From the Sector

Polyethylene and polypropylene account for two-thirds of the world’s plastics. But the polymers’ popularity has an equally large downside. Because they have similar densities and physical properties, the polymers are difficult – and expensive – to separate when mechanically recycled together. What results is a weak, degraded material that really isn’t good for anything.

Now, Cornell researchers have developed an inexpensive and potentially scalable approach that uses a commercially available peroxide to bind the polymers together, thereby creating a more useful, high-quality plastic recycling additive.

The findings were published May 19 in the Journal of the American Chemical Society. The co-lead authors were postdoctoral researcher Moritz Kränzlein and doctoral student Shilin Cui. The project was led by Geoffrey Coates, the Tisch University Professor of Chemistry and Chemical Biology in the College of Arts and Sciences, the paper’s senior author.

In a way, the project is itself a recycled product. In 2017, Coates’ lab worked with collaborators from the University of Minnesota to create a multiblock polymer that could combine polyethylene and polypropylene mixtures. The new material was an important scientific achievement, according to Coates, but it proved difficult to scale up. It was also too expensive to be practical.

“We had to go back to the drawing board and think of the Venn diagram of what material would work and what synthetic methods would be affordable,” he said. “Why didn’t we just do that in 2017? Trust me, if it was easy, somebody else would have done this long ago.”

The key to developing their new polyolefin compatibilizer was to look for  existing polymers that, with the right processing, could do the job, rather than creating a new one from scratch. Kränzlein began by experimenting with the materials that were already in the lab, always with a few parameters in mind.

“Every second meeting, when I was giving Geoff an update, his first question was, ‘What’s the cost?’ There was always this line of price per pound that I shouldn’t cross,” Kränzlein said. “We tried to really keep that as a focus of this project. Instead of finding a very elegant or sophisticated solution, we tried to find a real-world solution that works.”

A year and a half – and more than 200 experiments – later, the researchers settled on an organic alkyl peroxide that, when heated, essentially plucks hydrogen molecules off high-density polyethylene (HDPE) and isotactic polypropylene (iPP) so they can be grafted together and form a copolymer material that can be added to a mechanical recycling process for HDPE and iPP mixtures, restoring their properties.

The copolymer can basically be thought of as “plastic soap,” Kränzlein said.

“When we have mixtures of commodity plastics like HDPE and iPP, those don’t mix very well, and those phases separate from each other, which makes the material properties of those mixtures pretty bad,” Kränzlein said. “This process adds in a third component that acts like a soap between those two phases, and that soap facilitates a better miscibility between the polymers, and that restores the physical properties of those mixtures, essentially.

“It took us a very, very long time playing around with all the different tuning points,” he said, “until we finally achieved something that that we were happy with.”

To better understand their compatibilizer’s properties and the grafting reaction, the researchers turned to Brett Fors, the Frank and Robert Laughlin Professor of Physical Chemistry (A&S), and doctoral student Jenny Hu, who conducted rheological characterization studies on it.

“So we’ve got the material,” Coates said. “The question is, now can you make larger amounts? We’re doing grams-at-a-time scale. Ultimately, you’d want to be doing dozens of kilograms. We’re confident it’ll scale, but there’s going to be a lot of work to get it there.”

Coates is hopeful that the compatibilizer could also lead to the creation of new polymer alloys that leverage the respective strengths of different waste plastics. There would be no need for giant million-dollar plants: Just take some preexisting polymers and add the compatibilizer.

“You could make a whole kind of pallet of alloys that might have better properties than either one of the pure polymers alone, just like stainless steel,” said Coates, who recently launched a startup that specializes in the compatibilizer technology through Cornell’s Praxis Center for Venture Development. “The dream is, if you can make a really rigid polymer that’s also really tough, then you can make packaging that uses less material, yet has the same sort of properties. That’s one of the other big applications for this technology.”

Co-authors include Fors, Hu and research associate Anne LaPointe.

The research was supported the Gerstner Family Foundation, with additional funding from the U.S. Department of Energy through Ames National Laboratory’s Institute for Cooperative Upcycling of Plastics, an Energy Frontier Research Center.

Every year, millions of tons of PET and polyester waste end up in landfills or are incinerated, yet sustainable recycling solutions remain limited. DePoly - a leading sustainable PET-to-raw-material recycling company – announced the upcoming launch of a 500-tonne-per-year showcase plant in Monthey, Switzerland this summer, representing a critical step in the company's journey from laboratory breakthrough to industrial-scale implementation.

The facility will demonstrate DePoly's proprietary process that converts PET and polyester waste into virgin-quality raw materials without fossil fuels. Imagine a world where discarded items – from polyester shirts to water bottles – are not wasted anymore but resources transformed back into the building blocks for new products. After all, revolutionizing an industry isn't just about creating new technology – it's about proving it works at scale.

DePoly’s technology has already demonstrated its commercial impact through collaborations with some of the world’s leading companies—not only in fashion, like Odlo, but also in cosmetics and the broader consumer goods industry, including innovators such as PTI. Through these partnerships, DePoly has validated the quality of its recycled monomers by transforming PET waste into new bottles, high-performance textile fibers, and cosmetic packaging. This proves that DePoly’s recycled materials can meet, and even exceed, the highest standards of purity and performance across a wide range of industries.

By delivering oil-equivalent monomers, DePoly’s technology sets a new benchmark for circularity, offering a genuine alternative to virgin materials.

DePoly is ramping up with world-class innovators, bold thinkers and cutting-edge know-how—taking their pilot victory to industrial scale demands nothing less than unstoppable ambition. The company is planning to build a commercial plant in 2027 that will process significantly larger volumes of PET and polyester waste – a major leap in redefining recycling and advancing the circular economy, as DePoly strives to become the global leader in sustainable, circular plastics.

To further accelerate this expansion, DePoly has secured a total of $23 million in seed funding with MassMutual Ventures joining a second closing of its round. The expanded investor base positions DePoly as one of the biggest recycling technology companies in Europe, with more than $30 million raised across two rounds and grants. MassMutual Ventures joins existing investors, including Founderful, ACE & Company, Angel Invest, Zürcher Kantonalbank, BASF Venture Capital, Beiersdorf Venture Capital, and Syensqo.

The Cellulose Fibres Conference 2025 (CFC 2025), held on 12-13 March in Cologne, Germany, brought together industry leaders, innovators and researchers to explore the latest innovations and new technologies for fibres – in textiles, hygiene products and packaging. The conference has established itself as the leading international platform for the emerging cellulose fibre industry. Two days with high quality program and outstanding speakers highlighted the growing importance of addressing environmental concerns within the textile industry.

The main source for the production of staple fibres or filaments such as viscose, lyocell, modal or other types of new cellulose fibres is wood-based chemical pulp. At the same time, new sources such as agricultural wastes and fibres, paper grade pulp and recycled textiles are emerging on a global scale, with a variety of new sources and companies contributing new technologies, processing methods and ideas.

Biosynthetics, featured for the first time at the conference, drew significant attention. Experts discussed the challenges and opportunities of cellulose fibres and biosynthetics, with particular focus on scalability, biodegradability, and performance comparisons to conventional synthetic fibres from fossil origin.

Dynamic Engagement and Scientific Discourse
The CFC 2025 fostered discussions among attendees, with a strong emphasis on scientific advancements and sustainable practices. Participants actively engaged in sessions covering topics such as circular economy strategies fibre-to-fibre recycling from textile, marine biodegradability versus fibre microplastic formation, alternative feedstocks, and innovative technologies for pulp, fibres, biosynthetics, and yarns.

In order to support the development, innovation and market entry of cellulosic fibres, Dieter Eichinger, CIRFS (BE), presented a proposal for a new standard that includes all types of cellulosic fibres such as Viscose, Lyocell, Tencel, Modal, Cupra and new innovative fibres under the generic term "cellulose fibres". The proposal was widely supported by the participants. Anna Palmberg, IKEA (SE), also expressed a concrete interest in using more cellulose fibres in the future.

The event witnessed heightened activity on social media platforms, with delegates sharing insights, experiences, and key takeaways using the hashtag #CFC2025. This digital engagement extended the conference's reach, allowing a broader audience to participate in the discourse on sustainable textiles.

Innovation Award winner announced
The announcement of the "Cellulose Fibre Innovation of the Year 2025" award winners was undoubtedly one of the highlights of the conference. Sponsored by GIG Karasek, the award recognises groundbreaking developments in the field. Every year, the award recognises the three most promising innovations in the field of cellulose fibres, highlighting groundbreaking advancements and their potential impact. This year, for the first time, the award also offered the opportunity to recognise innovations in the field of biosynthetics. The top three outstanding technologies were honoured this year for their remarkable advancements. These three pioneers will certainly pave ways in the future of the sustainable fibres industry:

1. .SA-Dynamics (Germany): Cellulose Aerogel Textiles
   SA-Dynamics introduced revolutionary insulation materials made from 100% biodegradable cellulose aerogel fibres. These materials combine the flexibility of traditional fabrics with the superior thermal insulation properties of aerogels, offering a sustainable alternative to fossil-based and animal-derived insulation materials in textiles as well as in construction.  
2. Releaf Paper France (France): Releaf Fiber
   Releaf Paper France transforms urban fallen leaves into sustainable cellulose fibres, providing an eco-friendly alternative to traditional hardwood pulp. Their proprietary low-temperature extraction process yields high-quality fibres ideal for packaging materials, aligning with circular economy principles by repurposing urban leaf waste.
3. Uluu (Australia): Seaweed-Derived Biosynthetic Materials
   Uluu is set to replace plastics in textiles with natural PHA polymers, derived from farmed seaweed. In partnership with Deakin University, Uluu is developing textile fibres that perform like synthetic polyester but are biodegradable in various environments, eliminating persistent microplastic pollution in fashion. 

INDA, the Association of the Nonwoven Fabrics Industry, has announced the program for IDEA®25, a two-day Sustainability in Nonwovens Conference. IDEA25 will take place April 29-May 1, at the Miami Beach Convention Center in Florida.

The IDEA25 conference will bring together industry professionals to share knowledge and strategies to advance sustainable practices, highlighting the need for ongoing innovation, regulatory compliance, and incorporating eco-friendly materials to foster a more sustainable future.

The conference will include engaging sessions on various pertinent topics such as regulatory trends, data and technology, innovative and sustainable materials, hemp and natural fibers, bioplastics, equipment and processes, and integrating sustainability throughout the lifecycle of products.

Highlights of the IDEA25 Sustainability Conference

April 29:

• Navigating the Shifting Winds of Sustainability Regulations: Gain U.S. and European Union perspectives on compliance and innovation in the face of evolving regulations
• “In God We Trust… All Others Bring Data”: Learn how to craft a believable and transparent sustainability story
• Innovative and Sustainable Materials: Discover how green product development starts with greener nonwovens
• Hemp Fibers in Nonwovens: Explore the potential of hemp and other natural fibers and their applications in sustainable products

April 30:

• Cradle to Grave Bioplastics: Understand the importance of ensuring sustainability in the use of bioplastics from the beginning to the end-of-life
• Design for Sustainability: Explore the impact of product and process design on overall product sustainability, during two sessions
• Cradle to Next Life: Challenge the “to the grave” mentality and explore strategies for product reincarnation

The conference is an integral part of IDEA, the premier event for the nonwoven and engineered fabric industry. Hundreds of companies from around the globe representing the entire global supply chain will showcase their latest innovations at the exhibition. 

Starlinger & Co GmbH puts the focus on its technologies for sustainable and efficient polypropylene tape production as well as food-safe recycled PET and polyolefins at Chinaplas this year.

With a maximum melting capacity of 1000 kg per hour and production speeds of up to 550 meters per minute, Starlinger’s starEX 1600 tape extrusion line unites high efficiency with resource-saving state-of-the-art design. It produces top-quality PP or HDPE/LLDPE tapes for high-performance packaging applications for dry bulk goods such as woven PP sacks or big bags. Specially developed and worldwide unique machine components such as the eqoSTRETCH stretching and annealing system ensure energy-saving production and uniform tape characteristics, while the eqoCLEAN filter system enables the processing of high shares of recycled polypropylene for producing more sustainable woven PP packaging.

“We have gathered decades of expertise both in woven plastic packaging production as well as in plastics recycling,” said Harald Neumüller, Chief Sales Officer at Starlinger. “By combining this know-how, we have developed technology that helps packaging manufacturers to establish closed packaging loops and make plastic packaging circular.” Starlinger has already realised lighthouse projects with customers in the FIBC sector, proposing a closed-loop economy for big bags made from rPP and rPET. “We consider used plastics as a resource, not waste,” Neumüller continued. “This is the only way to get a grip on the increasing amount of plastic waste worldwide. By collecting used plastics and reprocessing it we protect our environment, conserve natural resources, and at the same time save money that would need to be spent for waste treatment facilities and environment clean-ups.”

Precision to the core
With its high-speed winding technology, the twinTAPE+ automatic precision winder is Starlinger’s top-scale tape winder model. It ensures that the produced PP tapes from the starEX tape extrusion line are wound into perfect packages that improve productivity and fabric quality on the looms. The bevelled bobbin edges avoid that tapes come off during doffing, transport and handling and increase loom efficiency during weaving. The automatic bobbin change procedure of twinTAPE winders reduces operator work significantly, and the patented linear traverse system features an infinitely variable stroke, allowing a wide variety of bobbin designs. As the winder does not need lubrication, maintenance work is reduced to cleaning, which saves significant amounts of operator time.

Kelheim Fibres, a leading manufacturer of specialty viscose fibres, has published their comprehensive sustainability report. By doing so, the company is setting another milestone for transparency while simultaneously emphasizing its commitment to the goals of the UN Global Compact.

An integral part of the sustainability report is the EMAS Environmental Statement, which – as it has been annually since 2020 – was audited by independent environmental experts as part of the EMAS (Eco-Management and Audit Scheme) revalidation. This confirms Kelheim Fibres’ high environmental performance and its continuous efforts towards sustainable corporate governance.

The sustainability report goes beyond mere environmental performance and addresses all aspects of Corporate Social Responsibility (CSR).

“Credibility and trust are based on transparency. With our new sustainability report, we demonstrate how we fulfil our responsibility for both people and the environment – and the contribution we make with our biodegradable fibres to combating one of the biggest global problems of our time, the growing plastic waste,” explains Wolfgang Ott, Head of CSR at Kelheim Fibres. The viscose fibres made from 100% plant-based raw materials represent a powerful alternative to conventional plastics in numerous applications and thus help reduce global waste.

INDA brought together hundreds of industry leaders to explore advancements in the absorbent hygiene and personal care markets during the 10th annual Hygienix™ event, held Nov. 18-21 at the Renaissance Nashville Hotel.

Themed Driving Absorbent Hygiene Product Innovation: Consumer Desires, Market Dynamics & Sustainability Solutions, key sessions included pricing strategies, global trade impacts, FemTech, adult care, period poverty, emerging pet care and wound care markets, environmental regulations on plastics and PFAS, and the impact of aging societies.

An event highlight was the presentation of the 2024 Hygienix Innovation Award® to: HIRO Technologies, Inc.’s World’s First MycoDigestable Diapers, diapers featuring plastic-eating mushrooms that combine excellent absorbency with natural materials.

The other finalists were:

• Harper HYGIENICS S.A.’s Cleanic Naturals Hemp Sanitary Pads (Day & Night) and Pantyliners, an innovative femcare line made with regenerative hemp fibers from Bast Fibre Technologies.
• Hello Hazel, Inc.’s High & Dry Briefs, the first and only disposable briefs for leaks designed to look, fit, and feel like real underwear.

Hygienix Highlights
Attendees gained insights and knowledge during three hands-on training sessions on Nov. 18, focused on fundamentals of absorption systems and opportunities in adult incontinence, innovations in menstrual care, and baby and infant care market dynamics.

Hygienix kicked off with a welcome reception that fostered networking. Attendees explored emerging trends and product innovations through Lightning Talks, connected with successful hygiene start-ups during Lunch Around sessions, and discovered the latest offerings at tabletop exhibits.

“Hygienix exemplifies INDA’s commitment to empowering companies in the absorbent hygiene and personal care markets to advance their businesses,” said INDA President Tony Fragnito. “The insights and connections made at this year’s event will drive growth and enable participants to meet evolving demands and market challenges.”    

INDA announced Hygienix 2025 will be held Nov. 17-20 at Omni Amelia Island Resort, Fernandina Beach, Florida.

The upcoming conference on 12-13 March 2025 in Cologne, Germany, will pave pathways to a sustainable textile industry.

Over the past few weeks, the Conference Advisory Board, and the experts from the nova-Institute, have thoroughly reviewed and evaluated over 40 submitted abstracts. The selected external experts bring new insights and perspectives from the pulp, fibre and further developing industries, promising to spark and deepen discussions at the event. Their expertise across the entire fibre value chain will enrich the topics covered and ensure a dynamic and insightful exchange of ideas. The presentations will provide a platform for the discussion at the conference after each session, and the Advisory Board members will foster a lively debate to drive innovation industry-wide.

Biosynthetics on the rise
Besides cellulose fibres, bio-based polymer fibres ("biosynthetics") are an excellent option to reduce fossil fibres in textiles. Biosynthetics offer a powerful alternative to traditional synthetic fibres, bringing both performance and technical properties that make them drop-in replacements. Derived wholly or partially from natural, renewable sources like lactic acids, sugar beet, sugarcane or wood, biosynthetics represent a bio-based option compared to fossil-based counterparts. In a special session “Biosynthetics - Replacing Traditional Synthetic Fibres”, experts will explore the latest advances, challenges and opportunities in the field. Discussing innovative approaches like biosynthetics is essential to drive sustainable transformation within the fashion and textile industries.

Fibre-to-Fibre Recycling: A Path to a Sustainable Textile Industry
The textile industry is at a crucial crossroad. The need for sustainable solutions to meet the EU's ambitious climate change targets is becoming increasingly urgent. Fibre-to-fibre recycling, which transforms discarded textiles into new, virgin fibres, holds great promise for reducing waste and resource consumption and helps to close the loop in textile production. While Europe has made progress in this area, challenges remain – in particular the management of mixed fibre textiles and the scaling up of recycling technologies. As new approaches are needed to tackle climate change, one session of the conference will focus on fibre-to-fibre recycling from textiles, exploring the latest innovations and technological advances, as well as the opportunities and barriers that need to be addressed to move the industry towards a circular, sustainable future.

Fibre Microplastic Formation versus Marine Biodegradability
The environmental impact of textiles extends far beyond landfill, with microplastics from synthetic fibres becoming a growing concern in marine ecosystems. A session at the conference will focus on the complex relationship between microplastic formation and marine biodegradability. While synthetic fibres shed microplastics during washing, these tiny particles, known as microfibres accumulate in the oceans and pose a serious threat to marine life. This session will explore the factors that influence fibre degradation in the marine environment and examine the potential of biodegradable fibres to reduce long-term pollution. Leading research institutes will discuss the challenges of balancing the prevention of microplastics with the development of fibres that can degrade naturally in marine ecosystems, and provide insights into innovative solutions that could help mitigate this pressing environmental issue.

Innovation Award “Cellulose Fibre Innovation of the Year 2025”
The nova-Institute, together with GIG Karasek, is looking for the best fibre innovations of the year. Applicants from the area of cellulose fibres as well as biosynthetics are welcome to submit their innovations. Technologie providers, research institutes or producers can apply until 30 November 2024. The innovation award “Cellulose Fibre Innovation of the Year 2025” is sponsored by GIG Karasek.

Apply for the “Cellulose Fibre Innovation of the Year 2025” award: cellulose-fibres.eu/award-application

Call for Posters
The poster exhibition is a highly anticipated scientific event at the conference, especially for early career scientists. Poster submission is open until 31 January 2025.

EDANA, the global association for the nonwovens and related industries, concluded its annual Sustainability Forum at the KBR Royal Library of Belgium in Brussels. This year's forum, themed “Building a Sustainable Future Together,” featured a series of keynote addresses, panel discussions, and collaborative sessions focused on environmental responsibility, corporate social responsibility, and circular economy innovations within the nonwovens sector. With an agenda that bridged policy and practice, the Forum highlighted the latest advancements and strategies aimed at tackling climate change, reducing waste, and enhancing sustainability practices.

Keynote Highlights
The forum featured two keynote speakers: Ana Rovzar, Founder of Polygon AR, opened the Forum with a keynote on the accelerating transition to clean energy. In her speech, she discussed the shift from conventional energy investments to renewables, noting a 50% growth in renewables in 2023 alone. “It is accelerating much faster than people think” she remarked, emphasizing that “real progress requires a united front from governments, businesses, and communities to remove regulatory and technological barriers”.

In another keynote, sustainability expert Mike Barry, formerly of Marks & Spencer, stressed the importance of aligning corporate strategy with sustainability. “Citizens see climate change as a top priority, and companies must act boldly to reduce emissions, especially Scope 3”, he said. “Sustainability is now a vital part of brand identity, and consumers expect more transparency and commitment than ever”.

Innovative Industry Perspectives and EU Policy Impacts
Brieuc Lits, Public Affairs Director at EDANA, examined the potential effects of the EU Green Deal on the nonwovens industry. “The EU’s shift towards balancing sustainability with competitiveness will shape not only policy but the very framework within which we operate”, he noted, emphasizing that the sector must adapt to stay competitive and aligned with regulatory expectations.

Lastly, Paolo Haeusermann, Senior Brand Director and Europe Sustainability Leader at Procter & Gamble, shared insights on advancing sustainability in absorbent hygiene products and emphasized the importance of these items. “We are talking about essential products in people’s lives”, he remarked.

Corporate and Product Sustainability: A Deep Dive
Several industry leaders shared insights on integrating sustainability at every level of business. Carsten Ruff from Nitto Advanced Film Solutions discussed the challenges and strategies of embedding sustainability in corporate culture, particularly in a multinational setting. “Sustainability is not a contradiction to industrial applications; it’s a powerful driver of innovation”, he observed.

Martijn Gipmans from Sphera Solutions highlighted the business value of transparency and life-cycle assessments (LCA). “LCA and transparent ESG reporting can catalyse both business growth and environmental progress”, he explained, stressing the importance of integrated sustainability assessments to reduce the carbon footprint of entire product portfolios.

Christophe Morel-Fourrier, Sustainability Leader for Hygiene, Packaging, and Converting Adhesives at Bostik, introduced the Archimedes tool as a strategic asset for Portfolio Sustainability Assessment. “Archimedes allows us to make transparent, informed decisions that align with our long-term sustainability goals”, he explained. He highlighted that this tool helps companies evaluate the sustainability of their product portfolios, empowering them to make impactful choices that support environmental goals.

The Path Forward: Advancing Circularity and Green Innovation
One of the most discussed topics was the industry's transition toward a circular economy. Albert Hammerschmied from Freudenberg Performance Materials highlighted the importance of post-industrial waste in achieving circularity, particularly in the automotive sector. “The potential for nonwovens in the automotive circular economy is vast, but requires industry-wide collaboration”, he commented.

In a session addressing the future of sustainable practices in building insulation, Alexandre Butté of ANDRITZ Laroche emphasized the importance of sustainable materials and collaboration among stakeholders. “The building industry faces unique sustainability challenges, but with innovation and eco-friendly materials, we can bridge the gap between goals and achievable practices”, he said.

Building a Sustainable Health Sector
Danielle van Horzen, Global Marketing Manager for Hygiene and Healthcare at SABIC, discussed advanced recycling solutions in the healthcare sector. Addressing the challenges of medical waste recycling, she stated, “A significant amount of medical waste is not contaminated, offering us opportunities to create circularity in healthcare.” She pointed to the potential for advanced chemical recycling to enable circular models, helping to tackle the pressing issue of sustainable medical waste management.

The day concluded with a session on the circular potential within healthcare. Kristien Depraetere, Sustainability Coordinator at UZ Leuven, outlined sustainable practices in hospitals, from waste reduction to advanced recycling in medical waste. “Healthcare can lead by example in the transition to circularity, yet we need practical and legislative support to address unique industry challenges”.

Visit to the European Commission
The third day of EDANA’s Sustainability Forum 2024 concluded with an insightful visit to the European Commission, offering attendees a unique opportunity to engage directly with policymakers and gain firsthand insights into the EU's sustainability agenda. Hosted at the Charlemagne Building, discussions centered on pivotal elements of the EU Green Deal, including the establishment of Extended Producer Responsibility (EPR), the scope and implementation of the Single-Use Plastics Directive (SUPD), and the Ecodesign for Sustainable Products Regulation.

Featuring presentations from prominent EU officials like Vicenzo Gente and Werner Bosmans, attendees delved into how these regulations are shaping sustainability strategies across industries. Bridging policy and practice emerged as essential, reinforcing the forum’s dedication to aligning industry actions with current EU regulatory frameworks. The session offered a strong conclusion to the event, reinforcing a shared commitment to a sustainable future in collaboration with EU leaders and regulatory bodies.

Teijin has teamed up with Germany's herone GmbH and the UK's Envision Racing to develop a composite wishbone which has the capability be used in a Formula E racing car using Tenax™ ThermoPlastics.

The new component is specifically designed to maximize performance while minimizing weight. By utilizing recycled materials from the aerospace industry and implementing herone's innovative pressing process, the partners are setting an example of environmental consciousness and technological excellence.

Multiple demonstrator parts were produced utilizing Tenax™ ThermoPlastic UniDirectional (TPUD) tapes. The material was braided to form the rod structure of the component. Recycled offcuts from part manufacturing in the aerospace industry were used for the functional elements. Those offcuts were injection molded to sockets which are needed for load introduction into the rod structure. herone’s innovative pressing process then compression molded the braids and at the same time co-consolidated the sockets into the rod structure to form the final part. All materials in this study were based on PPS polymer - thus making it attractive for further end-of-life recycling.

The use of these advanced materials makes it possible to reduce weight, minimize emissions, and increase performance at the same time. The combination of design and functionality opens new possibilities for future developments in the field of motorsport and beyond. We look forward to continuing to develop innovative solutions based on thermoplastic composites together with our partners and customers.