From the Sector

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

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

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

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

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

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

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

TCV, Teijin’s carbon fiber business base in Vietnam, was established in May 2019. Teijin Limited announced that Teijin Carbon Vietnam Co., Ltd. (TCV) in Ha Nam, Vietnam, has started operating commercially to manufacture carbon fiber products including prepreg, a fiber sheet pre-impregnated with matrix resin as an intermediate material for composites. TCV initially will produce carbon fiber materials for sports and outdoor activities, including fishing, golf, bicycle and ice hockey goods, for markets in Southeast and South Asia and Asia-Pacific. Sales will be handled by TCV as well as carbon　fiber sales affiliates of Teijin operating in these markets.

Teijin’s sales affiliates in Singapore, Shanghai and Taipei work to identify demand opportunities as well as provide customer services in Asia. Internal collaborations between these companies and TCV shall strengthen Teijin’s presence in the upstream and downstream sectors of Asia’s fast-growing markets.

Increasingly strict environmental measures and the upgrading of environmental frameworks, such as sustainable development goals (SDGs) and the Paris Agreement, are expected to stimulate greater use of lightweight and highly rigid carbon fiber. Demands are growing in Asia, especially in the fields of sports and outdoor activities, industry and aerospace. COVID-19, for example, has led to new trends in sports and　outdoor activities, such as renewed interest in fishing due its compatibility with social-distancing protocols.

From leaders to entrepreneurs, JEC COMPOSITES CONNECT is welcoming a lineup of special guests. As part of conferences, they will share their expertise, vision, and perspective in front of all the players in the composites industry.

AEROSPACE – Towards a More Sustainable Strategy, Tuesday, June 1st –  9am to 10:15am (CEST)
The aerospace industry is a major source of innovation and technological advancements that often originates inspiration across a wide variety of other industries. Nowadays, in a context where environmental constraints are becoming increasingly stringent especially when it comes to air mobility, OEMs are constantly in search of innovative answers and solutions that will allow them to create a ‘greener’ future. The need for light-weighting, reduced maintenance and waste, and repurposing aerospace-grade CFRP towards other applications are expected to drive demand and adoption of composites in aerospace applications.

Yannick Willemin, Head of Marketing & Business Development, 9TLabs, will chair this conference with Clémentine Gallet, CEO, Coriolis, Hervé Gilibert,CTO, ArianeGroup, Jean Botti, CEO, Voltaero and Scott Finn, Chief Consulting Engineer for Composites, GE Aviation.

AUTOMOTIVE – The Right Material at the Right Place, Tuesday, June 1st –  3 pm to 5:05 pm (CEST)
Among the many challenges facing the automotive industry, reducing vehicle mass and therefore emissions all while maintaining safety and cost-efficiency remain key. Lighter materials implying higher costs, they limit mass production. Therefore, a combination of materials, albeit hybrid solutions, would help solve this issue and are becoming increasingly attractive for manufacturers. This conference consists of industry presentations and a panel discussion involving major OEMs & Tier1s from all over the world. It covers the challenges & opportunities of using composites materials in the Automotive field.

Dale Brosius CFO, IACMI, will chair this conference with Alice Swallow, Senior Innovation Engineer, FORD MOTOR GROUP, Christophe Kühn, Senior Project Manager – Composites & Hybrid Components, VOLKSWAGEN, Dominik Klaiber, Doctoral Candidate Body Advanced Engineering, PORSCHE and Gerard LIRAUT, Expert Leader Polymers, GROUPE RENAULT – ALLIANCE RENAULT NISSAN MITSUBISHI.

With their recently installed high-temperature unidirectional tape line, Japan-based composites manufacturer MaruHachi enables new opportunities for high-end applications in demanding market segments like aerospace, automotive or others outperforming traditional materials based on PP and PA which are already widely available.

In the first phase, MaruHachi will produce up to 40 tons/year and focuses now specifically on high-temperature thermoplastic uni-directional (UD) tapes and multi-layer sheet laminates. The material is based on high-performance fibers like carbon, aramid, glass or natural fibers and the matrix can be high-performance polymers like PPS, PEEK or other higher temperature polymers, which are much tougher than epoxies and easy to recycle. With a width of 500 mm, a specific weight from 60 to 350 g/m2, depending on the chosen material, the lines can operate under temperatures up to 420 degrees Celsius. Working under these extremely high temperatures allows for better material properties of the final application, higher performance, increased resistance and integrated high-performance functionalities e.g. by overmoulding.

Since 2017, MaruHachi Group is active in the European market in cooperation with Dr. Michael Effing,the CEO of AMAC GmbH, who advises and supports the company strategically. The established, family-owned MaruHachi Group has a strong history in automotive and medical textiles and has been active in the innovative composites market for more than 15 years.

Toshi Sugahara, CEO of MaruHachi: “For many years, we have already been cooperating with domestic and international partners on high-demand applications and therefore, MaruHachi decided now to invest over 1 million EUR in this new line in phase 1, including a funding participation from the Japanese government NEDO. New developments in phase 2 will be be undertaken by end of 2021 on the downstream technologies like the automated preforming and consolidation. With our new products, we want to contribute to significant weight reductions of the final products, thus improve energy efficiency while offering a cost-efficient and high-quality solution.”

Dr. Effing, CEO of AMAC GmbH confirms: „The focus on the niche of high-temperature products based on PPS and PEEK allows MaruHachi on very demanding high-end applications such as structural frames on space and aircrafts, aircraft seats or engine components etc. The tapes are fully recyclable and can be processed e.g. with high-speed with laser-based tape placement machines and robots.”

The AVK – Industrievereinigung Verstärkte Kunststoffe e.V. – has once again announced the winners of its prestigious Innovation Awards. Decided by an expert jury, the awards recognise and honour sustainable innovations in three categories: “Innovative Products/Applications”, “Innovative Processes” and “Research and Science”.

Overview of all the winners in the three categories:

Category “Innovative Products/Applications”
1st Place: “Directly-cooled electric motor with integral lightweight housing made of fibre reinforced polymers - DEmiL” – developed by the Fraunhofer Institute for Chemical Technology ICT, Pfinztal, Germany, in partnership with the Karlsruhe Institute of Technology and Sumitomo Bakelite Co., Ltd.*

2nd Place: “Intrinsically Reprocessable, Repairable and Recyclable (3R) thermoset composites for more Competitive and Sustainable Industries” – developed by cidetec, Donostia-San Sebastian, Spain*

3rd Place: “Fireproof composite metal hybrid structure – LEO® fire protection sandwich with integrated Hyconnect steel-glass hybrid connector” – developed by SAERTEX GmbH & Co. KG and Hyconnect GmbH.*

Category “Innovative Processes”
1st Place: “Robotised Injection Moulding (ROBIN)” – developed by Robin, Dresden with the Institute for Lightweight Engineering and Polymer Technology at the TU Dresden*

2nd Place: “Omega stringer from the roll” – developed by the German Aerospace Center, Braunschweig*

3rd Place: “Hybrid die-casting – manufacturing of intrinsic CFRP-aluminium composite structures in aluminium high-pressure die-casting” – developed by Faserinstitut Bremen e. V. with Fraunhofer IFAM, Bremen*

Category “Research and Science”:
1st Place: “New high-temperature resistant UP resins and toughening agents” – developed by Münster University of Applied Sciences with BASF SE Global New Business Development, Leibniz Institute for Polymer Research e. V., Saertex multicom GmbH*

2nd Place: “Scientific basis for the industrial application of the thermoplastic resin transfer moulding (T-RTM) process” – developed by Fraunhofer Institute for Chemical Technology ICT, Pfinztal*

3rd Place: “The material- and energy-efficient production of turbine struts by the integrative combination of thermoset fibre reinforced materials” – developed by the Institute of Polymer Technology, University of Erlangen-Nuremberg with the German Aerospace Center, Gubesch Group, Schmidt WFT, Siebenwurst, Raschig.

Award ceremony on the Internet for the first time
For the first time, due to the Covid-19 pandemic, the award ceremony took place as an online event on 12 November 2020. Many of the award winners’ innovations will be presented again in this year’s AVK Innovation Award brochure. This will be available online: https://www.avk-tv.de/innovationaward.php

*Please see attached document for more information.

An impairment charge has become necessary based on the current status of the new 5 year plan.

(Market Abuse Regulation N° 596/2014)
•    Impairment loss amounting to €80-100 million in the fourth quarter 2020 in the business unit CFM
•    Restructuring program resolved with savings target of more than €100 million until 2023
•    Guidance 2020 for Group sales and operating recurring Group EBIT confirmed
•    Guidance 2020 for net result reduced to minus €130-150 million

In the current status of the 5 year plan, which is at present under preparation, significant deviations have already become apparent today, particularly in the market segments Automotive, Aerospace and Wind Energy in the business unit Composites – Fibers & Materials (CFM). Partially also due to the pandemic, Automotive and Aerospace is developing slower than anticipated in the last 5 year plan. In contrast, business with Wind Energy is growing much stronger than previously planned. These changes in the product mix lead to lower mid-term earnings at CFM compared to the prior 5 year plan. Following these deviations from the last 5 year plan, an event-driven impairment test was undertaken. This results in a non-cash impairment charge amounting to €80-100 million, which will be recorded in the fourth quarter 2020.

The Board of Management of SGL Carbon SE today also resolved the implementation of a restructuring program, with which the Company is targeting savings of more than €100 million until 2023 (compared to the base year 2019). These savings consist of a planned socially compatible reduction in personnel of more than 500 employees and substantial reduction in indirect spend, particularly in the areas of travel, consulting and external services. Costs of approximately €40 million are anticipated for the implementation of this restructuring program. A little more than half of this is expected to be recorded as expenses in the fourth quarter 2020, while the associated cash outflows are mainly forecasted for 2021.

This requires a partial adjustment of the guidance for 2020. The solid operational development in the third quarter 2020 with Group sales between €220 and €230 million and operating recurring EBIT1 between €13 and €15 million (plus approximately €9 million positive one-time effects) is within the framework of our expectations for the full year 2020. However, the Group net result is likely to develop below the prior year level of minus €90 million and reach approximately between minus €130 and €150 million due to the restructuring provisions as well as the impairment charge (prior guidance: improvement to a negative low double-digit million € amount).

With liquidity of €167 million as of September 30, 2020 (compared to €137 million at year-end 2019) and further cash inflows in the fourth quarter 2020 from successfully implemented additional funding measures, the Company’s position is solid. This liquidity is more than sufficient for the payment of the purchase price for SGL Composites USA in the amount of USD 62 million at the end of 2020 as well as the restructuring-related cash outflows expected mainly in 2021. The Company continues to have access to the revolving credit facility (RCF) in the amount of €175 million, which remains undrawn.

The quarterly statement as of September 30, 2020 will be published on November 12, 2020 as scheduled. Further details on the new 5 year plan as well as the guidance on the fiscal year 2021 will be presented with the publication of the Annual Report 2020 on March 25, 2021.

*The use of KPIs in this notification is aligned to the annual report 2019 and the interim report for the first half year 2020. There were no changes to the scope of consolidation or to valuation methods compared to the previous guidance.

Hexcel’s Leading Position in Aerospace and Automotive Makes Hexcel a Trusted Partner for Urban Air Mobility

At this year’s JEC World in Paris on March 3-5, Hexcel will highlight the growing need for innovations in composite materials to support the emerging Urban Air Mobility (UAM) market.

Urban air mobility – urban transportation systems that move people by air or enable cargo deliveries – is the next big transportation innovation. Similar to taxis or ride sharing today, UAM will help remove congestion from our streets and provide a convenient, rapid method for travel in urban centers as well as in remote areas.

Advanced composite materials will be at the heart of UAM vehicles by providing lightweight, efficient, reliable, and cost-competitive options for manufacturing. “Materials have been a key driver of efficiency for aircraft today, and they will be even more important for the emerging UAM marketplace,” said Imad Atallah, Director of Strategic Marketing for Aerospace and Urban Air Mobility at Hexcel.

Already, Hexcel is a leader in advanced composite materials for the aerospace market and is a key supplier of composite materials to the automotive industry. So, the company is well positioned to offer solutions to meet the critical needs of high-rate and quick-part manufacturing cycles, in addition to low-cost needs for this space. Hexcel’s materials solutions approach for UAM is to make it greener and more sustainable, safer, more comfortable, and more affordable.

Hexcel’s broad range of carbon fiber and HexPly® prepreg solutions, including snap cure thermosets and thermoplastics, coupled with the most qualified positions on aerospace programs in the industry make the company a trusted partner for UAM. In addition to offering composite materials from carbon fibers, prepregs, honeycomb and reinforcements, Hexcel’s best-performing market solution in noise absorption on aircraft jet engines, Acousti-Cap®, provides a strong position of innovation to solve one of the most critical problems in the UAM space – community noise. “We are applying our technologies to the unique needs of urban air mobility vehicles,” Atallah said.

Hexcel’s ability to bring materials technology from the aerospace and automotive industries represents a unique strength in solving the critical challenges of UAM, especially around high-rate manufacturing, low-cost materials, light weighting, and noise. “Both thermoplastics and quick-cure thermoset materials are expected to have applications on UAM vehicles,” Atallah said. Furthermore, Hexcel’s broad product portfolio including unsized carbon fiber has proven to be the most compatible with thermoplastic resins from a consolidation perspective.

SGL Carbon and Solvay collaborate to develop highly-competitive advanced carbon fiber composites for aerospace primary structures

SGL Carbon and Solvay have entered into a joint development agreement (JDA) to bring to market the first composite materials based on large-tow intermediate modulus (IM) carbon fiber. These materials, which address the need to reduce costs and CO2 emissions, and improve the production process and fuel efficiency of next-generation commercial aircraft, will be based on SGL Carbon’s large-tow IM carbon fiber and Solvay’s primary structure resin systems.

The agreement encompasses both thermoset and thermoplastic composite technologies. It builds on Solvay’s leadership in supplying advanced materials to the aerospace industry and SGL Carbon’s expertise in high-volume carbon fiber manufacturing.

“For Solvay, this is an opportunity to lead the aerospace adoption of a composite material based on 50K IM carbon fiber. This is a highly competitive value proposition that brings more affordable high-performance solutions to our customers. We see this as the first step in a long-term partnership,” said Augusto Di Donfrancesco, member of Solvay’s executive committee.

“By combining SGL’s carbon fiber expertise in our newly developed, unique 50K IM fiber with Solvay’s resin formulation and aerospace market expertise, both partners are aiming to develop an advanced aerospace material system. This alliance supports our strategic direction and accelerates our growth in the attractive aerospace market,” said Dr. Michael Majerus, spokesman of the management board of SGL Carbon.

Composite materials for aerospace applications represent a multi-billion-dollar market that is expected to grow strongly in the coming decade. Solvay and SGL Carbon are uniquely positioned to develop solutions to address the needs of this market.

The JEC innovation awards is a long-established and worldwide program with three simple goals: identify, promote, and reward the most innovative composite solutions in the world. Over the past 15 years, the JEC Innovation Program has involved 1,800 companies worldwide; 177 companies and 433 partners have been rewarded for the excellence of their composite innovations. The JEC Innovation Awards reward composites champions, based on criteria such as partner involvement in the value chain, technicality, or commercial applications of innovations.

« Every year, JEC rewards the best cutting-edge and ingenious projects using composites to their full potential in different categories. The JEC Innovation Awards program is emblematic and recognizes pioneers in composite innovation continuously reinventing the composites of tomorrow», says Franck GLOWACZ, Innovation Content Leader at JEC Group.

The winners have been rewarded for their innovative solutions, in 10 categories:

• Aerospace
• Automotive - Exterior
• Automotive - Structural
• Electrical, Electronics & Appliances
• Industrial Equipment
• Marine
• Railway
• Renewable Energy
• Smart Composites
• Sports & Leisure

The awards ceremony took place place on November 14, 2019, at 5:30 pm at the Startup Branch, COEX. Ben Bassat, President and CEO of Plataine Avner opened the ceremony with a keynote about “The 4th industrial revolution: implementing IIOT and AI to composite materials and manufacturing”.

Deterioration in market segments Textile Fibers and Industrial Applications in the business unit CFM will be counteracted with various measures; strategic growth markets remain intact

• Continued weakness in the business unit Composites – Fibers & Materials (CFM) in the final quarter of 2019 due to the further weakening in the market segment Textile Fibers as well as the deteriorated economic environment in the market segment Industrial Applications leads to a guidance adjustment for the full year 2019
• Earnings deterioration at CFM triggers an impairment testing; impairment charge will become necessary
• Initial outlook for 2020
• Comprehensive measures initiated to improve earnings of the CFM business unit
• CFM strategic growth markets automotive and aerospace remain intact
• Growth in higher-margin aerospace business to be accelerated

While the preliminary results for the first nine months 2019 remain, overall, within the scope of the full year outlook outlined in the ad-hoc notification of August 14, 2019 (preliminary 9M/2019 recurring EBIT: Group: approx. €54 million, CFM: approx. minus €2 million, GMS: approx. €71 million, Corporate: approx. minus €15 million), continued weakness is becoming apparent for the final quarter 2019 in the reporting segment Composites – Fibers & Materials (CFM). This is due to the further weakening in the market segment Textile Fibers as well as the deteriorated economic environment in the market segment Industrial Applications.

SGL Carbon therefore now expects for the full year 2019 a recurring EBIT in the reporting segment CFM in a negative mid to high single digit million € amount (previous guidance: positive mid-single digit million € amount). This results in a Group recurring EBIT for the full year 2019 in the magnitude of €45 to 50 million (previous guidance: approx. €55 million).

The earnings deterioration at CFM triggers an impairment testing. Based on the preliminary status of the new five-year plan, a non-cash impairment charge of €70 to 80 million is becoming apparent in CFM mainly due to the lower starting point in 2019 as well as the ongoing weakness in the market segments Textile Fibers and Industrial Applications. This impairment charge will be recorded in the third quarter 2019. In recent years acquired assets of the former joint ventures with BMW and Benteler are not affected by this impairment.