From the Sector

Technically and economically viable lightweight production based on fiber-reinforced plastics and multi-material systems requires an integrated approach. Due to the almost unlimited combination possibilities of different materials and the very complex interactions between materials, component design, manufacturing processes and the machine and system components, an optimal production process requires a direct link between materials science, process engineering and production technology.

As the official center for “Composite-based Lightweight Production” of the RWTH Aachen Campus, AZL Aachen GmbH uses its strong network to provide these capacities and possibilities on an interdisciplinary basis. Within walking distance, researchers and students are working on the latest technologies for the cost-efficient development and production of lightweight components on one of the largest research landscapes in Europe - the RWTH Aachen Campus: Aachen Center for Integrative Lightweight Production of RWTH Aachen University, Fraunhofer Institute for Production Technology IPT, Fraunhofer Institute for Laser Technology ILT, Institute for Automotive Engineering (ika) of RWTH Aachen University, Institute for Plastic Processing in Industry and Craft at RWTH Aachen University, Institute of Structural Mechanics and Lightweight Design (SLA) of RWTH Aachen University, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University, Welding and Joining Institute (isf) of RWTH Aachen University.

Exklusive insights into the latest lightweight technologies

Once a year, the AZL Open Day offers an exclusive and unique insight into the R&D capacities of the institutes in the field of lightweight construction and sustainable mobility. This year, nine AZL partner institutes opened their machine halls and research laboratories on April 9, 2025 to provide interested industrial players with comprehensive insights into their current focus areas along the value chain. Among other things, the institutes presented high-precision laser processes for plastics processing, new joining processes for thermoplastic composites, 5-axis CNC machining with real-time quality management, large-format 3D printing and their own tape lines & tape integration. Design, prototyping and testing of products & solutions such as crash-optimized vehicle structures, thermoplastic pressure vessels, digital twins for structural-mechanical monitoring as well as prototyping and recycling approaches for battery systems were also demonstrated. The range of topics, key activities & infrastructure, seen at the Open Day, enables new technologies to be tested under real production conditions and efficiently brought to market maturity.

“The AZL Open Day is a great opportunity to discover the numerous technology centers, labs, prototyping and testing facilities that are available on the Aachen campus, that makes it unique in its kind. The AZL organization and teams located there are a true catalyst for new projects and development for the Composites industry: they are creating the link between Market analysis & technology scouting, academic research resources and business opportunities with their industrial partners. They are currently working on several topics that are at the forefront of Composites” reports Éric Pierrejean, CEO of the JEC Group. Apart from being there as an interested participant, he also gave the audience an insight into the key topics and trends in the composites industry as seen at this year's JEC World Show.

Efficient use of established infrastructures & know-how

As a one-stop shop for lightweight solutions, AZL offers an interface for successful cooperation between research and industry. In close coordination between scientific developments and specific customer requirements, solutions are developed in a targeted and tailor-made manner: as part of the AZL partnership, consortial projects or individual projects. In addition to the know-how of the institutes, cooperation with the AZL's industrial partner network also enables direct access to the necessary infrastructure of components, materials, tools and machine and system parts, which can be tested, developed or newly constructed in integrated process chains on a large scale.

Thanks to the close networking between science, industry and the AZL team of experts, companies can access an established infrastructure and utilize synergies for their projects.
The date for the next AZL Open Day will be announced in the second half of the year.

The Aachen-Dresden-Denkendorf International Textile Conference 2025 will take place on November 27 and 28, 2025 at the Eurogress Aachen.

To contribute to the conference program and submit an abstract for a talk or poster presentation, please note that the Call for Abstracts for oral presentations ends on May 5, 2025. The Call for Abstracts for poster contributions is open until July 31, 2025.

The conference program includes plenary lectures and themed sessions in the areas of

• Sustainable Textiles and Circular Textile Economy
• Bio-based Fibers
• Synthetic High-Performance Fibers
• Artificial Intelligence in the Textile Sector
• Textile Production
• Smart Textiles & Applications
• Textiles for Medicine & Health Care
• Technology Transfer & Start-up Pitches
• Fiber Composites and Lightweight Construction
• Best-Practices – Examples from Collaboration Projects between Academia and Industry
• Functionalization & Finishing

Further information about the conference and the call for abstracts (including the submission form) at  https://www.aachen-dresden-denkendorf.de/en/itc/registration/call-for-abstracts/.

Fibre and fabric production technologies – especially in the area of composite reinforcements – have played an as-yet largely unheralded role in the development of the UK’s Formula One industry, but the British Textile Machinery Association (BTMA) aims to change that.

Motorsport Valley
“If there’s one thing the UK does well, it’s Formula One, with seven of the ten F1 teams located within just an hour of each other in the midlands region known as Motorsport Valley,” explains BTMA CEO Jason Kent. “They are all linked to a national network of around 4,500 companies involved in a motorsport and high-performance engineering industry worth around £9 billion annually and employing 40,000 people. This network draws on the services of a significant number of our member companies.”

“With the exception of the engine, virtually every part of a Formula One racing car now starts from a textile, including the bodywork, the tyres and many of the latest fuel systems,” says Richard Kirkbright, project manager at Leeds-based Roaches International. “This has influenced developments in the broader automotive sector, in addition to the aerospace industry.”

Show cars and memorabilia
While best known as the developer of textile testing systems, Roaches has over the years also supplied advanced autoclaves to the UK’s composites industry, including a recent delivery to Northampton-based Memento Exclusives, a specialist in the production of show cars working directly with F1 and its leading teams.

Each major F1 team sponsor is supplied with one or two show cars for use at exhibitions and a wide range of other promotional activities arranged around the racing event calendar. These cars have no engine and their bodies may be made of fewer carbon fibre plies, but they are otherwise identical to the latest cars being raced by the F1 teams.

Memento Exclusives has its own in-house carbon fibre parts manufacturing facility and the integration of the Roaches autoclave has significantly expanded its capabilities in show car production.

Master bakers
“Composite materials undergo a metamorphosis in the autoclave which subjects them to both mechanical and chemical processes,” explains Richard Kirkbright. “Trapped air and volatiles are expelled and plies are consolidated under precise pressure. Heat cycles are then introduced, curing the resin systems and yielding flawlessly crafted components. Autoclave specialists are a little like master bakers, knowing exactly how to treat their ingredients at every stage of the process, to achieve the desired final product.”

“The Roaches autoclave now enables us to cure large components with full control and achieve a swift turnover of parts while ensuring the highest quality finish,” adds Terry Wasyliw, Head of Build for Memento Exclusives.

McLaren’s influence
Woking, UK-headquartered McLaren was the very first F1 team to introduce a car chassis manufactured entirely from carbon fibre composites back in 1981, setting the ball rolling for the creation of a completely new and global supply chain.

McLaren has this year unveiled a world-first in supercar engineering – aerospace-derived Automated Rapid Tape (ART) carbon fibre, developed at the dedicated McLaren Composites Technology Centre (MCTC) facility in Sheffield. This is being employed to create the active front wings of the W1 hypercar which has a starting price of $2.1 million.

A rear floor component was also developed for McLaren as part of the recently-completed £39.6 million ASCEND programme involving a range of UK partners, including BTMA member Cygnet Texkimp.

Handling, converting and decarbonisation
A wide range of handling and converting machines are supplied to the composites industry by Cygnet Texkimp, including bespoke creels, prepreg, coating, slitting and filament winding machines.

Its technologies are employed in the construction of composite components for aerospace and automotive, as well as in the production of tyre cord and more recently in the advanced construction of hydrogen storage vessels which are largely viewed as the future of F1 propulsion, along with advanced batteries for electric vehicles.

Cygnet Texkimp has been involved in the F1 supply chain for over 20 years and most carbon fibre used in the industry has been processed on one of its VHD creels. The company is also the largest independent manufacturer of prepreg machines in the world and is currently leading the design and build of the UK’s first carbon fibre research lines for a project led by NCC (National Composites Centre) to accelerate the development of more sustainable carbon fibres.

In addition, Cygnet is licensed to design and build the DEECOM® composite recycling system developed by new BTMA member Longworth Sustainable Recycling Technologies, the first of which was recently commissioned by the Henry Royce Institute in Manchester. DEECOM® is a zero emission, low carbon pressolysis solution using pressure and steam to reclaim pristine condition fibres and resin polymers frocm production waste and end of life composites.

“Decarbonisation is a major priority for manufacturers globally,” says Cygnet CEO Luke Vardy. “At Cygnet Texkimp, we’re developing the capability to process technical fibres in ways that enable lightweighting, hydrogen power and electrification, reduce waste and revolutionise the end-of-life management of composite materials and parts. In collaboration with our industry partners, we’re bringing to market some of the most innovative new fibre processing technologies ever developed to deliver real-world benefits that support the sustainability agenda.”

Prepregging
Another new BTMA member, Emerson & Renwick (E+R), a specialist in print, forming, vacuum and coating technologies, also supplies technology for the production of carbon fibre prepregs, which are integrated rolls of fabrics and resins.

Its most recent 1.7-metre-wide line supplied to a customer in Italy operates at speeds of 40+ metres per minute for web coatings or prepreg fibre and resin consolidation, or a combination of both processes. It is distinguished by an ultra precise three-roll reverse roll coater for the processing of high viscosity thermo-activated resins and enables the automatic changeover of sensitive woven fabric materials at zero tension, with three high precision calendaring nips with hot/cool plates. Multiple unwind and rewind systems for intermediate lamination steps include side loading and reliable lap splicing and zero speed splicing with a web accumulator for the main product rewind.
 
 E+R has also been part of a consortium working on the development of lithium-sulphur (Li-S) batteries within the £540 million UK Faraday Battery Challenge. Once commercially viable, Li-S batteries promise to provide relatively high energy density at low cost for sustainable electric vehicles of the future – inevitably starting with F1.

Strong links
“In addition to our powerful base of textile testing and control companies, many other BTMA members are working on further F1 and advanced composite projects,” says Jason Kent in conclusion. “We are also forging strong links with the UK’s key research hubs such as Sheffield University’s Advanced Manufacturing Research Centre, the Northwest Composites Centre in Manchester, the National Centre for Motorsport Engineering in Bolton and the National Composites Centre in Bristol.

“The BTMA recently became an associate member of Composites UK too, because this sector is the crucible of innovation for tomorrow’s textiles.”

FILTREX™ 2025, EDANA’s flagship event for the filtration industry, wrapped up last week after two dynamic days of discussions, technical advancements, and industry collaboration. This 10th edition brought together more than 100 professionals to explore the latest developments in air and liquid filtration, sustainability, and regulatory challenges.

Industry Insights and Key Conversations
The FILTREX 2025 conference brought together experts from across the filtration industry to discuss innovation, sustainability, and regulatory challenges shaping the sector. The event opened with a keynote by Dr.-Ing. Frank Möbius, Senior Innovation Advisor at UnternehmerTUM and former BMW Group Manager, highlighting the role of Open Innovation in maintaining competitiveness in an evolving market.

Throughout the sessions, industry leaders addressed major trends influencing filtration. Dr. Marc Schmidt (AAF-Lufttechnik) explored how economic and social shifts are reshaping filtration markets, while Anthony Lawson (Hengst Filtration) examined the impact of evolving air quality guidelines and PFAS restrictions on filter design. Experts such as Cédric Vallet (Ahlstrom) and Christof Keppler (Gessner) presented innovations in filtration efficiency, carbon footprint reduction, and the development of biodegradable filter media. Meanwhile, Dr. Pero Mićić (FutureManagementGroup AG) offered a strategic framework for future-proofing businesses against industry disruptions.

Spotlight on Sustainability in Filtration
Sustainability took centre stage at FILTREX 2025, with a dedicated round table that saw insights from Oswaldo Anaya (Freudenberg Performance Materials), Cédric Vallet (Ahlstrom), and Bruce Lorange (Hollingsworth & Vose). The discussions focused on how the industry can reduce its environmental impact while still delivering high-performance solutions. Oswaldo Anaya, Product Marketing Manager at Freudenberg Performance Materials, reflected on the event, saying, “I was glad to join this last edition of FILTREX. It confirmed the great things I’d heard from colleagues about previous events. Highly relevant and timely topics for the filtration industry, plus valuable networking in a relaxed setting.”

FILTREX™ Innovation Award 2025
A major highlight of the event was the FILTREX™ Innovation Award, which this year went to Johns Manville for its Evalith® product. Their groundbreaking recycling process transforms HVAC glass microfiber waste into compounded pellets for injection molding, turning waste into durable, second-life products. The award was presented during a Networking Evening Cocktail at Vienna’s Kunsthistorisches Museum, providing an ideal atmosphere for further discussions and potential collaborations.

PFAS-Free Filtration and Industry Innovation
The closing session tackled the critical topic of PFAS-free filtration, revealing solutions like high-performance PFAS-free HEPA media and nanofiber membranes that not only enhance performance but also reduce environmental impact. Industry leaders also discussed upcoming changes in PFAS regulations and the continued push for safer alternatives in the filtration industry.

Looking Ahead
FILTREX™ 2025 firmly established itself as the key event for the filtration industry, providing a platform for knowledge exchange, collaboration, and innovation. As Bruce Lorange, Global Marketing Communications Director at Hollingsworth & Vose, put it: “The recent FILTREX event in Vienna presented a unique opportunity to network, learn, see old friends, and make new ones in the filtration and nonwovens space. The quality of presentations was top-notch—informative and thought-provoking—and the venue provided the perfect backdrop for the thought leaders gathered to take our industry to the next level. A sincere thanks to the EDANA FILTREX team for arranging such an impactful event!”

The number of lithium-ion battery electric vehicles (BEV) in use worldwide is growing rapidly. As a result, ensuring the safety of the battery pack and thus minimizing the risk of fire accidents has become a key issue for car manufacturers across the globe. In order to protect vehicle occupants in the event of a so-called thermal runaway, in which the battery heats up quickly and uncontrollably and, in the worst case, ignites or explodes, fire protection materials and components such as flame shields are among the most effective methods.

Autoneum’s new E-Fiber flame shields offer flame protection and electrical insulation inside the battery housing. They can withstand extreme temperatures, pressure and abrasions, thus significantly increasing the safety of passengers in the event of the battery overheating and catching fire. As the shields are made from a composite material, they are also considerably lighter, mechanically stronger and more cost-efficient than the mineral mica alternatives on the market.

Autoneum’s new E-Fiber flame shields offer flame protection and electrical insulation inside the battery housing. They can withstand extreme temperatures, pressure and abrasions, thus significantly increasing the safety of passengers in the event of the battery overheating and catching fire. As the shields are made from a composite material, they are also considerably lighter, mechanically stronger and more cost-efficient than the mineral mica alternatives on the market.

In contrast to alternative standard products, which often consist of heavy and brittle mineral materials such as mica, the innovative shields based on E-Fiber are lightweight, stiff and stable and offer optimum flame protection and fire blast resistance. Due to the moldability of the material, the shields also ensure excellent battery coverage and design flexibility. Thanks to the possibility of manufacturing components with complex 3D shapes, there is also the potential to integrate an additional function to guide hot gases away from the battery. The shields are based on a composite material made of reinforcing fibers and resin, which are formed into thin layers of one to two millimeters.

The heat resistance of up to 1400°C and the mechanical strength of the material significantly increase the shields’ resistance to high temperatures, but also hot particle abrasion and gas pressure. Moreover, the fibers provide the part’s non-conductive and insulating properties, which are necessary for the battery system’s electrical insulation and thermal safety.

The E-Fiber flame shields can be installed between the battery cells and the battery cover or the vehicle floor and contribute significantly to increasing the safety of vehicle occupants in the event of a battery thermal runaway. They thus offer a lightweight, safe and geometrically adaptable alternative to standard flame shields on the market. In addition, the composite shields are completely riskfree from a compliance perspective. This is in contrast to mica-based products, which can prove problematic in terms of responsible sourcing.

Autoneum’s E-Fiber flame shields have already been validated in battery tests and are currently in pre-development with various customers in Europe.

Large-area filtration faces the stigma of high costs, maintenance efforts, and time-consuming changeover and cleaning activities. However, good filtration is unavoidable with increasing rPET proportions. So, BB Engineering has addressed these issues with its decades of experience in extrusion and filtration. The new COBRA filter combines continuous and automated large-area filtration with integrated intermediate filter cleaning – setting a new standard in efficiency, ease of use and resource saving, and finally meeting the demanding requirements of recycling processes.

Large-area fine filtration made for recycling
Recyclers are currently dealing with a dilemma when it comes to filtration. Increasing recycling quotas coupled with insufficient availability mean that lower input qualities are also being considered for recycling, resulting in more challenging contaminants. At the same time, higher-quality applications are being targeted, which further intensifies the requirement for fine filtration. There are systems for large quantities of contaminants, but they do not filter as finely as a candle filter. There are also candle filters that provide excellent filtration but cannot cope with high levels of contamination.

The new COBRA filter can do both. It was specially developed for demanding filtration tasks with high levels of contamination, particularly in PET recycling. Multitasking is the keyword. COBRA unites large-area fine filtration with simultaneous, fast and effortless cleaning, and is therefore able to handle higher contamination rates, which common candle filters would fail on. However, this allrounder can also be used for other applications, e.g. in synthetic fiber spinning.

Continuity and process stability thanks to automation
As a continuous filter, the COBRA filter has two filter inserts, one of which is always active in production mode and the other either in stand-by mode or in intermediate cleaning. The automated switchover ensures a smooth changeover between the inserts. The status of the filter inserts is constantly checked by the system and, if necessary, the COBRA filter automatically initiates the cleaning and changeover process. All the operator has to do is confirm this on the user interface – no further manual intervention is required. The process thus continues to run stably and safely without interruption. Operator-related deviations in the switching process, operating errors or delays, all of which could affect the process, cannot occur.

Effortless inline cleaning – effective and safe
The highlight of the COBRA filter is the integration of BBE’s White Filter Cleaning technology (WFC). This process enables absolutely chemical-free and environmentally friendly intermediate cleaning of the filter inserts using hot steam alone and extends the filter’s service life many times over. BBE has already had WFC in its product portfolio as a stand-alone solution for several years. Now, for the first time, the cleaning system is integrated directly into a filter, bringing additional advantages, like cleaning speed and wear-reduction. Production and cleaning becomes an alternating interaction. Only after multiple operating/cleaning cycles (the exact number depends on product and degree of soiling) is it necessary to completely remove the filter insert for a service check and full cleaning. The WFC cleaning process only takes around 10 hours, whereas conventional cleaning takes several days. Filtration and cleaning form a self-contained, automated system that guarantees process and operating safety in equal measure: The operator does not have to handle melt or chemicals.

Development goals: Simplified handling, economic efficiency
BBE focused on simplifying filter changes and cleaning processes through automation as well as significant savings in operating costs. And that has been successful. Comparing the COBRA filter with other fine filters with a throughput of 2000 kg/h reveals a saving of 40% in pure operating costs. This saving results from various aspects. One significant part of the savings comes from the reduction of melt loss through backflush-cycles. Another key point is the continuous operation with significantly longer service life thanks to the integrated cleaning with steam. This is linked to reduced use of spare parts and consumables due to the gentle treatment, conversion costs and a lower energy requirement, as no heating and cooling phases and generally lower cleaning temperatures are required. Costs of chemicals are completely eliminated. Automation reduces personnel costs due to the low operating effort and training requirements. In terms of operation, the COBRA filter is also very safe - the closed system of filtration and cleaning without chemicals eliminates many of the risks associated with conventional filters and cleaning methods, such as the risk of injury and fire.

The cost savings are even more far-reaching if you extend the consideration to the downstream processes. The outstanding cleaning performance of COBRA saves a great deal of effort, interruptions and further processing.

The new COBRA filter will be presented to the public for the first time at the PRSE in Amsterdam at the beginning of April.