). Despite the slight decrease in sales, the adjusted EBITDA margin improved from 15.4% in Q1 and 16.7% in Q2 to 16.9% in Q3 and amounted to 16.3% after nine months (9M 2023: 15.8%). The reasons for the improved adjusted EBITDA margin are, in particular, product mix effects in the Graphite Solutions and Process Technology business units. By contrast, the ongoing weakness in demand and the associated price pressure for carbon and textile fiber products in the Carbon Fibers business unit continued to weigh on the Group's sales and earnings development.

“Even with our diversified product portfolio, we can no longer completely withdraw from the generally weak economic environment. In addition, there was a decline in demand for specialty graphite products for the semiconductor industry in the third quarter. In particular, our products for the manufacture of silicon carbide-based semiconductors are suffering from the restrained demand for electric vehicles on the customer side,” explains CEO Dr. Torsten Derr. “While the last 18 months were characterized by enormous demand for silicon carbide semiconductors and insufficient production capacities, the market has cooled down significantly. Due to a lack of demand from the automotive industry, our semiconductor customers have significantly reduced order volumes. We do not expect to see a significant upturn in demand for our specialty graphite products until the sales figures for electric vehicles pick up again.”

Based on the adjusted EBITDA of €127.6 million and taking into account depreciation and amortization of €41.0 million (9M 2023: €43.3 million) and one-off effects as well as non-recurring items of minus €18.3 million (9M 2023: minus €47.2 million), EBIT after nine months of 2024 will be €68.3 million (9M 2023: €39.5 million). The one-off effects and non-recurring items result, among other things, from the restructuring measures at Carbon Fibers and the Battery Solutions business line as well as from expenses for a strategy project. When comparing with the previous year, it should be noted that the first nine months of 2023 were disproportionately affected by an impairment loss on the assets of Carbon Fibers (€44.7 million).

Development of the business units
The Carbon Fibers business unit's sales for the first nine months of 2024 amounted to €157.1 million, significantly below the figure of €179.6 million for the prior-year period. The decline is due in particular to the continued weak demand from the wind industry and to the increasing competitive pressure resulting from global overcapacities for carbon and textile fibers.

Idle production capacities and the associated lack of fixed cost absorption as well as declining margins for commodity products led to a further deterioration in the adjusted EBITDA of the Carbon Fibers. The adjusted EBITDA of the Carbon Fibers business unit fell to minus €7.9 million in the first nine months of 2024 (9M 2023: €3.2 million). It should be noted that the adjusted EBITDA of the Carbon Fibers business unit includes an earnings contribution of €11.6 million from the joint venture BSCCB, which is accounted for At-Equity (9M 2023: €14.1 million). Excluding this contribution from the At-Equity accounted BSCCB, the adjusted EBITDA of Carbon Fibers would have been minus €19.6 million (9M 2023: minus €10.5 million).

SGL Carbon assumes that demand for carbon fibers will not recover in the coming months and that the realizable prices for these products will remain at a low level beyond 2025. Therefore, SGL Carbon anticipates that the expected improvement in sales and earnings for the Carbon Fibers segment will be delayed and is revising its existing mid-term planning for this segment. Due to the expected deviation, an ad hoc impairment test is currently being carried out. This indicates a non-cash impairment charge of €60–80 million, which will be recognized in Q4 2024. The structured transaction process initiated for Carbon Fibers is still ongoing.

Sales in the Composite Solutions business unit amounted to €95.8 million in the first nine months of 2024, down 16.2% (9M 2023: €114.3 million). The decline is due in particular to the early termination of a project-related supply contract with an automotive customer. Furthermore, the lower sales figures for electric vehicles are also having an impact on Composite Solutions.

Adjusted EBITDA in Composite Solutions fell from €16.6 million in the prior-year period to €10.7 million (minus 35.5%), due in particular to lower volumes. The adjusted EBITDA margin weakened accordingly to 11.2% (9M 2023: 14.5%).

Outlook
Macroeconomic conditions, lower than expected sales volumes in some customer groups and price pressure for commodity products are increasingly hindering SGL Carbon's growth ambitions. Thomas Dippold, CFO of SGL Carbon, explains: “Due to the diverse and diversified industrial applications of our products and our strict cost management, we continue to expect to achieve our guidance for 2024 at the lower end of the range of €160–170 million. The coming months will not be easier. We need to prepare for a flat demand development in some of our sales markets.”

More information:
SGL Carbon business report
Source:

SGL Carbon SE

24.10.2024

SGL Carbon SE: Impairment in the Carbon Fibers business unit

With the publication of the half-yearly figures for 2024, SGL Carbon already announced that the company expects to achieve its adjusted EBITDA guidance for fiscal year 2024 at the lower end of the range of €160 to 170 million. Based on the preliminary figures for the first nine months of the fiscal year 2024, SGL Carbon confirms this statement.

With the publication of the half-yearly figures for 2024, SGL Carbon already announced that the company expects to achieve its adjusted EBITDA guidance for fiscal year 2024 at the lower end of the range of €160 to 170 million. Based on the preliminary figures for the first nine months of the fiscal year 2024, SGL Carbon confirms this statement.

According to preliminary figures, Group sales of SGL Carbon for the first nine months of fiscal year 2024 decreased by 4.8% year on year to €781.9 million (9M 2023: €821.7 million). Preliminary adjusted EBITDA, on the other hand, remained at a comparable level to the prior-year period, at €127.6 million (9M 2023: €130.0 million). Despite the slight sales decline, the adjusted EBITDA margin improved to 16.3% after nine months in 2024 (9M 2023: 15.8%). The reasons for the improved adjusted EBITDA margin are, in particular, product mix effects in the Graphite Solutions and Process Technology business units. By contrast, the ongoing weakness in demand for carbon and textile fiber products in the Carbon Fibers business unit and the early termination of a customer contract at Composite Solutions weighed on the Group's sales and earnings development.

The business unit Carbon Fibers manufactures carbon and textile fibers for the wind and automotive industries as well as various industrial applications. As expected by the Company for the fiscal year 2024, demand for carbon fibers from the wind and automotive industries remains weak. In addition, there is increasing competitive and price pressure due to global overcapacity for both carbon fibers and textile fibers. The company does not expect demand to recover in the coming months and the realizable prices for these products will remain at a low level beyond 2025. Furthermore, SGL Carbon expects that the anticipated improvement in sales and earnings for the Carbon Fibers business unit will be delayed and is revising its existing medium-term planning for Carbon Fibers.

Due to the associated expected deviation an event-driven impairment test is currently being carried out. This indicates a non-cash impairment charge of €60–80 million, which will be recorded in the fourth quarter of 2024. The impairment relates exclusively to Carbon Fibers; the operating business of the other business units is not affected.

SGL Carbon's equity ratio after the impairment is approx. 40% (September 30, 2024: 43.3% according to preliminary figures).

The review of all strategic options for the Carbon Fibers business unit, which was announced by SGL Carbon on February 23, 2024, and has already begun, remains unaffected by the impairment and is currently continuing.

colouring process Photo (c) Hypetex
22.05.2024

First technical coloured flax fibre replacing carbon fibre?

British technology company Hypetex has been awarded a significant grant from Innovate UK to develop the world’s first technical coloured flax fibre, which will have applications in the sustainable manufacturing of cars, boats and other products that are usually made with carbon fibre.

Called FlaxTex the material is strong, lightweight and 100 per cent biodegradable, having a net positive carbon footprint at point of manufacturing. It can be colourised whilst enhancing its performance properties, with the process adding some important manufacturing attributes compared to standard flax fibre.

As such, FlaxTex’s mechanical properties represent the closest sustainable substitute for robust and lightweight materials like glass fibre and carbon fibre in composite structures.  

The performance of standard flax fibre is often hindered by its high moisture absorption, resulting in reduced structural integrity when used in composite construction. In addition, the natural brown colour of flax has been deemed unappealing for product use.

British technology company Hypetex has been awarded a significant grant from Innovate UK to develop the world’s first technical coloured flax fibre, which will have applications in the sustainable manufacturing of cars, boats and other products that are usually made with carbon fibre.

Called FlaxTex the material is strong, lightweight and 100 per cent biodegradable, having a net positive carbon footprint at point of manufacturing. It can be colourised whilst enhancing its performance properties, with the process adding some important manufacturing attributes compared to standard flax fibre.

As such, FlaxTex’s mechanical properties represent the closest sustainable substitute for robust and lightweight materials like glass fibre and carbon fibre in composite structures.  

The performance of standard flax fibre is often hindered by its high moisture absorption, resulting in reduced structural integrity when used in composite construction. In addition, the natural brown colour of flax has been deemed unappealing for product use.

Flaxtex solves these issues by removing moisture through the colouring process and sealing the fibres, which waterproofs them and enabling their core mechanical properties. Hypetex’s patented nano-pigment technology changes the colour adding an aesthetic quality to the material.  

This colouring process is set to transform industrial design possibilities of Flax natural fibres by enhancing the strength and performance while simultaneously reducing post-processing requirements and total energy usage. This also aligns with Hypetex's commitment to supporting the green transition and helping manufacturers meet government expectations on the path to UK Net Zero targets and the European Green Deal.

Over the course of a 12-month industrial research project, Hypetex will further optimize its resin systems and processes, expanding the use of FlaxTex across various markets.  

FlaxTex has a range of industry uses, including on construction, automotive, sports equipment and furniture products.

More information:
HYPETEX® flax carbon fibers
Source:

Hypetex

Graphic Toray
20.12.2023

Recycled carbon fiber: When a Boeing 787 turns into a Lenovo ThinkPad

Toray Industries, Inc. announced the successful development of recycled carbon fiber (rCF) derived from the production process of the Boeing 787 components using Toray’s advanced carbon fiber, TORAYCA™. The rCF, which is based on pyrolysis recycling process, has been integrated into the Lenovo ThinkPad X1 Carbon Gen 12 as reinforcement filler for thermoplastic pellets. Toray and Lenovo will continue to collaborate to expand the usage of rCF in other Lenovo products.

Toray rCF is the outcome of Boeing and Lenovo’s shared commitment to minimize their environmental impact. Boeing’s objective is to reduce solid waste going to landfill and produce recyclable materials, while Lenovo has been exploring materials to reduce the carbon footprint of their products. Toray rCF connects these visions by repurposing Toray’s high-performance carbon fiber from the Boeing aircraft production process into Lenovo’s ultra-light laptop PC.

Toray Industries, Inc. announced the successful development of recycled carbon fiber (rCF) derived from the production process of the Boeing 787 components using Toray’s advanced carbon fiber, TORAYCA™. The rCF, which is based on pyrolysis recycling process, has been integrated into the Lenovo ThinkPad X1 Carbon Gen 12 as reinforcement filler for thermoplastic pellets. Toray and Lenovo will continue to collaborate to expand the usage of rCF in other Lenovo products.

Toray rCF is the outcome of Boeing and Lenovo’s shared commitment to minimize their environmental impact. Boeing’s objective is to reduce solid waste going to landfill and produce recyclable materials, while Lenovo has been exploring materials to reduce the carbon footprint of their products. Toray rCF connects these visions by repurposing Toray’s high-performance carbon fiber from the Boeing aircraft production process into Lenovo’s ultra-light laptop PC.

TORAYCA™ is an established aerospace material known for its high strength, stiffness, and lightweighting properties. These qualities have led to its adoption in other applications such as electrical and electronic equipment housings, sports equipment, and other industrial applications.

A key advantage of carbon fiber is the ability to retain its primary mechanical properties even after the recycling process. Toray is actively advancing recycling technologies and establishing a strategic business model for rCF. Given that the carbon footprint of rCF is lower than that of virgin carbon fiber, Toray is proactively recommending the adoption of rCF to reduce the environmental impact of customers’ products. This commitment aligns with Toray’s dedication to fostering a circular economy, thereby reducing landfill waste.

Source:

Toray Industries

Prof. Dr Tae Jin Kang (Seoul National University), Dr Musa Akdere (CarboScreen), Dr Christian P. Schindler (ITMF), from left to right. Source: ITMF
Prof. Dr Tae Jin Kang (Seoul National University), Dr Musa Akdere (CarboScreen), Dr Christian P. Schindler (ITMF), from left to right.
01.12.2023

Faster and cheaper carbon fibre production with CarboScreen

Faster and more cost-effective carbon fibre production - the technology of the start-up CarboScreen comes a good deal closer to this dream. The founders Dr. Musa Akdere, Felix Pohlkemper and Tim Röding from the Institut für Textiltechnik (ITA) of RWTH Aachen University are using sensor technology to monitor carbon fibre production, thereby doubling the production speed from the current 15 to 30 m/min in the medium term and increasing turnover by up to €37.5 million per year and system. This ground-breaking development also impressed the jury at the ITMF at their Annual Conference in Keqiao, China, and was honoured with the ITMF StartUp Award 2023 on 6 November 2023.

Dr. Musa Akdere accepted the award on behalf of the CarboScreen founding team.

Carbon fibres can only develop their full potential if they are not damaged during production and further processing. Two types of fibre damage occur more frequently during fibre production: Superficial or mechanical damage to the fibres or damage to the chemical structure.

Faster and more cost-effective carbon fibre production - the technology of the start-up CarboScreen comes a good deal closer to this dream. The founders Dr. Musa Akdere, Felix Pohlkemper and Tim Röding from the Institut für Textiltechnik (ITA) of RWTH Aachen University are using sensor technology to monitor carbon fibre production, thereby doubling the production speed from the current 15 to 30 m/min in the medium term and increasing turnover by up to €37.5 million per year and system. This ground-breaking development also impressed the jury at the ITMF at their Annual Conference in Keqiao, China, and was honoured with the ITMF StartUp Award 2023 on 6 November 2023.

Dr. Musa Akdere accepted the award on behalf of the CarboScreen founding team.

Carbon fibres can only develop their full potential if they are not damaged during production and further processing. Two types of fibre damage occur more frequently during fibre production: Superficial or mechanical damage to the fibres or damage to the chemical structure.

Both types of damage cannot be optimally detected by current means or only become apparent after production, to name just two examples. This leads to higher production costs. In an emergency, faulty production can even lead to plant fires. For this reason, and to ensure good production quality, the system is run at 15 m/min below its production capacity for safety reasons. However, 30 m/min or more would be possible. With the sensor-based online monitoring of CarboScreen, the production capacity can be doubled to 30 /min. This would lead to higher production, resulting in lower manufacturing costs and wider use of carbon fibres in mass markets such as automotive, aerospace and wind energy.

More information:
carbon fibers sensors Startup
Source:

ITA – Institut für Textiltechnik of RWTH Aachen University
 

Bac Mono Photo Hypetex
22.09.2023

Hypetex: Coloured carbon fibre replacing paint coating

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without technical compromises, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138 grams per metre squared, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving.
This bespoke version of BAC’s single-seater Mono R was subject to BAC’s renowned BAC Bespoke programme, which ensures that no two Monos are the same. The client, a US-based collector, worked with BAC’s design team to design the car to their personal taste.   

Born out of Formula 1 technology, Hypetex offers manufacturers sustainable aesthetic materials with technical and efficiency benefits. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers in Automotive, Aerospace and Defence markets. BAC’s supply chain is 95% UK-based.  

Hypetex continues to expand its growing portfolio of the use of coloured carbon fibre to add personalisation to the automotive field, with its material recently featured on the 2024 Ford Mustang Dark Horse.  

 

More information:
HYPETEX® carbon fibers
Source:

Hypetex

Brembo SGL Carbon Ceramic Brakes expands production capacity (c) SGL CARBON SE
13.09.2023

Brembo SGL Carbon Ceramic Brakes expands production capacity

SGL Carbon and Brembo agreed to expand production capacities for the joint venture Brembo SGL Carbon Ceramic Brakes (BSCCB). Both companies have been working together with BSCCB on the conditions and implementation plans for this in the preceding months. BSCCB will invest around €150 million until 2027 to expand by more than 70% production capacities at the sites in Meitingen (Germany) and Stezzano (Italy).

The capacity enlargement includes the construction of two new production facilities at the SGL Carbon Meitingen site with a total area of around 8,500 m² and the installation of new production machinery. The groundbreaking in Meitingen will take place this fall.

At the Stezzano site, production areas will be extended by around 4.000 m² to existing buildings and investments will be made in new production machinery.

SGL Carbon and Brembo agreed to expand production capacities for the joint venture Brembo SGL Carbon Ceramic Brakes (BSCCB). Both companies have been working together with BSCCB on the conditions and implementation plans for this in the preceding months. BSCCB will invest around €150 million until 2027 to expand by more than 70% production capacities at the sites in Meitingen (Germany) and Stezzano (Italy).

The capacity enlargement includes the construction of two new production facilities at the SGL Carbon Meitingen site with a total area of around 8,500 m² and the installation of new production machinery. The groundbreaking in Meitingen will take place this fall.

At the Stezzano site, production areas will be extended by around 4.000 m² to existing buildings and investments will be made in new production machinery.

The extensive expansion of production capacities will enable Brembo SGL Carbon Ceramic Brakes (BSCCB) to meet the high market demand and to cover the increasing customer requests in the future. The need for carbon ceramic brake discs from BSCCB increased worldwide. This is mainly due to the high product quality and performance of carbon ceramic brake discs, which meet the specific requirements of automotive manufacturers, especially in the premium and luxury segments, where high braking performance is needed.

Source:

SGL CARBON SE

Professor Dr Thomas Gries with the award winner Flávio André Marter Diniz Hanns-Voith-Stiftung, Oliver Voge
Professor Dr Thomas Gries with the award winner Flávio André Marter Diniz
11.07.2023

Future cost reduction through ultra-thin PE carbon fibres

  • ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

  • ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

The use of carbon fibres in highly stressed lightweight construction solutions, such as today's growth applications of wind turbines or pressure tanks, has become indispensable due to their excellent mechanical properties and low density. High manufacturing costs of conventional PAN precursor-based carbon fibres make the material very cost-intensive. In addition, it is not sufficiently available. New manufacturing approaches that develop alternative raw materials and manufacturing processes can be a key and growth engine for further industrial composites applications.

The aim of the work was to develop a new and cost-effective manufacturing process for high-quality ultra-thin carbon fibres using a polyethylene precursor. For this purpose, the sulphonisation process, which is time-consuming today, was to be significantly shortened. As a result, Mr. Marter Diniz produced novel ultra-thin polyethylenebased carbon fibres with a filament diameter < 3 μm with an excellent surface quality of the fibres without detectable structural defects. The fibre diameter is 2-3 times smaller than that of conventional PANbased CF. This provides the basis for mechanically high-quality material properties. At the same time, Mr. Marter Diniz was able to reduce the sulphonisation time by 25 percent. The developed material and technology set important milestones on the way to cheaper carbon fibres. With PE-based precursors, the price of CF can be reduced by 50 percent compared to conventional PAN-based CF.  

A total of five other young scientists were awarded in six categories (Drive Technology, Innovation & Technology/Artificial Intelligence, New Materials, Paper, Hydropower and Economic Sciences. This year, for the 10th time, the Hanns Voith Foundation awarded the Hanns Voith Prize to outstanding young scientists.

Source:

ITA Institut für Textiltechnik of RWTH Aachen University

06.09.2022

SGL Carbon increases sales and earnings guidance again for 2022

Due to the continued good business development, especially in the Carbon Fibers Business Unit, SGL Carbon SE is increasing its Group sales and earnings guidance for the current fiscal year and now expects Group sales of approximately €1.2 billion (previously: approximately €1.1 billion). The company expects to achieve adjusted EBITDA (EBITDA pre = earnings before interest, taxes, depreciation and amortization before one-off effects and non-recurring items) of €170 - €190 million (previously: €130 - €150 million) in 2022.

Based on lower prices for acrylonitrile as main raw material of the Business Unit Carbon Fibers as well as higher than expected customer demand for acrylic and carbon fibers combined with consistently good production capacity utilization and capability, the management of SGL Carbon SE assumes an improved earnings development of this Business Unit.

Due to the continued good business development, especially in the Carbon Fibers Business Unit, SGL Carbon SE is increasing its Group sales and earnings guidance for the current fiscal year and now expects Group sales of approximately €1.2 billion (previously: approximately €1.1 billion). The company expects to achieve adjusted EBITDA (EBITDA pre = earnings before interest, taxes, depreciation and amortization before one-off effects and non-recurring items) of €170 - €190 million (previously: €130 - €150 million) in 2022.

Based on lower prices for acrylonitrile as main raw material of the Business Unit Carbon Fibers as well as higher than expected customer demand for acrylic and carbon fibers combined with consistently good production capacity utilization and capability, the management of SGL Carbon SE assumes an improved earnings development of this Business Unit.

SGL Carbon assumes that the factors mentioned will continue at least until the end of the year and that the earnings situation of the Business Unit Carbon Fibers will exceed previous expectations. Combined with the continued good business development of the other three Business Units (Graphite Solutions, Process Technology and Composite Solutions), an improvement in the sales and earnings situation at Group level is expected.

In line with the forecast increase for adjusted EBITDA (EBITDA pre) to between €170 and €190 million (previously: €130 - €150 million), the company is forecasting adjusted EBIT (earnings before interest and taxes and before one-off effects and non-recurring items) of between €110 and €130 million (previously: €70 - €90 million). The forecast for return on capital employed (ROCE) of originally 7% - 9% has been raised to 10% to 12% corresponding to the development of earnings. The expectations for free cash flow (significantly below previous year's level of €111.5 million) remain unaffected by the expected improvement in sales and earnings.

The updated forecast for fiscal 2022 has been prepared on the basis of the currently prevailing market environment and assumes no deterioration in the general conditions, in particular due to the war in Ukraine and its consequences for the global economy.
 
The definition of key figures used in this release is aligned to the Annual Report 2021. There were no changes in the scope of consolidation or accounting methods compared with the previous guidance.

Source:

SGL CARBON SE

(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

Hypetex at JEC World 2022 (c) Hypetex
Hypetex® to Showcase Coloured Carbon and Flax Fibre Solutions
20.04.2022

Hypetex at JEC World 2022

  • Hypetex® to Showcase Coloured Carbon and Flax Fibre Solutions
  • Hypetex, London, April 20 2022, Booth R52, Hall 6

Hypetex, the market leaders in colouring carbon and natural fibre materials, will demonstrate both the processing and sustainability benefits of its patented colourisation technology when it exhibits for the first time at JEC World 2022.

  • Hypetex® to Showcase Coloured Carbon and Flax Fibre Solutions
  • Hypetex, London, April 20 2022, Booth R52, Hall 6

Hypetex, the market leaders in colouring carbon and natural fibre materials, will demonstrate both the processing and sustainability benefits of its patented colourisation technology when it exhibits for the first time at JEC World 2022.

Exhibiting as part of the Composites UK stand (Booth R52), Hypetex will display its portfolio of uniquely coloured carbon fibre materials including 3K woven styles, ultra-lightweight spread tow fabrics, UD, and 3D materials. Hypetex will also present details of its latest eco-friendly coloured flax materials  which combine sustainably grown natural flax with sustainable colouring technologies. Hypetex patented colouring technology, available in an extensive palette of standard and bespoke colours and shades, can be applied to traditional woven fabric constructions, non-woven UDs, spread tow and bespoke fabric designs. The technology replaces a traditional coloured painted finish, providing an exceptional depth of colour to any composite part, improving thermal conductivity and reducing heat absorption ,whilst reducing the overall weight and processing time with no compromise to the mechanical performance of the composite structure.

By removing the need for painting, and the associated preparation steps, Hypetex technology provides manufacturers with a repeatable straight out of the mould coloured finish, that is not only easy to integrate into all composite processes, but also takes additional materials, consumables, and process time out of the component cost. As part of its continued commitment to leading the drive for more sustainable composite solutions, and its focus on improvements based on the ESG framework. Hypetex will also display its new range of coloured flax fibre textiles. The advanced colouring technology used protects the natural flax fibres throughout the high temperature processes required for composite production, avoiding burning or any discolouration issues common to natural fibres. In addition, Hypetex colouring solution is an ecofriendly sustainable alternative to traditional dyeing processes which are a significant cause of global water pollution.

The Hypetex team will be on hand throughout the show to provide additional details on Hypetex materials and their integration into the manufacturing process. Visitors to the Hypetex stand will be able see Hypetex carbon and flax products in raw fabric, and how its unique colour palette translates into the most distinctive finished moulded components. Hypetex partners SHD Composites, Textreme, Sigmatex and Angeloni will also have materials and components on display at JEC World 2022, including sporting equipment such as racquets, sticks, and skateboards, which highlight the massive range of processing options and potential applications for this novel technology. One such application, the adidas Kromaskin field hockey stick, with a unique Hypetex coloured Textreme spread tow carbon finish, will also be part of the JEC Innovation Planets feature.

Source:

100% Marketing

19.10.2021

Teijin to boost Heat-Resistant Carbon Fiber Prepreg Production

Teijin Limited announced today that its carbon fiber subsidiary Renegade Materials Corporation, a leading U.S.-based supplier of highly heat-resistant thermoset prepregs, resins and adhesives for the aerospace industry, will expand its prepreg production by 2.5 times approximately. The increased capacity, which aligns with Renegade’s capacity expansion strategy at the Miamisburg, Ohio location, is the result of a USD 4 million investment made in December 2019 and the construction was started in March 2020. Operation of the new production lines will commence January 2022.

Renegade Materials' heat-resistant thermoset prepregs, resins and adhesives are well trusted by U.S. and European aircraft manufacturers and aircraft engine suppliers.

Renegade Materials will showcase its high heat-resistant thermoset prepreg at the Composites and Advanced Materials Expo (CAMX), one of the largest, most comprehensive composites and advanced materials event in North America, at the Dallas Convention Center in Dallas, Texas, from October 19 to 21.

Teijin Limited announced today that its carbon fiber subsidiary Renegade Materials Corporation, a leading U.S.-based supplier of highly heat-resistant thermoset prepregs, resins and adhesives for the aerospace industry, will expand its prepreg production by 2.5 times approximately. The increased capacity, which aligns with Renegade’s capacity expansion strategy at the Miamisburg, Ohio location, is the result of a USD 4 million investment made in December 2019 and the construction was started in March 2020. Operation of the new production lines will commence January 2022.

Renegade Materials' heat-resistant thermoset prepregs, resins and adhesives are well trusted by U.S. and European aircraft manufacturers and aircraft engine suppliers.

Renegade Materials will showcase its high heat-resistant thermoset prepreg at the Composites and Advanced Materials Expo (CAMX), one of the largest, most comprehensive composites and advanced materials event in North America, at the Dallas Convention Center in Dallas, Texas, from October 19 to 21.

Source:

Teijin Carbon Europe GmbH

Visionary building – with composite textiles by vombaur (c)vombaur
From the H-profile to the chamber structure – vombaur offers individually developed composite textiles with complex shapes
13.10.2021

Visionary building – with composite textiles by vombaur

  • Hightech textiles for future-oriented construction projects

Building shells, bridges, staircases, façades ... construction projects are exposed to enormous mechanical loads. Often there are also considerable climatic or environmental influences. This has prompted the increasing use of fibre-reinforced materials in construction projects. After all, besides many other exciting properties, they offer high mechanical rigidity, low weight and excellent corrosion resistance.

Tapes, tubulars, sections and 3D woven textiles by vombaur form the perfect basis for these innovative building materials. The seamless round or shaped woven narrow textiles made of high-performance fibres are extremely loadable because they have neither seams nor welds – and therefore no undesirable breaking points. Their surface properties are identical over the entire length. In challenging tasks, composite textiles by vombaur offer a lightweight solution that is as reliable as it is durable.

  • Hightech textiles for future-oriented construction projects

Building shells, bridges, staircases, façades ... construction projects are exposed to enormous mechanical loads. Often there are also considerable climatic or environmental influences. This has prompted the increasing use of fibre-reinforced materials in construction projects. After all, besides many other exciting properties, they offer high mechanical rigidity, low weight and excellent corrosion resistance.

Tapes, tubulars, sections and 3D woven textiles by vombaur form the perfect basis for these innovative building materials. The seamless round or shaped woven narrow textiles made of high-performance fibres are extremely loadable because they have neither seams nor welds – and therefore no undesirable breaking points. Their surface properties are identical over the entire length. In challenging tasks, composite textiles by vombaur offer a lightweight solution that is as reliable as it is durable.

Safe and durable solutions for challenging applications
The potential applications for lightweight components in the construction industry are as numerous as the project ideas of the planning and construction teams.
•    Ropes and tensioning elements made of carbon fibre reinforced plastic (CFRP)
•    Reinforcement of building structures made of concrete, steel, wood or other materials
•    Sustainable restructuring of constructions and urban districts for bridges and buildings
•    CFC slats as reinforcements in case of repairs
•    (Filled) GRP pipes made of seamless round woven tubes by vombaur as columns/pillars
•    CFRP sections as steel girder substitutes
•    Hollow profiles with individually designed cross-sections
•    Glass fibre reinforced connecting elements for glazing to minimise expansion differences between the connecting element and the glass
•    Individual light wells

Implementing visions – with composite textiles by vombaur
As your development partner, vombaur facilitates innovative composites projects for challenging applications. In innovative and safety-sensitive industries such as automotive and aviation, chemical and plant engineering.  The composites experts at vombaur develop, create samples of and manufacture woven tapes and seamless round or shaped woven textiles by vombaur – in collaboration with the customer's enterprise development teams and individually for the respective projects. This is how novel and unique lightweight components made of high-performance textiles are created for visionary lightweight construction projects.

"Fibre-reinforced composites are the ideal material for future-oriented construction projects," explains Dr.-Ing. Sven Schöfer, Head of Development and Innovation at vombaur. "Their outstanding technical properties and design possibilities open up new and fascinating perspectives for construction projects. From building construction to civil engineering, from bridge construction to interior design. As an experienced development partner for sophisticated lightweight components, we at vombaur contribute our seamless solutions to these kinds of future-oriented projects."

More information:
vombaur Composites carbon fibers
Source:

vombaur GmbH & Co. KG

Composite textiles by vombaur for innovations in architecture and the construction industry (c) vombaur
Low effort, low weight: Maintenance with fibre-reinforce materials
13.10.2021

Composite textiles by vombaur for innovations in architecture and the construction industry

  • Composites in the construction industry - The lightweight construction material of the future

Building with fibre-reinforced materials opens up completely new possibilities. In terms of engineering, design, and organisation. This is due, on the one hand, to the excellent properties of fibre-reinforced materials (FRM) and, on the other hand, to the fact that the material – unlike wood or brick, for example – is not machined or processed for its use, but custom-produced.

Excellent properties – in terms of engineering, design, and organisation
Fibre-composite materials offer a whole range of technical properties for innovative and sustainable building:
•    High mechanical rigidity
•    Low weight
•    High corrosion resistance
•    Low material fatigue
•    Low heat transfer coefficient of the plastic matrix
•    Resistance to frost and de-icing salt
•    Good draping capability

  • Composites in the construction industry - The lightweight construction material of the future

Building with fibre-reinforced materials opens up completely new possibilities. In terms of engineering, design, and organisation. This is due, on the one hand, to the excellent properties of fibre-reinforced materials (FRM) and, on the other hand, to the fact that the material – unlike wood or brick, for example – is not machined or processed for its use, but custom-produced.

Excellent properties – in terms of engineering, design, and organisation
Fibre-composite materials offer a whole range of technical properties for innovative and sustainable building:
•    High mechanical rigidity
•    Low weight
•    High corrosion resistance
•    Low material fatigue
•    Low heat transfer coefficient of the plastic matrix
•    Resistance to frost and de-icing salt
•    Good draping capability

In addition, fibre composites offer numerous design options for novel and exceptional new building and maintenance projects:
•    Unique variety of shapes
•    Different structures of the textiles
•    Large spectrum of colours and colour combinations
•    Translucency of the plastic matrix
Thanks to these properties, composites can be used to produce coloured, phosphorescent, thermochromic or – through the use of LEDs or light-conducting fibres permanently integrated into the matrix – luminescent components.

In addition, there are organisational benefits for planning, construction and maintenance work with fibre-reinforced materials:
•    Easier handling and assembly of the far lighter and more flexible components – compared with steel, concrete or wood
•    Faster installation
•    Shorter construction site times in road and bridge maintenance
•    Shorter delivery times
•    Ability to integrate electronic monitoring systems

Individual composite textiles – for every lightweight engineering project
The composites experts at vombaur develop and manufacture woven tapes and seamless round or shaped woven textiles from carbon, glass, flax or other high-performance fibres on special weaving lines for individually specified round and shaped woven textiles – and can therefore offer you the best possible fibre base for every lightweight construction project.

"Regardless of whether it's a new construction or a renovation project, a façade design, a bridge or a staircase – as your development partner for composite textiles, we have plenty of experience with composites for demanding tasks," emphasises Dr.-Ing. Sven Schöfer, Head of Development and Innovation at vombaur. "We develop, create samples and manufacture woven tapes and seamless round or shaped woven textiles – in collaboration with the customer enterprise development teams and individually for the respective projects." This is how novel and unique lightweight components made of high-performance textiles are created for visionary projects.

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.”

COBRA continues Its Partnership with Fliteboard (c) COBRA
11.07.2021

COBRA continues Its Partnership with Fliteboard

COBRA International is pleased to confirm its continued partnership with Fliteboard as the builders of the new Fliteboard Series 2.  

Conceived in 2016, the Fliteboard range of electric foiling surfboards has established a leading position in the eFoil market. In early 2021, Fliteboard announced a package of evolutionary improvements to the original award-winning design for which COBRA has installed significant additional manufacturing capacity.

With Fliteboard growing rapidly, and thousands of boards now delivered across more than 80 countries,  COBRA will continue to support Fliteboard with additional moulds and lean manufacturing production lines added to reduce customer lead times. In addition to this production capacity expansion, COBRA has successfully met the technical challenges set by the Fliteboard team to incorporate all the new Series 2 board features into the existing production processes.

COBRA International is pleased to confirm its continued partnership with Fliteboard as the builders of the new Fliteboard Series 2.  

Conceived in 2016, the Fliteboard range of electric foiling surfboards has established a leading position in the eFoil market. In early 2021, Fliteboard announced a package of evolutionary improvements to the original award-winning design for which COBRA has installed significant additional manufacturing capacity.

With Fliteboard growing rapidly, and thousands of boards now delivered across more than 80 countries,  COBRA will continue to support Fliteboard with additional moulds and lean manufacturing production lines added to reduce customer lead times. In addition to this production capacity expansion, COBRA has successfully met the technical challenges set by the Fliteboard team to incorporate all the new Series 2 board features into the existing production processes.

Fliteboard’s first composite models used a carbon fibre and Innegra sandwich laminate over a moulded EPS foam core, combining maximum strength, stiffness, and durability with a low overall board weight. The same construction concept is used for the Series 2 boards, with several new finishes added to the range along with lighter colour matched EVA deck pads and upgraded latches on the carbon fibre board lid. New wood grain and metallic paint finishes have been introduced with COBRA’s semi-transparent paint system used to save weight and display the stunning hexagonal weave pattern of the carbon and Innegra reinforcement fabrics.

Source:

COBRA / 100% Marketing

Hexcel showcases Carbon Fiber Prepreg Capability for UAV Applications (c) Hexcel Corporation
07.07.2021

Hexcel showcases Carbon Fiber Prepreg Capability for UAV Applications

Hexcel, a global leader in advanced composites technologies, announces the successful maiden flight of a lightweight camera drone, developed using Hexcel HexPly® carbon fiber prepregs. The composite drone was developed by a team of students from the University of Applied Sciences Upper Austria in Wels with composite materials supplied by Hexcel Neumarkt in Austria.

A team of six students in the university’s lightweight construction and composite materials course was responsible for the complete design, engineering, and manufacture of the camera drone over a period of 18 months. Hexcel materials and optimization of the composite engineering enabled the team to reduce the composite structural mass by an impressive 42% compared to similar drones.

Hexcel, a global leader in advanced composites technologies, announces the successful maiden flight of a lightweight camera drone, developed using Hexcel HexPly® carbon fiber prepregs. The composite drone was developed by a team of students from the University of Applied Sciences Upper Austria in Wels with composite materials supplied by Hexcel Neumarkt in Austria.

A team of six students in the university’s lightweight construction and composite materials course was responsible for the complete design, engineering, and manufacture of the camera drone over a period of 18 months. Hexcel materials and optimization of the composite engineering enabled the team to reduce the composite structural mass by an impressive 42% compared to similar drones.

Hexcel Neumarkt was one of eight industrial partners supporting the university team throughout the project, providing all carbon fiber prepreg materials used for the drone’s landing gear as well as the fuselage. The ultra-lightweight 32g landing gear was laid up and cured in the press, whereas the fuselage was autoclave cured by the student team using Hexcel HexPly M901 and HexPly M78.1 prepreg resin systems with a combination of woven and unidirectional carbon fiber reinforcements.

With the development of Unmanned Aerial Vehicles (UAV) as a key emerging market and innovation space in the transportation sector, Hexcel’s collaboration with the University of Applied Sciences Upper Austria team not only creates an important link with the next generation of lightweight composite engineers but also highlights the weight saving and structural benefits of Hexcel composite material solutions.

"The massive weight saving achieved with their updated version of the camera drone is a fantastic achievement by the student team," said Michael Rabl, Dean of FH Wels of the Upper Austria University of Applied Sciences. "The joint study not only illustrates the wide range of complex and innovative composite techniques present in the drone sector but also presents the opportunities that exist for further development in the wider Urban Air Mobility (UAM) and aerospace composites markets.”

Hexcel congratulates the project team which includes Lukas Weninger, Karl-Heinz Schneider, Jakob Schlosser, Matthias Thon, Marla Unter, and Simone Hartl on an exceptional piece of lightweight composite design and thanks them for showcasing the contribution of Hexcel materials with a presentation and drone flight. Johanna Arndt, research and technology group leader at Hexcel Neumarkt, said, “It was a great pleasure to work with the team who were very cooperative and self-motivated to succeed. Watching the drone just fly around the Neumarkt plant was just great.”

Hexcel manufactures a complete range of carbon fibers, dry carbon UD tapes, specialty reinforcements, prepregs, and honeycomb core materials, providing customized manufacturing options for new UAM applications that combine aerospace reliability with the high-rate production required. Hexcel composite materials are the ideal solution for the lightest and most efficient cost-competitive transportation vehicles of the future.

Source:

Hexcel Corporation / 100% Marketing

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.

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Teijin