From the Sector

The Teijin Group companies Teijin Carbon America, Renegade Materials and Teijin Aramid will participate in CAMX. the largest, most comprehensive composites and advanced materials event in North America, in San Diego, USA. At the TEIJIN booth, visitors can explore innovative composite solutions and learn about the comprehensive technical support and provided services.

Teijin's diverse network of materials companies excels across various fields, ranging from high-performance carbon and aramid fibers to cutting-edge industrial textiles and revolutionary, cost-effective prepreg composite solutions. The shared commitment to quality, innovation, and environmental responsibility unites Teijin in their mission to deliver eco-friendly solutions across multiple industries and applications, including pressure vessels, aerospace, and both defense and commercial aircraft construction.

Teijin’s dedication to acquiring appropriate certifications for sustainable production and product development underscores the high level of commitment to lead in this field. In the past years, Teijin has continuously striven to minimize their carbon footprint and global impact, while also supporting customers on their own sustainability journeys. This year, Teijin Aramid achieved the EcoVadis Gold Medal recognition, placing the company in the top 5% of all companies across all industries globally and in the top 3% of all man-made fiber manufacturers worldwide.

Teijin Carbon has been awarded the ISCC Plus certification for its production in Germany and Japan and is on track to receive the same certification in the U.S. in the coming months. This accreditation allows the Teijin Carbon Group to prove to its customers sustainable products that contribute to a circular economy. Teijin Carbon is diligently working toward establishing new sustainability standards, promoting ecological innovations, and fostering partnerships for a more sustainable world.

Teijin is looking forward to engaging with customers and partners at CAMX 2024 in San Diego to discuss innovative ideas for the circular economy and recycling processes.

Teijin Carbon is one of the world's leading manufacturers of Tenax™ carbon fibers and carbon fiber-based materials, with production sites in the US, Germany, Japan and Vietnam. Teijin Carbon develops solutions for the aerospace, automotive, energy, electronics and sporting goods industries using high-performance technologies in an international environment. They work closely with their partners to create a fully circular value chain. The goal to make Teijin’s products net CO₂-free by 2050 aligns with the commitment to global society to find solutions and take action to combat it.

As a manufacturer of intermediate materials in the US, Renegade Materials is known for its product expertise and commitment to customer satisfaction. Renegade Materials distinguishes itself by merging cutting-edge materials science with advanced prepreg manufacturing and testing equipment, all meticulously controlled by rigorous quality management systems. Renegade is steadfast in their commitment to the development and largescale production of advanced, multi-functional materials that offer engineered solutions to the current composite design, usage and affordability initiatives in the aerospace industry.

Teijin Aramid is a global leader in high-performance aramid fiber, a subsidiary of the global Teijin Group. Specializing in high-performance aramid fibers, their materials are used in automotive and aerospace industries, ballistic protection and more.

AZL Aachen GmbH announces a ‘Joint Partner Project’ focusing on the technology for reinforcing electric motors with fibre composite reinforcement sleeves. The nine-month project will investigate current and future applications for electric motors, their requirements for armouring sleeves and provide technological insights.

The project, entitled "Rotor Sleeves for Electric Motors: Potentials for Composite Materials and Technologies", aims to address the growing demand for more efficient, powerful and compact electric motors in mobility and industrial applications.

Compared to metals, composite rotor sleeves with their high stiffness, low density, almost zero thermal expansion and favourable electromagnetic properties are particularly suitable to contribute to all the development goals.

The application, manufacturing and material technologies for composite rotor sleeves have been proven to be mature, so far mostly in niche high power applications. Due to the increasing demand for efficient electric drives, the demand for rotor sleeves and the corresponding production volumes is growing rapidly. Composite based rotor sleeves are expected to expand into mass applications for electric vehicles, power tools, machine tools, electric aircraft and other industrial applications.

AZL will bring together experts from across the value chain to investigate current and future applications, analyse requirements and assess the impact on design, material selection and production concepts.

Companies interested in the project can join the consortium consisting of Kümpers GmbH, Rassini and Schunk Kohlenstofftechnik GmbH, among others, until the kick-off on September 12th, 2024.

Successful SMCCreate 2023 Design Conference in Prague

With over 60 participants from Europe and the USA the second edition of the SMCCreate Design Conference took place from November 7th to 8th in Prague. The conference was jointly organized by the AVK – Federation of Reinforced Plastics and the European Alliance for SMC BMC, promoting the use of SMC and providing design tools to designers for applying these versatile materials.

During the SMCCreate 2023 conference topics covered the wide spectrum of the design with fiber composite/composite components in SMC and BMC technology, from conceptual design, development, and scale-up, with a special emphasis on recycling and sustainability solutions. 18 speakers from various European countries showed how they address important market trends and changing customer needs, and which solutions their companies offered in terms of materials, performance and much more.

As an introduction, speakers - including CTC/Airbus and Teijin - presented different possible applications for SMC and BMC components, including aircraft interiors, bicycle boxes, and applications in e-mobility. The topic of sustainability was broadly covered, highlighting recycling solutions and experiences (Siemens, IDI, OC, AOC), the use of renewable raw materials, as well new LCA models developed by the SMC BMC Alliance (LCS),

Specifically for designers, the use of the SMC flow and curing modelling was presented (ESI, OC), SMC positioning vs. aluminium (Spartners). The second day concluded with contributions on process optimization options for component production, including speeches by Dieffenbacher, Netzsch and EBG.

Ahead of the extra-ordinary Council on 6 October in Granada, EURATEX President, Alberto Paccanelli, and CIE President, Jose Vte Serna, call on the EU Presidency to develop a new competitiveness strategy, which can relaunch the European industry and ensure it will remain competitive in the decades to come. This means bringing together trade, energy, state aid and sustainability policies into a single, integrated, comprehensive approach, which can support a robust and modern European manufacturing industry.  
 
To consolidate a strong industrial structure in Europe, the Union should

1. secure the supply of clean energy at a competitive cost;
2. support innovation and foster the necessary talent pool and
3. be more assertive in achieving an international level-playing field on sustainability, based on the European model.  

During the past few years the implementation of incoherent and conflicting objectives under the trade, energy, industrial and sustainability policy has been observed. As a matter of fact, while the circular economy promised to be a recipe for a competitive industry of the future, the likelihood of pushing the EU industry out of the market and driving investment elsewhere than in Europe is very high. If this approach were to continue in the next years, it will result in a de-industrialised Europe, depending on imports from abroad. Such a Europe would be more exposed to geopolitical turmoil, with no agency to deliver its vision of peace, well-being and a healthy environment to its citizens.

It is fundamental for Europe to pursue a more coherent set of policies that put the competitiveness of its domestic industry at the core. In this context, all the industrial manufacturing sectors should be in the scope, including the textile industry, given its importance in providing essential products and applications to our society. A first impactful action that can be taken in this direction, would be to expand the scope of the Net-Zero Industry Act (NZIA) to include the textiles and clothing industry.
 
The history of European industry is fully woven in the birth and expansion of the European textiles industry since the XVIII century. Still today, the European textiles and clothing industry holds a pivotal position in the market, encompassing a diverse range of sectors and applications. In terms of employment, our industry creates 1,3 million direct jobs in Europe, encompassing a wide range of roles, from design and production to distribution and retail. European textiles have a wide range of applications, the most common one is of course clothing and fashion. The industry has a long history of producing high-quality apparel, with various regions specializing in specific niches.
 
Beyond clothing, there is a wide range of industrial sectors were textiles play an essential role, including  Automotive (used for upholstery, interior components, and even lightweight composite materials), Aircraft and Shipbuilding (where textiles are employed for their lightweight and high-strength properties, to enhance fuel efficiency, reduce emissions, and improve overall performance), Building and Construction (insulation, roofing, geotextiles, and architectural textiles), or Personal Protective Equipment, for medical personnel, firefighters, police and army officers. This includes masks, gowns, uniforms, helmets, and fire-resistant clothing, ensuring safety in hazardous environments.
 
Textiles are essential components of our society and our well-being. It is key for Europe to maintain its capacity to manufacture high-quality, sustainable and high-technology textiles.  With this in mind, the competitiveness policy of the future and the related funds to support it, should include the textile ecosystem in its scope.  

A €20 million investment has been announced by AkzoNobel to increase and improve production at two of its sites in France. Around 30 new jobs will be created.

A total of €15 million will be spent on the company’s aerospace coatings facility in Pamiers, which was taken over following the Mapaero acquisition in 2019. Production capacity is being boosted by 50%, while the funds will also be used to reduce environmental impact and improve safety processes and working conditions.

The other €5 million will be spent on improving production flexibility at the decorative paints site in Montataire, which is one of the company’s most important manufacturing locations for wall paints in Europe.

The plans for Pamiers include the construction of two extensions, one for storage and one for cleaning and waste treatment. The project will also enable the company to relocate the production of exterior polyurethane paints for aircraft widely used in Europe from its Waukegan plant in the US.

Building work is expected to start by the end of 2023, with the new installations at both locations due to be operational in early 2025.

AkzoNobel employs nearly 1,500 people in France and operates four production facilities, in Montataire (decorative paints), Dourdan (powder coatings), Limoges (adhesive markings) and Pamiers (aerospace coatings).

On 27 November 2021, the Scientific Award for International Sustainable Aviation and Energy Society (SARES Award) was awarded to Professor Dr Thomas Gries from the Institut für Textiltechnik of RWTH Aachen University. The award ceremony took place during the closing ceremony of the International Symposium on Sustainable Aviation (ISSA) in a hybrid format online and simultaneously at Kasetsart University, Bangkok, Thailand.
 
With the award, the committee recognised the ongoing contribution of Pro-fessor Gries and the Institut für Textiltechnik to the digitisation and bio-transformation of the textile sector, as well as the Institute as a place of innovation for sustainable aviation.

Examples of this include the development of 3D braided ceramic matrix composite components for aircraft engines, which were researched together with partners in a Horizon 2020 project (EU project AllOxITD). The ongoing Chrysomallos research project as another example, funded under the national aeronautics research programme in Germany, aims to develop a completely new and sustainable high-performance insulator for aircraft cabins based on aerogels. These have a significantly lower weight than the glass fibre mats used up to now, while providing the same insulation performance, and solve the problem of the previously high manufacturing costs of aerogels. The aim of the project is to develop an insulation material with reduced density (reduction of more than 20 percent). To this end, a new type of insulation material based on aerogel is to be developed. The basis is an aerogel fleece (0.06 W/mK at 28 kg/m³), which has already been developed as part of a dissertation at the Institut für Textiltechnik of RWTH Aachen University (Mroszczok, J.: 2019).

The aviation industry is one of the fastest growing industries in the world. Due to this fact and its importance for society and the global economy, it needs to make special efforts towards sustainability. The ISSA, an international multi-disciplinary symposium, aims to address current issues in aviation such as improving aircraft fuel efficiency, promoting the use of biofuels, minimising environmental impact, mitigating greenhouse gas emissions and reducing engine and aircraft noise. ^

Through the award, SARES honours scientists and researchers whose work on sustainable aviation issues has made an important contribution at the international level. The selection is based on the scientific publications of the applicant or nominee, the h-index, i.e. the key figure for the worldwide perception of a scientist in professional circles, the project topics and the project results.

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 Carbon Europe introduces a new thermoplastic carbon fiber tape (TPUD) based on PPS. The new Tenax™ TPUD with PPS matrix allows entry in new cost-sensitive markets while offering the typical TPUD advantages like high resistance to chemicals and solvents, low flammability, storage or shipping at room temperature and recyclability.  

Due to its flame retardant properties and low smoke emission, it can be used in interior applications of aircraft or rail vehicles, among others. The maximum continuous operating temperature is up to 220 °C. Very low water absorption, excellent creep resistance even at elevated temperatures and high dimensional stability round off the property portfolio of this new TPUD. It is therefore also suitable for demanding applications in the aerospace, oil & gas, sporting goods or industrial sectors, while remaining cost-effective. These properties make the product perfect for highly automated processing routes such as ATL or AFP in combination with overmolding for complex geometries. Production start for the Tenax™ TPUD with PPS matrix is the first quarter in 2021.

For almost 10 years, unidirectional tapes (TPUD) have been manufactured from carbon fibers and thermoplastics in Heinsberg, Germany. The semi-finished products have so far been offered with PEEK or PAEK – and PPS is now added to the list of available matrixes. PPS allows a lower process temperature compared to PEEK or PAEK. For the industrial market in particular, increasing the production rate to make processes more cost-efficient is an opportunity.

Hexcel and Safran Expand Scope of Existing Contract for Advanced Composite Materials on Commercial Aerospace Programs

Hexcel Corporation (NYSE: HXL) announced today that the scope of its long-term supplier contract with Safran S.A. has been expanded to include advanced composite materials for a broader range of commercial aerospace applications.

For more than three decades, Hexcel has been a trusted, leading supplier of high-performance, advanced composites such as carbon fiber, adhesives, prepregs, dry fabrics, and honeycomb core to Safran programs. Since 2013, Hexcel HexTow® IM7 carbon fiber has been supplied for the LEAP*-1A, -1B and -1C engine programs. That contract now has been amended to include HexTow IM7 for the GE9X engine that powers the Boeing 777X.The contract also includes Hexcel core, adhesives, prepregs, and fabrics for additional applications on engine nacelles and aircraft interiors.

“It was time to include Safran Cabin, Safran Seats and Safran Aerosystems within our global long-term agreement,” said Thierry Viguier, Vice President, Safran Materials Purchasing. “Hexcel has shown again, during this difficult period of time, that they are a strong and reliable long-term partner.”

“This contract expansion is the result of a successful, collaborative relationship between Safran and Hexcel that started more than 35 years ago to serve the aerospace industry,” said Thierry Merlot, President Aerospace Europe, Asia Pacific, Middle East, Africa & Industrial. “This agreement will further strengthen the long-term partnership between our companies and reinforces our strategic position within Safran’s First Circle suppliers.”

STAMFORD – German ultralight aircraft specialist Flight Design has chosen Hexcel as its key supplier adopting low-temperature curing prepreg into its aircraft production. Hexcel’s HexPly® M79 Carbon Fiber prepregs deliver a more consistent final product by ensuring constant material quality and processing parameters and produce a lighter and stronger aircraft at a more competitive overall cost.

Flight Design has always relied heavily on composites for its aircrafts’ ultralight construction and turned to long-term composite materials partner Lange + Ritter, part of Hexcel’s European distribution network, when they began searching for a prepreg material solution. Hexcel and Lange + Ritter created several new product codes specifically for Flight Design and then supplied materials for initial handling trials and prototyping. Hexcel’s HexPly M79 low temperature curing out of autoclave solution was first used in the new F2 prototype. As part of its material supply package, Lange + Ritter also sent a team for on-site training and technical support, allowing the Flight Design production team to get up to speed with prepreg as quickly as possible.

HexPly M79 prepregs can be cured at temperatures as low as 70˚C for eight hours or 80˚C for four hours, reducing tooling costs and increasing build rates. When combined with Hexcel’s innovative air venting Grid Technology, HexPly M79 UD carbon tapes can also be laminated with reduced debulking steps to produce void contents <1% irrespective of laminate thickness. With consistently low void contents and improved mechanical properties, designers and engineers are able to further optimize highly loaded composite aerostructures.

As more and more of its composite aircraft parts are transferred to prepreg technology, Flight Design is seeing the benefits of its switch to HexPly M79. Lay-up is cleaner and more precise, low temperature oven curing is quick and energy efficient, and the manufacturing process consistently outputs exceptionally high-quality laminates and components. The long-term strategy is to integrate HexPly M79 across the range, with Hexcel materials lightening the ultralight aircraft at Flight Design even further.

“The materials and technology package from Hexcel and Lange + Ritter has been a big success for us at Flight Design,” comments Daniel Gunther, Managing Director at Flight Design. “When we took the decision to switch to prepreg, we looked at many options but only Hexcel and Lange + Ritter could offer us low temperature out-of-autoclave (OOA) curing, globally respected material quality and the customer service levels we were searching for.”