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.

Germany-based ZwissTex is a leading manufacturer of textiles with over 150 years of experience, creating innovative and sustainable textile solutions for the automotive and apparel industries. The company also operates in Mexico, to specifically serve the automotive sector across North American Free Trade Agreement (NAFTA) markets. Via OEMs, ZwissTex supplies German automakers including Volkswagen Auto Group, BMW, and Mercedes, as well as American manufacturers in select cases.

Unlike other Kornit customers, ZwissTex had no previous experience printing their own materials, and saw Kornit’s sustainable, single-step, Presto MAX S production system as an effective means of increasing their product capabilities.

“Our textiles were not classically printed in the past, and we did not produce any classical textiles in fashion, which is why we didn’t have any printing experience internally,” said Ralph Moldan, Technical Specialist at ZwissTex, as the system was being installed in their facility. “The only option was to find a system that would enable us to implement the areas in which we are active on the market easily and quickly, without requiring a lot of printing experience.”

One benefit of integrating Kornit technology into the ZwissTex production ecosystem: applying ink only where it is needed and seen, rather than to the full surface of each material. This translates to both reducing the company’s carbon footprint, and minimizing materials waste for a more cost-effective operation.

Prior to making the decision to invest in Kornit, ZwissTex conducted a series of tests and consultations, evaluating possible applications for different materials and engaging with their own key clients to ensure these finished products would meet their rigorous quality and durability standards. This included presenting Kornit-decorated samples at the Techtextil 2022 exhibition in Frankfurt.

Moldan found Kornit’s production capabilities opened new doors to customization of interior areas, a market that continues to grow. He anticipates this technology will create new opportunities with customers they could not reach previously, including new opportunities in sectors such as motor homes, airlines, and aircraft outfitters.

Hexcel Corporation hosted customers and public officials at its manufacturing site in the Midparc Free Trade Zone in Casablanca as the company broke ground on an expansion that will double the size of its existing engineered core manufacturing operation in Morocco to meet increased demand from aerospace customers for lightweight advanced composites.

The expansion, announced in September 2021, is expected to be completed in early 2023. The plant size will double to 24,000 square meters and employment is expected to increase from 120 to 400 people when the expansion is completed.

The Casablanca facility was built as part of Hexcel’s ongoing worldwide investment to create a diversified and robust global supply chain to support aerospace customers’ growing demand for engineered core. At the plant, Hexcel transforms lightweight honeycomb materials into engineered core parts to reinforce structures in the aerospace industry, particularly for aircraft, engine nacelles, and helicopter blades.

At the event, Thierry Merlot, Hexcel President – Aerospace for Europe, MEA/AP & Industrial, said, “We are pleased to celebrate this milestone with our customers and with the local community. The increased demand for lightweight, aerodynamic, advanced composites is growing, and our customers including Safran, Airbus, Airbus Atlantic, Boeing and Spirit AeroSystems have shown confidence in our ability to meet that demand. We appreciate the support from them as well as from the Ministry and everyone in the local community who continue providing us with the opportunity to further our investment in Morocco. The very successful establishment of Hexcel, the qualification of the workforce, the support of the state and the proximity of our customers have been real assets to launch this extension of our site in Casablanca.”

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.

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.”

As the first composites trade show worldwide since the Covid-19-crisis, the China Composites in Shanghai (September 2 to 4, 2020) took up its activity. The show counted about 600 exhibitors and over 20 000 visitors, mostly Chinese locals, attended the exhibition.

Chinese Reach Group under the lead of its president Daniel He represented a large portfolio of European companies and their recent developments through their cooperation with Dr. Michael Effing´s AMAC/Germany, among them Airborne (NL), Textechno (D) and Conbility (D).

Daniel He describes the situation: „The Chinese market is picking up again; a price increase of 7% for glass fibers was announced right before the China Composites Show, on August 25th 2020, which was even leading to a temporary material shortage. Today, the most booming industries in China are wind energy, building and infrastructure and innovation for electric cars. Unlike the rest of the world, where the aircraft industry undergoes a deep decline, in China it takes up by 50 %, which is very promising. Furthermore, we expect half a year for a full recovery of the industry, while the China growth of 2020 is still expected to be between 2 and 4 %.“

Michael Effing replied: “Enabling the composites business between China and Europe is the aim of our cooperation with Reach and with our customers, which are active in digital automatization, testing equipment or cost optimization software. We are very happy to have been present in China through our representant Reach and are looking forward to bridge and overcome the Covid-19-crisis with our upcoming event in Germany, the Composites for Europe in Stuttgart in November and hope to be back to full global business speed at the JEC in Paris in 2021.“

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.

As of October 1st, 2019, the Netherlands-based global market leading manufacturer of advanced automation equipment and solutions for composites, Airborne, strengthens its activities particularly in German speaking countries, the so-called D-A-CH region, comprising Germany, Austria and Switzerland with Dr. Michael Effing from AMAC. The Dutch company is looking for specialised partnerships to develop and deepen its international business opportunities in the aerospace and automotive markets.

Airborne’s focus is on high-end composite components, at high production rates at radically low conversion costs. Airborne is building up a suite of automated solutions for the manufacturing of composites with the aim to radically reduce costs and touch labour, minimize the footprint and use of material, and improve the time to market for their clients. The company offers i.a. solutions in automated honeycomb potting, automated kitting and automated lamination of thermosets and thermoplastics. In order to develop new business opportunities in the D-A-CH region for the end-markets aerospace and automotive, Airborne is cooperating with AMAC to accelerate the process of locating suitable partnerships.

Dr. Effing, CEO of AMAC GmbH confirms: "As a first step for the establishment of Airborne on the German market, we just signed their membership at AZL in Aachen which will help to connect with over 80 companies and latest research developments. In the framework of theirstrategy to strengthen the supply to the aircraft sector, Airborne will also exhibit at the Aircraft Interiors Expo in Hamburg from March 31st to April 2nd 2020.”

Hexcel, Progen and Future Aerospace today celebrated the official opening of their new joint venture laboratory and materials testing facility in Shanghai, China.

Future Aerospace Hexcel Commercial Composite Testing Limited (FAHCCT) will provide China with a world-class aerospace standard materials testing laboratory that provides technical services including support with materials qualification for commercial aircraft programs. Planned activities at the site will include mechanical and chemical testing of composite laminate specimens (including fatigue performance), material qualifications, and provision of support for customer supply chains in China.