From the Sector

Autoneum expands its sustainable product portfolio for commercial vehicles with new polyester-based side and rear wall panels. Their carrier material consists of Propylat PET, the company’s eco-friendly and fully recyclable Pure technology made of 100 percent polyester. Autoneum’s components thus offer a significantly more sustainable alternative to the composite or thermoset resin panels commonly used in trucks today, which are difficult to recycle. Thanks to the unique material composition of Propylat PET, they contribute to optimized acoustic and thermal management.

With the establishment of a dedicated Business Unit Commercial Vehicles at the beginning of 2024, Autoneum has set the course for further sustainable and profitable growth in this market segment on a global scale. Manufacturers of medium and heavy trucks as well as agricultural vehicles thus benefit not only from Autoneum’s existing production footprint and comprehensive product and technology portfolio, but also from the Company’s longstanding experience in the development and manufacturing of environmentally friendly monomaterials. Components such as the new polyester-based side and rear wall panels support customers in improving the environmental performance of commercial vehicles and are therefore an important step towards a circular economy also in this vehicle segment.

The carrier material of Autoneum’s sustainable trim components consists of 100 percent polyester. Thanks to the high content of recycled fibers and the excellent end-of-life recyclability of Propylat PET, the side and rear wall panels from Autoneum are considerably more environmentally friendly than the composite or thermoset resin alternatives commonly used in trucks today. Furthermore, additional components can be welded onto the material without the use of adhesives or other chemicals, which further increases the products’ recyclability at the end of their service life. Due to the unique material composition of Propylat PET, the components also improve the acoustic and thermal insulation of the vehicle interior and are characterized by minimal emission of volatile organic compounds as well as low odor. In addition, Autoneum continues to invest in the develop-ment of monomaterial components for commercial vehicles, where both the carrier material and the aesthetic surface are made entirely of polyester, thus further advancing the transition to a sustaina-ble circular economy.

Autoneum has supported Renault Group in the development of Renault Emblème, a low-carbon demonstration car designed to reduce greenhouse gas emissions by 90 percent over its entire life cycle. As a key partner of the project, Autoneum further optimized the environmental performance of its sustainable Pure technologies, which were used for numerous components in the vehicle interior and exterior. Leveraging its proven expertise in the development of lightweight and fully recyclable monomaterials with a high recycled content, as well as in the areas of life cycle analysis (LCA) and product innovation, Autoneum was able to reduce the carbon footprint of its parts and contribute to a significant reduction in vehicle weight for Renault Emblème.

Increasingly stringent regulations to reduce greenhouse gas emissions on a global scale, new directives and the electrification of mobility require innovative approaches from the entire automotive industry. To support vehicle manufacturers in achieving their sustainability targets, Autoneum continuously optimizes the environmental performance of its products and processes: from further increasing the share of recycled content and the end-of-life recyclability of its lightweight technologies to reducing waste and shifting to renewable energy in its production facilities. In addition, the Company is working closely with customers and partners to validate data and products together. One of the most recent examples of such a successful collaboration is Autoneum’s contribution to Renault Emblème.

The Renault Emblème demonstration car emits 90% fewer greenhouse gases over its entire life cycle than a comparable vehicle produced today. To achieve these ambitious decarbonization targets, Renault Group assembled more than twenty suppliers from across the industry to participate in specialized projects in five different areas: eco-design, raw material selection, manufacturing, use and end of life. In addition to providing valuable expertise in the areas of LCA and product development, Autoneum’s contribution entailed the further optimization of its environmentally friendly Pure technologies, which already today are characterized by an excellent sustainability performance across the product life cycle and also include the Company’s growing portfolio of monomaterial technologies made of 100 percent polyester.

Autoneum’s innovative and lightweight materials were used for around thirty fiber-based components in the interior and exterior of Renault Emblème, including the carpet, the underbody panels and wheelhouse outer liners as well the front and rear trunk. Thanks to the high recycled content, the waste-free production process and the excellent recyclability of the materials at the end of their service life, Autoneum was able to reduce drastically the carbon footprint of the components. This outstanding achievement was made possible by further boosting the sustainability performance of existing technologies such as Ultra-Silent, Propylat PET, Hybrid-Acoustics and Autoneum’s monomaterial polyester carpet systems. In addition, the parts contributed to a weight reduction, which positively affected both the carbon footprint and the range of the electric car.

SAATI Germany, a leading manufacturer of highly developed technical fabrics, has further optimised its production processes by using innovative measurement and control technology from Mahlo.

The globally active SAATI Group produces filter fabric for blood transfusion devices, aramid fabric for bulletproof vests and functional fabric for mobile phones and tablets, among other things. SAATI is known for its high precision and quality, which is maintained at all stages of production.

The installation of a Mahlo distortion control system Orthopac FMC-15 and a Famacont PMC-15 yarn density meter in the outfeed of a stenter frame was a further step in this optimisation process.

As Saati produces highly technical fabrics, the exact thread count (up to over 300 F/cm) is an essential quality feature. The PMC-15, a camera-based measuring system, can continuously record and log this parameter. At the same time, the FMC-15 records residual distortion and contributes to the elimination of so-called back sheet distortion in the fabric by automatically controlling the take-off roller of the stenter frame. This ensures the consistently high quality of the end products and reduces potential sources of error.

The investment in these systems proved so successful that SAATI initiated the next stage of process optimisation in 2024. „With the installation of an Orthopac GRVMC-15 straightening machine before the infeed of the stenter frame, we have further perfected the control of fabric
quality,“ says Operations Manager Thomas Brockmeier. The heavyweight among the Mahlo straightening systems with a working width of 2,800 mm enables SAATI to correct skew and bow distortions in the raw fabric even before the stenter frame. This is because a weft yarn that is only slightly skewed or curved can render the fabric unusable or visually unfit for use.

By combining the GRVMC-15 with the FMC-15 already installed in the outfeed, SAATI now has a fully automatic system that offers maximum monitoring and control options. The co-operation of these two technologies enables the company to deliver precisely shot-straight items. „I am delighted that we were able to complete the project so successfully,“ says Brockmeier.

The Chinese Junma Group has expanded its HMLS capacities by 20 positions, hence becoming one of the largest tire cord manufacturers in China. At present, the company has 64 positions of HMLS systems from Oerlikon Barmag.

Junma processes the tire yarn produced in the titer range of 1100 dtex to 2200 dtex in-house into tire cord using the downstream processes of dipping and weaving. The largest HMLS single project for Junma and Oerlikon Barmag to date was put into operation in record time. After just two weeks, the various yarn specifications were approved.

High-end HMLS technology for the international tire market
Junma supplies its end products to renowned international tire manufacturers and sees definite growth potential in this segment of the automotive industry. “This year, we opened our first branches outside of China. And for the coming year, we are planning our first production facility in Thailand,” says Wang Hongbin. In doing so, Junma continues to rely on the expertise of Oerlikon Barmag. The HMLS process from Oerlikon Barmag scores particularly highly with production speeds of up to 6300 m/min, at which the core components of high-speed godets and winders demonstrate their reliability.

Adient, Jaguar Land Rover, and Dow have worked together to produce seat foam for the luxury car manufacturer’s vehicles using closed-loop recycled components. This represents an industry-first in the automotive sector, heading towards a circular economy and a lower CO₂ footprint for cars as the end product.

In order to address the environmental impact of polyurethane (PU) foams used in car seats, the industry partners decided to team up. This means so-called ‘post-consumer’ PU molded foams have previously been collected from end-of-life vehicles, sorted, and shredded. On this basis, Dow produces a new, circular polyol, which is subsequently processed and integrated into Adient’s seating formulas. As a result, the Adient Front Seat Cushion prototypes are currently composed of 20% re-polyol from PU end-of-life vehicles.

This is the first time, to the awareness of all parties involved, that a PU molded foam for seating applications has been produced under these conditions. This milestone represents a significant leap forward for the automotive industry, positioning PU at the heart of a circular economy system. By integrating recycled components into luxury vehicle seat foams, the partners are not only reducing the environmental impact but also paving the way for a more sustainable future in automotive manufacturing.

“Developing components with closed-loop recycled foams represents a major milestone for the team and simultaneously spurs us on to continuously increase the proportion of recycled materials in our seating systems in the future,” said Frank Toenniges, Director Sustainable Product Design & Business Process Improvements at Adient. “Additionally, it positions the actors along the value chain favorably to comply with the proposed European End-of-Life Directive.”

Andrea Debbane, Chief Sustainability Officer at JLR stated: “This breakthrough is a great example of how the automotive value chain can work as a collective to demonstrate that full circularity is feasible and unlock meaningful change at scale. This way of working holds significant potential for increasing sustainability and is critical to JLR's transition to more circular vehicles.”

As a next step, further research will be conducted to increase the percentage of re-polyol content. At the same time, the closed-loop seat foam will be tested with JLR on a production scale from early 2025.

In line with the new Level Up corporate strategy, which focuses on innovation and a future-fit product portfolio among other things, Autoneum has further expanded its research and development activities in 2024 with a particular focus on New Mobility. In addition to establishing a specialized team to accelerate the development and market readiness of novel products and technologies for electric vehicles, the Company has complemented its global innovation network with a new Research & Technology (R&T) Center in Shanghai, China.

Innovation is and always has been an integral part of Autoneum’s corporate strategy and thus a key factor for business success. The Company’s innovation activities are also an important aspect of its vision: to be the global leader for innovative and sustainable solutions bringing comfort to every vehicle. Against the backdrop of the rapidly advancing electrification of mobility and Autoneum’s strategic focus on further expanding its presence in the Asian growth markets, the expansion activities of the company-wide innovation network this year concentrated on two key areas in particular: New Mobility and presence in China.

Responding to the increasing demand for new components for electric vehicles, Autoneum has formed a specialized team dedicated exclusively to New Mobility to further strengthen its position in this growing market segment. The New Mobility team was established in fall 2023 and has been completed over the past twelve months with members from different departments. It unites a broad set of skills from various fields of expertise such as product innovation, product development and industrialization, sales and business development. The team places a particular focus on accelerating the development and time to market of new products and technologies specifically for the fast-evolving battery systems and architectures of electric vehicles. It also acts as a catalyst for innovation pro-jects and strategic partnerships. The New Mobility experts work in close collaboration with the various departments across the organization and are based at Autoneum’s Swiss headquarters in Win-terthur, at the German locations in Gundernhausen and Munich and in Shanghai, China.

Shanghai is also the location of Autoneum’s third R&T Center worldwide, which was opened in China this summer to enhance the Company’s competitiveness in Asia and cater to the development and innovation needs in this key strategic market. The new center aims to intensify and accelerate the development and production of innovative components and materials, especially regarding e-mobility. The establishment of an R&T team in China allows Autoneum to develop products in a timely manner to respond to the dynamic market conditions and the rapidly evolving requirements of Chinese vehicle manufactures. In terms of material development, the center will support the wider organization in the further development of sustainable materials, especially polyester. In addition, it will promote the introduction of Autoneum’s environmentally friendly products such as the Company’s monomaterial carpet systems featuring Autoneum’s innovative and latex-free alternative backcoating (ABC) process to the Chinese market. Moreover, the R&T Center in Shanghai will also serve as a valuable point of contact with the 14 production facilities of the Jiangsu Huanyu Group, whose acquisition of a majority stake of 70 percent by Autoneum was recently announced and is expected to be closed in March 2025 (see media release of November 19, 2024). While the plants in China will benefit from the local R&T team’s expertise in the company’s technologies, the existing broad customer base of Jiangsu Huanyu Group will support Autoneum in better understanding and serving the innovation needs of Chinese vehicle manufacturers.

The new R&T Center in Shanghai complements the primary R&T Center in Winterthur, Switzerland, which supports the global network with its expertise and a vast array of services in the areas of pre-development as well as acoustic and thermal benchmarking, simulation and testing, and the center in Bocholt, Germany. The latter was integrated into Autoneum’s innovation network following the acquisition of Borgers Automotive last year and has since established itself as the Company’s competence center for trunk and trim components. Including the new center in China, a total of approximately eighty R&T employees – including engineers, chemists, physicists and product designers – are continuously working on new ideas aimed at the next technological breakthrough in acoustic and thermal management and shielding technologies.

Autoneum signed an agreement to acquire 70 percent of the shares of Jiangsu Huanyu Group, a leading automotive supplier for acoustic and thermal management in China. Business Group Asia is thus expanding its customer base to include major Chinese vehicle manufacturers such as BYD, BAIC and GAC, and will significantly increase its annual revenue. The transaction is scheduled to close in March 2025.

With around 30 million light vehicles produced annually, China is the world’s largest automotive market and, with an expected increase to 32.4 cars in 2030, it is also one of the most important growth markets for the automotive industry. Established in 2001, Jiangsu Huanyu Group is today one of China’s leading suppliers of lightweight components for light and commercial vehicles. The company operates 14 production facilities with around 1 100 employees in the immediate vicinity of local automotive manufacturers in the north, west and southeast of China.

Jiangsu Huanyu Group’s product portfolio includes components for the vehicle interior such as carpets, inner and outer dashes, headliners, trunk and interior trim, wheelhouse outer liners as well as insulation for the engine bay and the underbody. Jiangsu Huanyu Group also supplies commer-cial vehicle manufacturers in China, supporting Autoneum’s strategic initiative to grow its truck business in China. Synergies in the areas of technology and purchasing will also contribute to the further development of Business Group Asia. In the 2023 financial year, Jiangsu Huanyu Group generated revenue of around CHF 130 million and is recording strong growth in 2024. It is planned to continue operating the company under the Chinese company name.

The acquisition of Jiangsu Huanyu Group will be done in two phases. The closing of phase 1, the takeover of a majority stake of 70 percent at a purchase price of around CHF 75 million (excluding cash and cash equivalents and debt), is expected in March 2025 after approval by the authorities. As for the acquisition of the remaining 30 percent of the share capital, phase 2, Autoneum has a call option, which can be exercised in 2028. This two-phase approach binds both the current shareholders and the employees in key positions and allows Autoneum, together with Jiangsu Huanyu Group, to continue and further develop existing business activities smoothly.

“Jiangsu Huanyu Group has broad customer access to the largest local vehicle manufacturers in China. With its plants in the key automotive hubs in China, the company is an excellent strategic addition to Autoneum and brings us a significant step closer to our medium-term target of generating 20 percent of Group revenue in Asia,” explains Eelco Spoelder, Chief Executive Officer of Autoneum. “The acquisition of the majority stake in Jiangsu Huanyu Group will strengthen our position in China, the world’s largest and fastest-growing market, both in the light and commercial vehicle business. This step not only gives us access to an established customer base in China, but also allows us to further expand our presence and gain strong influence in the booming automotive hubs of Anhui and Shaanxi.”

A new generation of space materials left Earth November. 5 as they head to the International Space Station (ISS) to undergo testing in the brutal conditions of low Earth orbit.

Developed at the University of Bristol, these high-performance materials could be used to build future space stations, spacecraft for interplanetary travel or a new ISS.

They will be placed on the Bartolomeo platform, located on the front of the ISS, where they will orbit Earth up to 9,000 times over the next 12 to 18 months at speeds of 17,000 mph.

The carbon fibre reinforced composites will need to survive temperatures between -150ºC and +120ºC, space debris travelling seven times faster than a bullet, severe electromagnetic radiation, high vacuum and atomic oxygen, which erodes even the toughest materials.

Prof Ian Hamerton, Professor of Polymers and Sustainable Composites in the University of Bristol’s world-leading Bristol Composites Institute, said:  

“Space is the most challenging environment for which to design new materials. You’re pitting your materials expertise, skills and ingenuity against extremes of temperature, mechanical stress, radiation, high speed impacts and more.

“Any one of those might be difficult, and, unfortunately, gaining access to repair them is not an easy option, so the materials we build must survive without maintenance.  

“The opportunity to test our materials in the proving ground of space is priceless and will help our University of Bristol scientists on the ground improve fibre-reinforced materials for next-generation space missions.”

There are four laboratory-made polymers heading to the ISS, each of which has been reinforced with carbon fibres and two contain nanoparticles. All four are the result of University of Bristol research and one is patented.

 If the materials cope in the harsh environment, they could be used to create longer-lasting space components, allowing spacecraft to travel further, and spend more time in space.

Future communities on new planets will need protection against galactic cosmic radiation. Dr Ali Kandemir, Senior Research Associate at the University of Bristol, is one of several Bristol researchers, supported by the UK Space Agency (UKSA), examining the effects of simulated galactic cosmic radiation on the materials, in a European Space Agency (ESA) project.

Dr Kandemir said: “We want materials that are resilient in the space environment and, importantly, materials that can shield humans from that radiation.

“We also want to make these materials sustainable, so that when they reach the end of their life they can be recycled and used again for the same purpose.”

The launch of the Space X Dragon CRS-2 spacecraft this morning is the culmination of five years of work for Prof Hamerton and his team.

It has included the efforts of early career researchers, postgraduates and several Aerospace Engineering undergraduates at the University of Bristol, whose final year research projects have been linked to the space materials project.

The practical support of the University of Bristol-hosted National Composites Centre (NCC) was crucial to the scale up of the composite materials.

Prof Kate Robson Brown, Vice-President for Research, Innovation and Impact at University College Dublin, and a collaborator on the project, said:

“After nearly five years of research to develop novel composite materials for space applications it is very exciting to see our experiment launch to the International Space Station.

“I am proud to be part of this mission, and to be working with the multidisciplinary and multisector research team to deliver integrated real world and digital testing for innovative materials which will help to drive growth in the new space economy.

“This mission also demonstrates how space research funding creates career changing opportunities for early career researchers and PhD students in a sector of huge value to both Ireland and the UK.”

Funding to support the project was supplied by the ESA, the UKSA, Oxford Space Systems and others.

In recent years, Vietnam has rapidly transformed into one of the world’s key textile producers, solidifying its position as the world’s third-ranked exporter behind China and Bangladesh. With a history rooted in silk textile craftsmanship and currently embracing wide ranging modern textile production, the country’s thriving sector offers tremendous growth prospects for both domestic and international businesses. In a bid to harness the potential in Vietnam and Southeast Asia, the Vietnam International Trade Fair for Apparel, Textiles and Textile Technologies (VIATT) will return from 26 – 28 February 2025, with a renewed focus on promoting sustainability and digital transformation.

Vietnam's textile and apparel sector comprises approximately 7,000 companies and employs over three million workers, with 80% of production capacity used for export and 20% for domestic consumption. Progress is aided by well-developed logistics networks, skilled labour and a stable political environment. As its textile industry evolves, several key trends are influencing its future direction, reflecting a growing emphasis on sustainability and technological advancement, and leading to new opportunities for exhibitors and buyers across the value chain at Vietnam’s comprehensive textile showcase.

Major trends shaping Vietnam's textile market reflected at VIATT
More Vietnamese enterprises are adopting eco-friendly materials, including organic cotton, recycled polyester, and Tencel, while numerous global brands manufacture in Vietnam, and have committed to the "Fashion Industry Charter on Climate Action", aiming to achieve net-zero carbon emissions by 2050.

To further advance sustainable initiatives in the domestic and international textile industry, VIATT 2025 will introduce Econogy Hub, a dedicated platform for innovative, eco-friendly suppliers and service providers to connect with like-minded visitors. The show’s other new Texpertise Econogy features will include the Econogy Finder, an independent verification tool to help sustainable exhibitors effectively communicate their green credentials, and Econogy Talks, the overarching category for eco-focused seminars, forums, and product presentations.

Apart from sustainability, the Vietnamese textile industry is also embracing advanced technologies in design and manufacturing. The launch of the fair’s Innovation & Digital Solutions Zone will provide a centralised platform for exhibitors to showcase innovations such as 3D printing, AI-driven design, and digital printing, which enable manufacturers to boost efficiency and customise products to meet specific market demands.

As well as the introduction of two new product zones, the India Pavilion, organised by The Cotton Textiles Export Promotion Council (TEXPROCIL), will also make its debut at VIATT 2025. Additionally, the Japan and Taiwan Pavilions have confirmed their return, with the Japan Pavilion recognised by VIATT’s visitors as a standout showcase within Southeast Asia's textile fair landscape. Overall, the fair will feature a diverse range of exhibitors across apparel, home textiles, and technical textiles, with many showcasing innovative and sustainable products.

The Vietnam International Trade Fair for Apparel, Textiles and Textile Technologies (VIATT) is organised by Messe Frankfurt (HK) Ltd and the Vietnam Trade Promotion Agency (VIETRADE), covering the entire textile industry value chain.

The ZEBRA (Zero wastE Blade ReseArch) project marks a significant leap forward in the recycling and circular economy for wind turbine blades. This collaborative effort demonstrates a breakthrough in the complete recycling of thermoplastic blades achieving significant environmental and economic benefits.

The ZEBRA project is a unique partnership led by the French Institute for Technological Research, IRT Jules Verne. Joining forces are industry leaders Arkema (resin supplier), Owens Corning (glass fiber supplier), LM Wind Power (blade manufacturer), SUEZ (dismantling and waste processing), CANOE R&D center (recycling technology), and ENGIE (life cycle analysis).

Each company played a crucial role in the development of the closed-loop recycling process:

• Arkema developed and validated the generation of recycled Elium® monomer through thermolysis, and, together with its subsidiary Bostik, an innovative adhesive for the blade assembly that is recycled together with Elium® paving the way for industrial-scale implementation.
• Owens Corning successfully recovered glass fiber at pilot scale, enabling its reintroduction into the production process for their Sustaina® product line.
• LM Wind Power manufactured two wind turbine blades with Arkema’s Elium® resin and Owens Corning’s Ultrablade® fabrics; one blade including a large structural element made with recycled Elium® resin.
• SUEZ provided cutting and grinding expertise for processing the blades.
• CANOE R&D center optimized recycling for production and carbon blade waste, additionally developing methods for repurposing waste streams through mechanical recycling.
• ENGIE conducted a comprehensive life cycle analysis demonstrating the environmental benefits of closed-loop ZEBRA blades and validated their economic viability.

A Sustainable Future for Wind Energy
The ZEBRA project successfully recycled Elium® resin and Ultrablade® fabrics from wind turbine blades and manufacturing waste, reformulating them back into usable materials. This closed-loop process addresses the growing challenge of end-of-life blade management within the wind energy industry.

• Recycled Elium® Monomer: Arkema achieved a yield of over 75% in the thermolysis process, paving the way for industrial-scale production of recycled resin.
• Recovered Glass Fiber: Owens Corning successfully retrieved glass fiber for remelting and reintegration into their Sustaina® product line.
• Life Cycle and Cost Analysis: ENGIE's study confirmed the significant environmental benefits and economic viability of ZEBRA blades when assuming a closed-loop recycling system from production to end-of-life.

ZEBRA blade using Elium® thermoplastic resin, Bostik’s highly compatible adhesive and Ultrablade® fabrics is bringing the best closed-loop recycling solution compared to traditional thermoset system. The operating cost and investments for recycling facility are significantly lowered. The CO2 emission linked to the recycling operations is reduced as well. All those results are making the closed-loop recycling solution of ZEBRA blades a viable option both on economic and environmental standpoints.

By demonstrating the feasibility of full wind turbine blade recycling, the ZEBRA project paves the way for a more sustainable future in the wind energy sector.