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Winder manufactured by Comoli Fermo S.r.l, Paruzzaro, Italy Photo: ITA – Institut für Textiltechnik of RWTH Aachen University
Winder manufactured by Comoli Fermo S.r.l, Paruzzaro, Italy
06.03.2024

ITA: Unique Winder for Elastic Filament Yarn Development

Since March 1st 2024, the technical centre of Institut für Textiltechnik of RWTH Aachen University (ITA) has been equipped with an additional winder.

This globally unique winder has been manufactured by Comoli Fermo S.r.l, Paruzzaro, Italy, and enables the development of elastic yarns for numerous and innovative areas of application. Monofilament and multifilament yarns can be spun within a speed range of 100 to 3,200 m/min on bobbins with an industrial standard size of 73.6 mm x 83.8 mm x 115.5 mm.

The use of these bobbins enables immediate further processing along the textile process chain, for example in production of elastic combination yarns or knitting. Due to the high flexibility of this winder in combination with the available spinning plants at ITA, testing is possible with material amounts starting from a few hundred grams up to hundreds of kilograms.

Since March 1st 2024, the technical centre of Institut für Textiltechnik of RWTH Aachen University (ITA) has been equipped with an additional winder.

This globally unique winder has been manufactured by Comoli Fermo S.r.l, Paruzzaro, Italy, and enables the development of elastic yarns for numerous and innovative areas of application. Monofilament and multifilament yarns can be spun within a speed range of 100 to 3,200 m/min on bobbins with an industrial standard size of 73.6 mm x 83.8 mm x 115.5 mm.

The use of these bobbins enables immediate further processing along the textile process chain, for example in production of elastic combination yarns or knitting. Due to the high flexibility of this winder in combination with the available spinning plants at ITA, testing is possible with material amounts starting from a few hundred grams up to hundreds of kilograms.

Source:

ITA – Institut für Textiltechnik of RWTH Aachen University

Presentation of the certificate for 1st place in the business plan competition KEUR.NRW 2023 to the RWTH start-up SA-Dynamics; from left to right: Oliver Krischer (Minister for the Environment, Nature Conservation and Transport of the State of NRW), Sascha Schriever (SA-Dynamics); Maximilian Mohr (SA-Dynamics); Jens Hofer (SA-Dynamics); Christian Schwotzer (SA-Dynamics) © Business Angels Deutschland e. V. (BAND)
Presentation of the certificate for 1st place in the business plan competition KEUR.NRW 2023 to the RWTH start-up SA-Dynamics; from left to right: Oliver Krischer (Minister for the Environment, Nature Conservation and Transport of the State of NRW), Sascha Schriever (SA-Dynamics); Maximilian Mohr (SA-Dynamics); Jens Hofer (SA-Dynamics); Christian Schwotzer (SA-Dynamics)
26.01.2024

Start-up: Bio-based aerogel fibres replace synthetic insulation materials

The Aachen-based start-up SA-Dynamics is developing sustainable, bio-based and biodegradable insulation materials made from aerogel fibres, thereby setting new standards in resource-saving construction. Dr Sascha Schriever (Institut für Textiltechnik ITA), Maximilian Mohr (ITA), Dr Jens Hofer (ITA Postdoc) and Dr Christian Schwotzer (Department for Industrial Furnaces and Heat Engineering IOB), who trained at RWTH Aachen University, were awarded first place in the KUER.NRW Business Plan Competition 2023 and prize money of €6,000.

SA-Dynamics relies on the impressive properties of aerogel fibres: they have excellent insulating properties, are lightweight, durable, robust, versatile and can be processed very well on conventional textile machines thanks to their flexibility. This makes them comparable to polystyrene, but still sustainable, as SA Dynamics uses bio-based and biodegradable raw materials.

The Aachen-based start-up SA-Dynamics is developing sustainable, bio-based and biodegradable insulation materials made from aerogel fibres, thereby setting new standards in resource-saving construction. Dr Sascha Schriever (Institut für Textiltechnik ITA), Maximilian Mohr (ITA), Dr Jens Hofer (ITA Postdoc) and Dr Christian Schwotzer (Department for Industrial Furnaces and Heat Engineering IOB), who trained at RWTH Aachen University, were awarded first place in the KUER.NRW Business Plan Competition 2023 and prize money of €6,000.

SA-Dynamics relies on the impressive properties of aerogel fibres: they have excellent insulating properties, are lightweight, durable, robust, versatile and can be processed very well on conventional textile machines thanks to their flexibility. This makes them comparable to polystyrene, but still sustainable, as SA Dynamics uses bio-based and biodegradable raw materials.

"We can revolutionise the construction world with bio-based aerogel fibres," explains ITA founder Dr Sascha Schriever proudly. "If all insulation materials in construction are converted to bio-based aerogel fibres, all builders can realise their dream of a sustainable house."

SA Dynamics has come a good deal closer to its founding goal by winning the KUER.NRW 2023 business plan competition. The spin-off from Institut für Textiltechnik (ITA) and Department for Industrial Furnaces and Heat Engineering (IOB) at RWTH Aachen University is scheduled for spring 2025.

Source:

ITA – Institut für Textiltechnik of RWTH Aachen University

AZL Aachen GmbH: Kick-off meeting for "Trends and Design Factors for Hydrogen Pressure Vessels" project (c) AZL Aachen GmbH
21.12.2023

AZL Aachen GmbH: Kick-off meeting for "Trends and Design Factors for Hydrogen Pressure Vessels" project

The kick-off meeting for the "Trends and Design Factors for Hydrogen Pressure Vessels" project, recently held at AZL Aachen GmbH, was a successful event, bringing together more than 37 experts in the field of composite technologies. This event laid a solid foundation for the Joint Partner Project, which currently comprises a consortium of 20 renowned companies from across the composite pressure vessel value chain: Ascend Performance Materials, C evotec GmbH, Chongqing Polycomp International Corp. (CPIC), Conbility GmbH, Elkamet Kunststofftechnik GmbH, F.A. Kümpers GmbH & Co. KG, f loteks plastik sanayi ticaret a.s., Formosa Plastics Corporation, Heraeus Noblelight GmbH, Huntsman Advanced Materials, Kaneka Belgium NV, Laserline GmbH, Mitsui Chemicals Europe GmbH, Plastik Omnium, Rassini Europe GmbH, Robert Bosch GmbH, Swancor Holding Co. Ltd. Ltd., TECNALIA, Toyota Motor Europe NV/SA, Tünkers do Brasil Ltda.

The project follows AZL´s well proven approach of a Joint Partner Project, aiming to provide technology and market insights as well as benchmarking of different material and production setups in combination with connecting experts along the value chain.

The kick-off meeting for the "Trends and Design Factors for Hydrogen Pressure Vessels" project, recently held at AZL Aachen GmbH, was a successful event, bringing together more than 37 experts in the field of composite technologies. This event laid a solid foundation for the Joint Partner Project, which currently comprises a consortium of 20 renowned companies from across the composite pressure vessel value chain: Ascend Performance Materials, C evotec GmbH, Chongqing Polycomp International Corp. (CPIC), Conbility GmbH, Elkamet Kunststofftechnik GmbH, F.A. Kümpers GmbH & Co. KG, f loteks plastik sanayi ticaret a.s., Formosa Plastics Corporation, Heraeus Noblelight GmbH, Huntsman Advanced Materials, Kaneka Belgium NV, Laserline GmbH, Mitsui Chemicals Europe GmbH, Plastik Omnium, Rassini Europe GmbH, Robert Bosch GmbH, Swancor Holding Co. Ltd. Ltd., TECNALIA, Toyota Motor Europe NV/SA, Tünkers do Brasil Ltda.

The project follows AZL´s well proven approach of a Joint Partner Project, aiming to provide technology and market insights as well as benchmarking of different material and production setups in combination with connecting experts along the value chain.

The kick-off meeting not only served as a platform to foster new contacts and get informed about the expertise and interests of the consortium members in the field of hydrogen pressure vessels, but also laid the groundwork for steering the focus of the upc oming project's ambitious phases. As a basis for the interactive discussion session, AZL outlined the background, motivation and detailed work plan. The central issues of the dialogue were the primary objectives, the most pressing challenges, the contribut ion to competitiveness, and
the priorities that would best meet the expectations of the project partners.

Discussions covered regulatory issues, the evolving value chain and the supply and properties of key materials such as carbon and glass fibres and resins. The consortium defined investigations into different manufacturing technologies, assessing their matu rity and potential benefits. Design layouts, including liners, boss designs and winding patterns, were thoroughly considered, taking into account their implications for mobile and stationary storage. The group is also interested in cost effective testing m ethods and certification processes, as well as the prospects for recycling into continuous fibres and the use of sustainable materials. Insight was requested into future demand for hydrogen tanks, OEM needs and strategies, and technological developments to produce more economical tanks.

The meeting highlighted the importance of CAE designs for fibre patterns, software suitability and the application dependent use of thermoset and thermoplastic designs.

The first report meeting will also set the stage of the next project phase, which will be the creation of reference designs by AZL's engineering team. These designs will cover a range of pressure vessel configurations using a variety of materials and production concepts. The aim is to develop models that not only re flect current technological capabilities, but also provide deep insight into the cost analysis of different production technologies, their CO2 footprint, recycling aspects and scalability.

AZL's project remains open to additional participants. Companies interested in joining this initiative are invited to contact Philipp Fröhlig.

Prof. Dr Tae Jin Kang (Seoul National University), Dr Musa Akdere (CarboScreen), Dr Christian P. Schindler (ITMF), from left to right. Source: ITMF
Prof. Dr Tae Jin Kang (Seoul National University), Dr Musa Akdere (CarboScreen), Dr Christian P. Schindler (ITMF), from left to right.
01.12.2023

Faster and cheaper carbon fibre production with CarboScreen

Faster and more cost-effective carbon fibre production - the technology of the start-up CarboScreen comes a good deal closer to this dream. The founders Dr. Musa Akdere, Felix Pohlkemper and Tim Röding from the Institut für Textiltechnik (ITA) of RWTH Aachen University are using sensor technology to monitor carbon fibre production, thereby doubling the production speed from the current 15 to 30 m/min in the medium term and increasing turnover by up to €37.5 million per year and system. This ground-breaking development also impressed the jury at the ITMF at their Annual Conference in Keqiao, China, and was honoured with the ITMF StartUp Award 2023 on 6 November 2023.

Dr. Musa Akdere accepted the award on behalf of the CarboScreen founding team.

Carbon fibres can only develop their full potential if they are not damaged during production and further processing. Two types of fibre damage occur more frequently during fibre production: Superficial or mechanical damage to the fibres or damage to the chemical structure.

Faster and more cost-effective carbon fibre production - the technology of the start-up CarboScreen comes a good deal closer to this dream. The founders Dr. Musa Akdere, Felix Pohlkemper and Tim Röding from the Institut für Textiltechnik (ITA) of RWTH Aachen University are using sensor technology to monitor carbon fibre production, thereby doubling the production speed from the current 15 to 30 m/min in the medium term and increasing turnover by up to €37.5 million per year and system. This ground-breaking development also impressed the jury at the ITMF at their Annual Conference in Keqiao, China, and was honoured with the ITMF StartUp Award 2023 on 6 November 2023.

Dr. Musa Akdere accepted the award on behalf of the CarboScreen founding team.

Carbon fibres can only develop their full potential if they are not damaged during production and further processing. Two types of fibre damage occur more frequently during fibre production: Superficial or mechanical damage to the fibres or damage to the chemical structure.

Both types of damage cannot be optimally detected by current means or only become apparent after production, to name just two examples. This leads to higher production costs. In an emergency, faulty production can even lead to plant fires. For this reason, and to ensure good production quality, the system is run at 15 m/min below its production capacity for safety reasons. However, 30 m/min or more would be possible. With the sensor-based online monitoring of CarboScreen, the production capacity can be doubled to 30 /min. This would lead to higher production, resulting in lower manufacturing costs and wider use of carbon fibres in mass markets such as automotive, aerospace and wind energy.

More information:
carbon fibers sensors Startup
Source:

ITA – Institut für Textiltechnik of RWTH Aachen University
 

Gerhard Lettl (AVK Board Member, C.F. Maier Europlast GmbH & Co. KG), Felix Pohlmeyer (ITA), Prof. Dr Jens Ridzewski (AVK Board Member, IMA Materialforschung und Anwendungstechnik GmbH), Tim Röding (ITA), from left to right © AVK
Gerhard Lettl (AVK Board Member, C.F. Maier Europlast GmbH & Co. KG), Felix Pohlmeyer (ITA), Prof. Dr Jens Ridzewski (AVK Board Member, IMA Materialforschung und Anwendungstechnik GmbH), Tim Röding (ITA), from left to right
23.11.2023

CarboScreen: Sensor monitoring for complex carbon fibre production

Felix Pohlkemper and Tim Röding from Institut für Textiltechnik (ITA) of RWTH Aachen University are developing a technology with their start-up CarboScreen GmbH that makes complex carbon fibre production controllable through sensor monitoring. With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 m/min to 30 m/min in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year and production plant. Felix Pohlkemper and Tim Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for this ground-breaking development. The award ceremony took place during the JEC Roof Forum in Salzburg, Austria.

Felix Pohlkemper and Tim Röding from Institut für Textiltechnik (ITA) of RWTH Aachen University are developing a technology with their start-up CarboScreen GmbH that makes complex carbon fibre production controllable through sensor monitoring. With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 m/min to 30 m/min in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year and production plant. Felix Pohlkemper and Tim Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for this ground-breaking development. The award ceremony took place during the JEC Roof Forum in Salzburg, Austria.

The production of carbon fibres is highly complex. In the current state of the art, however, the manufacturing process is only monitored manually by semi-skilled workers. However, even minimal fibre damage during production leads to a reduction in the quality of the carbon fibre. In extreme cases, it can also lead to plant fires. To ensure production quality, the production speed is currently limited to a maximum of 15 m/min. In fact, the production speed of the systems could be higher. The sensor-based online monitoring of Carbo-Screen makes it possible to increase the production speed to 30 m/min in the medium term. As a result of the increased production volume per system, the specific production costs of the carbon fibre are reduced, which can result in lower prices.

A reduced sales price would make it possible to use carbon fibres and their composite materials even more widely in traditional markets such as aerospace technology and wind energy, as well as for mass production in the automotive industry.

The CarboScreen online monitoring system is currently being developed for industrial use. It is to be validated at an industrial plant in 2024. CarboScreen GmbH was founded as part of EXIST funding and offers AI-supported sensor systems for carbon fibre production. The sensor technology continuously monitors the fibre throughout the entire production process. Deviations are detected automatically.

The winners of the AVK Innovation Award are honoured annually by the AVK Industrievereinigung Verstärkte Kunststoffe. Companies, institutes and their partners are honoured in three categories: products and applications, processes and procedures, and research and science.

Winners of AVK Innovation Award 2023 (c) AVK
Winners of AVK Innovation Award 2023
25.10.2023

Winners of AVK Innovation Award 2023

The winners of the prestigious Innovation Award for Fibre-Reinforced Plastics of the AVK, the German Federation of Reinforced Plastics, were presented in Salzburg this year. This award always goes to businesses, institutions and their partners for outstanding innovations in composites the three categories Products & Applications, Processes & Methods and Research & Science. Projects are submitted in all three categories and are evaluated by a jury of experts in engineering and science as well as trade journalists, who look at each project in terms of their levels of innovation, implementation and sustainability.

Products & Applications category
First place: “Insulating Coupling Shaft for Rail Vehicles” – Leichtbauzentrum Sachsen GmbH, partner: KWD Kupplungswerk Dresden GmbH

Second place: “Electric Car Battery Housing Components Based on Innovative Continuous Fibre-Reinforced Phenolic Resin Composites” – SGL Carbon

The winners of the prestigious Innovation Award for Fibre-Reinforced Plastics of the AVK, the German Federation of Reinforced Plastics, were presented in Salzburg this year. This award always goes to businesses, institutions and their partners for outstanding innovations in composites the three categories Products & Applications, Processes & Methods and Research & Science. Projects are submitted in all three categories and are evaluated by a jury of experts in engineering and science as well as trade journalists, who look at each project in terms of their levels of innovation, implementation and sustainability.

Products & Applications category
First place: “Insulating Coupling Shaft for Rail Vehicles” – Leichtbauzentrum Sachsen GmbH, partner: KWD Kupplungswerk Dresden GmbH

Second place: “Electric Car Battery Housing Components Based on Innovative Continuous Fibre-Reinforced Phenolic Resin Composites” – SGL Carbon

Third place: “High Performance Recycled Carbon Fibre Materials (HiPeR)” – Composites Technology Center GmbH (CTC GmbH), partners: Faserinstitut Bremen e. V, Sächsisches Textilforschungsinstitut e.V., C.A.R. FiberTec GmbH; partners Japan: Faserinstitut Bremen e.V., Sächsisches Textilforschungsinstitut e.V., C.A.R. FiberTec GmbH; Partner Japan: CFRI Carbon Fiber Recycle Industry Co., Ltd., IHI Logistics and Machinery Corporation, ICC Kanazawa Institute of Technology

Innovative Processes & Methods category
First place: “Chopped Fibre Direct Processing (CFP)” – KraussMaffei Technologies GmbH, partner: Wirthwein SE

Second place: “CIRC - Complete Inhouse Recycling of Thermoplastic Compounds” – Fraunhofer Institute for Production Engineering and Automation (IPA), partners: Schindler Handhabetechnik GmbH, Vision & Control GmbH

Third place: “CarboScreen – Sensor-Based Monitoring of Carbon-Fibre Production” – CarboScreen GmbH, partner: Institute of Textile Technology at RWTH Aachen University

Research & Science category
First place: “Development of a Stereocomplex PLA Blend on a Pilot Plant Scale” – Faserinstitut Bremen e. V.

Second place: “Fibre-Reinforced Salt as a Robust Lost Core Material” – Technical University of Munich, Chair of Carbon Composites, partners: Apppex GmbH, Haas Metallguss GmbH

Third place: “VliesSMC – Recycled Carbon Fibres with a Second Life in the SMC Process” – Sächsisches Textilforschungsinstitut e.V. (STFI), partner: Fraunhofer Institute for Chemical Technology (ICT)

 

Entries for the next Innovation Award 2024 can be submitted from January 2024 onwards.

Source:

AVK – Industrievereinigung Verstärkte Kunststoffe e.V.

Industriebrache Pixabay; Tama66
19.07.2023

IVC und ZVI positionieren sich klar gegen Pauschalverbot von PFAS

"Viele Unternehmen sitzen bereits auf gepackten Koffern und haben ihre Investitionsentscheidungen sind getroffen." Deutschland sei gerade erneut dabei, sich in multiple internationale Abhängigkeiten zu begeben und seinen Abschied aus dem Kreis der Industrienationen vorzubereiten. So beurteilen der Geschäftsführer der Industrievereinigung Chemiefaser e.V. (IVC), Dr. Wilhelm Rauch, und der Ressortleiter Umwelt-& Chemikalienpolitik des Zentralverbands Oberflächentechnik e.V. (ZVO), Dr. Malte M. Zimmer gemeinsam mit verschiedenen Unternehmen die Konsequenzen aus dem Plan der European Chemicals Agency (ECHA), rund 10.000 Alkylsubstanzen zu verbieten.

"Viele Unternehmen sitzen bereits auf gepackten Koffern und haben ihre Investitionsentscheidungen sind getroffen." Deutschland sei gerade erneut dabei, sich in multiple internationale Abhängigkeiten zu begeben und seinen Abschied aus dem Kreis der Industrienationen vorzubereiten. So beurteilen der Geschäftsführer der Industrievereinigung Chemiefaser e.V. (IVC), Dr. Wilhelm Rauch, und der Ressortleiter Umwelt-& Chemikalienpolitik des Zentralverbands Oberflächentechnik e.V. (ZVO), Dr. Malte M. Zimmer gemeinsam mit verschiedenen Unternehmen die Konsequenzen aus dem Plan der European Chemicals Agency (ECHA), rund 10.000 Alkylsubstanzen zu verbieten.

Die EU lasse dabei die Folgen auf Schlüsseltechnologien wie beispielsweise die grüne Energiewende komplett außer Acht. Lithiumbatterien, Windräder, Brennstoffzellen, Computerchips - für PFAS existierten aktuell zumindest in Hightech-Anwendungen keine Alternativen. Bis auf wenige längere Ausnahmeregelungen seien aktuell 18 Monate als Übergangsfristen vorgesehen. Das sei ein ausreichendes Zeitfenster, um die Produktion in Europa abzuwickeln und nach neuen Standorten zu suchen, beispielsweise in den USA. Dort werde die Fluorchemie als Schlüsseltechnologie massiv aufgebaut und als kostbares Gut mit Exportverboten belegt.

IVC und ZVO monierten, dass das Innovationsvermögen der europäischen Industrie hergeschenkt werde und man anderen Ländern den Markt mit allen preislichen und wettbewerblichen Konsequenzen überlasse. Als besonders betroffene Branchen führten die Verbände die Medizintechnik, Schutzausrüstung, Flugzeugbau und Automobilelektronik, den Textilmaschinenbau und Industrietextilien an. Abluftfilter mit PTFE-Membranen oder aus PTFE-Fasern stellten in der Müllverbrennung und in Zementwerken den Umweltschutz sicher, so dass keine Schadstoffe in die Atmosphäre gelangten. Membranen für Wasserstoff-Brennstoffzellen, Wasserstoffelektrolyseure, Lithium-Ionen-Batterien aus Karbonfaservliesen und der fluorchemischen Protonenaustauscher Nafion-Membran würden in Zukunft verboten und damit die die Pläne für eine Wasserstoffenergiewende dauerhaft nicht umsetzbar.

Source:

Industrievereinigung Chemiefaser e.V., Zentralverband Oberflächentechnik e.V.

Professor Dr Thomas Gries with the award winner Flávio André Marter Diniz Hanns-Voith-Stiftung, Oliver Voge
Professor Dr Thomas Gries with the award winner Flávio André Marter Diniz
11.07.2023

Future cost reduction through ultra-thin PE carbon fibres

  • ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

  • ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

The use of carbon fibres in highly stressed lightweight construction solutions, such as today's growth applications of wind turbines or pressure tanks, has become indispensable due to their excellent mechanical properties and low density. High manufacturing costs of conventional PAN precursor-based carbon fibres make the material very cost-intensive. In addition, it is not sufficiently available. New manufacturing approaches that develop alternative raw materials and manufacturing processes can be a key and growth engine for further industrial composites applications.

The aim of the work was to develop a new and cost-effective manufacturing process for high-quality ultra-thin carbon fibres using a polyethylene precursor. For this purpose, the sulphonisation process, which is time-consuming today, was to be significantly shortened. As a result, Mr. Marter Diniz produced novel ultra-thin polyethylenebased carbon fibres with a filament diameter < 3 μm with an excellent surface quality of the fibres without detectable structural defects. The fibre diameter is 2-3 times smaller than that of conventional PANbased CF. This provides the basis for mechanically high-quality material properties. At the same time, Mr. Marter Diniz was able to reduce the sulphonisation time by 25 percent. The developed material and technology set important milestones on the way to cheaper carbon fibres. With PE-based precursors, the price of CF can be reduced by 50 percent compared to conventional PAN-based CF.  

A total of five other young scientists were awarded in six categories (Drive Technology, Innovation & Technology/Artificial Intelligence, New Materials, Paper, Hydropower and Economic Sciences. This year, for the 10th time, the Hanns Voith Foundation awarded the Hanns Voith Prize to outstanding young scientists.

Source:

ITA Institut für Textiltechnik of RWTH Aachen University

Recycled yarn (c) ITA Aachen
05.05.2023

ITA at the ITMA: Smart Circular Economy

"ITA Aachen and ITA Augsburg are part of the ITA Group International Centre for Sustainable Textiles. Experience our textile innovations at two exhibition booths," explains ITA Institute Director Professor Dr. Thomas Gries. "See our ring spinning tester at booth H3-B304, which spins recycled fibres sustainably and individually in a previously impossible fineness. In addition, there is digital yarn monitoring, which enables new market potentials. Get an idea of the Recycling Atelier of ITA Augsburg at booth H3-A207 and see the textile cycle from used textile to solution steps for industrial implementation together with industry partners. Join us on the Walk4Recycling and follow the path from used textile to a new knitted pullover on a tour of the trade fair. This is how we live up to our claim as the ITA Group: sustainable - digital - individual."

"ITA Aachen and ITA Augsburg are part of the ITA Group International Centre for Sustainable Textiles. Experience our textile innovations at two exhibition booths," explains ITA Institute Director Professor Dr. Thomas Gries. "See our ring spinning tester at booth H3-B304, which spins recycled fibres sustainably and individually in a previously impossible fineness. In addition, there is digital yarn monitoring, which enables new market potentials. Get an idea of the Recycling Atelier of ITA Augsburg at booth H3-A207 and see the textile cycle from used textile to solution steps for industrial implementation together with industry partners. Join us on the Walk4Recycling and follow the path from used textile to a new knitted pullover on a tour of the trade fair. This is how we live up to our claim as the ITA Group: sustainable - digital - individual."

ITA Aachen - Digital ring spinning tester for recycled fibres enables spinning of fine yarns with high recycled fibres content
The Institut für Textiltechnik of RWTH Aachen University (ITA) will be exhibiting a digital ring spinning tester, which spins recycled fibres directly and conventionally with a particularly high content of 60-70 percent. Up to now, recycled yarns have mainly been rotor-spun in this blend ratio. This results in rather coarse yarns and is not suitable for finer textiles such as outerwear. Ring spinning of recycled yarns now enables the spinning of finer yarns and thus a higher application level for recycled materials.

A unique selling point of the ITA ring spinning tester is the simultaneous spinning in the direct spinning process from the sliver and in the classic ring spinning process. For this purpose, the strength and elongation of the spun yarn are determined online and digitally for the first time. The real-time measurement allows process parameters and yarn properties to be adjusted iteratively and quickly. The ring spinning tester was upgraded from an existing tester to Industry 4.0 standard and is operated via a tablet. Operation via tablet enables the adjustment of process parameters including online quality monitoring remotely from anywhere in the world.
 
For this purpose, the ring spinning tester is also able to produce fine ring spun yarns. These yarns made from recycled material opens up a multitude of further fields of application for woven and knitted goods. Now, for example, clothing and technical textiles can be made from recycled material, the production of which was not possible before - such as outerwear made from recycled material. The development of new industries and fields of application opens up new market potential for recycled yarns - also and especially for processing in Europe. This creates the opportunity to preserve key technologies and jobs in cost-intensive locations.

ITA Augsburg - Recycling Atelier: Walk4Recycling
The Recycling Atelier of the Institut für Textiltechnik Augsburg gGmbH on stand H3-A207 presents the textile recycling from used textiles into new products via the various process steps and, together with the industrial partners, opens up solution paths for industrial implementation.

Under the headline "Walk4Recycling", a tour of the fair shows the cycle of used textiles from used knitwear into a new knitted pullover via a ring yarn made from a blend of 65 percent recycled cotton and 35 percent virgin polyester. The key innovation here is the high proportion of recycled fibres from post-consumer textiles for a ring yarn of this fineness. Today, mainly coarse rotor yarns for low-quality textiles are spun from these materials. The industrial partners participating in the Walk4Recycling are partners of the Recycling Atelier and contribute with their technologies to the fact that fibre material from old clothes can be processed in various process stages into a yarn of new value and high-quality ready-made garments.

The Walk4Recycling offers visitors the opportunity to experience a complete recycling cycle with the numerous process stages from tearing the old textiles, preparing and spinning the fibres and knitting a new jumper live during the fair. Get detailed information on the mechanical recycling of clothing via QR code, website and flyer about the participating exhibitors and their machines and technologies. A short movie will give you additional insights into the various processes involved in the production of the jumper.

Winding unit for the continuous production of fibre-reinforced thermoplastic pipe profiles (c) ITA. Winding unit for the continuous production of fibre-reinforced thermoplastic pipe profiles
30.03.2023

Composites made by ITA at JEC World 2023

  • Less C02 emissions + sustainable + recyclable

Sustainability first - this is the principle of the Institut für Textiltechnik (ITA) of RWTH Aachen University at JEC World 2023. ITA combines various lightweight construction technologies to reduce C02 and to use renewable and/or recyclable raw materials.

ITA presents innovations in the production of reinforcing fibres and in the textile processing of high-modulus fibres. It also shows the impregnation of high-modulus fibres with thermosetting and thermoplastic matrix systems.  

ITA will be exhibiting in hall 6 together with Textechno, Mönchengladbach, Germany, textile testing equipment and Maruhachi Fukui, Japan, Thermoplastic Composite Material Systems. The Interreg AACOMA project will also be presented at the stand. 

  • Less C02 emissions + sustainable + recyclable

Sustainability first - this is the principle of the Institut für Textiltechnik (ITA) of RWTH Aachen University at JEC World 2023. ITA combines various lightweight construction technologies to reduce C02 and to use renewable and/or recyclable raw materials.

ITA presents innovations in the production of reinforcing fibres and in the textile processing of high-modulus fibres. It also shows the impregnation of high-modulus fibres with thermosetting and thermoplastic matrix systems.  

ITA will be exhibiting in hall 6 together with Textechno, Mönchengladbach, Germany, textile testing equipment and Maruhachi Fukui, Japan, Thermoplastic Composite Material Systems. The Interreg AACOMA project will also be presented at the stand. 

Source:

ITA Institut für Textiltechnik of RWTH Aachen

Dr Ioana Slabu and Benedict Bauer with the nanomodified stent. Photo Peter Winandy
30.03.2023

Nanomodified polymerstent: Novel technology for tumour therapy

  • Electromagnetically heatable nanomodified stent for the treatment of hollow organ tumours wins second place at the RWTH Innovation Award

Almost every fourth person who dies of cancer has a hollow organ tumour, for example in the bile duct or in the oesophagus. Such a tumour cannot usually be removed surgically. It is only possible to open the hollow organ for a short time using a stent, i.e. a tubeshaped prosthesis. However, the tumour grows back and penetrates the hollow organ through the stent. Ioana Slabu from the Institute of Applied Medical Technology and Benedict Bauer from the Institut für Textiltechnik of RWTH Aachen University have now developed a novel technology for the therapy of hollow organ tumours, which was awarded second place in the RWTH Innovation Award. This involves a polymerstent that contains magnetic nanoparticles. When electromagnetic fields are applied, these nanoparticles lead to a controlled heating of the stent material and thus of the tumour. Because the tumour reacts much more sensitively to heat than healthy tissue, it is destroyed and the hollow organ remains open. Thus, the stent develops a self-cleaning effect.  

  • Electromagnetically heatable nanomodified stent for the treatment of hollow organ tumours wins second place at the RWTH Innovation Award

Almost every fourth person who dies of cancer has a hollow organ tumour, for example in the bile duct or in the oesophagus. Such a tumour cannot usually be removed surgically. It is only possible to open the hollow organ for a short time using a stent, i.e. a tubeshaped prosthesis. However, the tumour grows back and penetrates the hollow organ through the stent. Ioana Slabu from the Institute of Applied Medical Technology and Benedict Bauer from the Institut für Textiltechnik of RWTH Aachen University have now developed a novel technology for the therapy of hollow organ tumours, which was awarded second place in the RWTH Innovation Award. This involves a polymerstent that contains magnetic nanoparticles. When electromagnetic fields are applied, these nanoparticles lead to a controlled heating of the stent material and thus of the tumour. Because the tumour reacts much more sensitively to heat than healthy tissue, it is destroyed and the hollow organ remains open. Thus, the stent develops a self-cleaning effect.  

Ioana Slabu of the AME explains: "Not only can we drastically reduce treatment costs, but above all we can provide relief for millions of patients worldwide.
 
A manufacturing process and proof of concept for magnetic hyperthermia are already in place. This novel technology has a very high development potential because it can also be used for tumours in other parts of the body such as the prostate, stomach, intestine or urinary bladder or for cardiovascular diseases.  

The AiF/IGF project started under the project title "ProNano" funded by BMWK. Now the approval for the follow-up project "ProNano2" has also been received. The approved project is called: "Validation of the innovation potential of heatable stents for heat-induced treatment of cavity tumours" and is funded by BMBF in course of the VIP+ program. With the Clinic for General, Visceral and Transplantation Surgery of the University Hospital Aachen and the Institute for Technology and Innovation Management at RWTH Aachen University, the consortium is enriched by clinical and economic expertise. Every year, RWTH Aachen University honours particularly innovative university projects with the Innovation Award. Professor Malte Brettel, Prorector for Business and Industry, presented the certificates to four outstanding projects as part of RWTHtransparent.

Source:

ITA – Institut für Textiltechnik of RWTH Aachen University

02.03.2023

Recycling Atelier Augsburg and Kelheim Fibres cooperate

Kelheim Fibres, a leading manufacturer of viscose speciality fibres, has joined Recycling Atelier Augsburg. Recycling Atelier Augsburg is a unique centre for research and development in the field of textile recycling. It is located at the Institut für Textiltechnik Augsburg an affiliated institute of Augsburg University of Applied Sciences. The two institutions founded the Recycling Atelier in June 2022 together with twelve partners from the German textile industry.

In the Recycling Atelier, the focus is on the triad of technical and ecological sense as well as economic benefit. In this way, the partners of the Recycling Atelier are standing up against fast fashion, outsourced corporate responsibility and a general decline in raw material quality, which often fuels downcycling - the low-quality reuse - of materials.

Kelheim Fibres, a leading manufacturer of viscose speciality fibres, has joined Recycling Atelier Augsburg. Recycling Atelier Augsburg is a unique centre for research and development in the field of textile recycling. It is located at the Institut für Textiltechnik Augsburg an affiliated institute of Augsburg University of Applied Sciences. The two institutions founded the Recycling Atelier in June 2022 together with twelve partners from the German textile industry.

In the Recycling Atelier, the focus is on the triad of technical and ecological sense as well as economic benefit. In this way, the partners of the Recycling Atelier are standing up against fast fashion, outsourced corporate responsibility and a general decline in raw material quality, which often fuels downcycling - the low-quality reuse - of materials.

As a model factory, the Recycling Atelier Augsburg combines the most important processes of textile recycling and offers holistic and comprehensive research along the value chain," explains Georg Stegschuster, head of the Recycling Atelier Augsburg. The scientists research on all process steps of textile recycling: from material analysis to sorting, preparation and textile processing to sustainable product design. Comprehensive data collection and the use of artificial intelligence as well as innovative materials play a central role.

Kelheim Fibres is a producer of high-quality viscose fibres, which consist of cellulose, the main component of the renewable raw material wood, and are used worldwide for products in areas such as hygiene, textiles, and technical applications.

"In New Business Development as well as Fibre and Application Development, we follow the Open Innovation concept - the cooperation with the Recycling Atelier offers us an ideal platform for this. Here we work with partners to advance sustainability and performance," explains Maik Thiel, project manager at Kelheim Fibres.

Recycled cotton fibres are often very short or of uneven length, which makes further processing of 100 % recycled material a challenge. Adding speciality fibres from Kelheim Fibres should enable the production of high-quality new products, such as nonwovens. In the future, the fibres provided by Kelheim Fibres will also be made from recycled pulp.

Source:

Kelheim Fibres GmbH

Photo VDMA
12.12.2022

Young Talent Award for AI supported production control of carbon fibres

  • Formula 1 cars will be cheaper in future

Carbon is the stuff Formula 1 cars are made of, at least the bodywork. But until now, carbon has been expensive. It can be produced more cheaply and efficiently if artificial intelligence monitors the production processes. A camera system combined with artificial intelligence automatically detects defects in the production of carbon fibres. This makes expensive manual inspection of the carbon fibres obsolete and the production price of the carbon fibre can be reduced in the long term.

For this idea, the young engineer Deniz Sinan Yesilyurt received the second prize of the "Digitalisation in Mechanical Engineering" Young Talent Award on 6 December.

  • Formula 1 cars will be cheaper in future

Carbon is the stuff Formula 1 cars are made of, at least the bodywork. But until now, carbon has been expensive. It can be produced more cheaply and efficiently if artificial intelligence monitors the production processes. A camera system combined with artificial intelligence automatically detects defects in the production of carbon fibres. This makes expensive manual inspection of the carbon fibres obsolete and the production price of the carbon fibre can be reduced in the long term.

For this idea, the young engineer Deniz Sinan Yesilyurt received the second prize of the "Digitalisation in Mechanical Engineering" Young Talent Award on 6 December.

Carbon fibres are sought after because of their good properties. They are very light - they weigh up to 50 percent less than aluminium. The combination of low weight and good mechanical properties offers many advantages. Especially in times of the energy transition, lightweight materials like carbon are more relevant than ever before. At the same time, carbon fibres are as resistant to external stresses as metals. However, achieving these good properties of carbon fibres is very complex.


Up to 300 individual fibre strands - bundles of individual fibres - have to be monitored simultaneously during production. If carbon fibres tear, it costs time and money to sort out the damaged fibres. This is just one example of various defects that can occur in the fibres during production.


Therefore, Deniz Sinan Yesilyurt attached a camera to the carbon fibre line that takes pictures of various fibre defects during production and collects them in a database. The artificial intelligence in the camera's information technology system evaluates the fibre defects by assigning the images to predefined reference defects. In doing so, it recognises various fibre defects with a classification accuracy of 99 per cent. The process can also be used in other areas that produce chemical fibres.

Deniz Sinan Yesilyurt received the prize from the German Engineering Federation (VDMA) in Frankfurt am Main, Germany. He is a Bachelor's graduate at the Institut für Textiltechnik (ITA) of RWTH Aachen University. The full title of his bachelor's thesis is: "Development of a Kl-supported process monitoring using machine learning to detect fibre damage in the stabilisation process". The VDMA awarded the prize to a total of four theses from different universities. The prize is awarded for outstanding theses and was offered in Germany, Austria and Switzerland.

Source:

ITA – Institut für Textiltechnik of RWTH Aachen Universit

(c) Zünd Systemtechnik AG
25.10.2022

Zünd: Heat Sealing Module – HSM receives composites industry award

At the recent CAMX 2022 Composites and Advanced Materials Expo in Anaheim, California, The Heat Sealing Module – HSM from Zünd was recognized with an Unsurpassed Innovation Award. The HSM significantly facilitates the processing and handling of dry fiber materials with thermoplastic content. This new tool is Zünd’s answer to a demand in the composites industry for wider-spread use and easier processing of these types of materials.

The American Composites Manufacturing Association, ACMA, proclaimed the Heat Sealing Module – HSM the winner of the ACE Award for Unsurpassed Innovation in the “Manufacturing: Equipment and Tooling” category. This award is presented annually to equipment, tooling, a production aid, or software designed to improve manufacturing production, environmental sustainability, or product quality and performance in composites manufacturing.

At the recent CAMX 2022 Composites and Advanced Materials Expo in Anaheim, California, The Heat Sealing Module – HSM from Zünd was recognized with an Unsurpassed Innovation Award. The HSM significantly facilitates the processing and handling of dry fiber materials with thermoplastic content. This new tool is Zünd’s answer to a demand in the composites industry for wider-spread use and easier processing of these types of materials.

The American Composites Manufacturing Association, ACMA, proclaimed the Heat Sealing Module – HSM the winner of the ACE Award for Unsurpassed Innovation in the “Manufacturing: Equipment and Tooling” category. This award is presented annually to equipment, tooling, a production aid, or software designed to improve manufacturing production, environmental sustainability, or product quality and performance in composites manufacturing.

During processing, dry fiber materials are prone to fraying along the edges. Using hot air, the HSM seals the fabric along the cut path in advance of the Zünd Power Rotary Tool – PRT cutting it. Because of this sealing process, the cut can then be performed at full speed, in any direction, and produces both higher-quality parts and greater production efficiencies.

The HSM helps create clean, sealed edges when cutting fiber-reinforced thermoplastic composites. It benefits not only the cutting process itself, but other production processes downstream. Cutting this way leaves behind no loose or uncut fibers and maintains a clean cutting surface and uncontaminated production environment. At the same time, it ensures that cut parts maintain their shape, and this increased stability makes them much easier to handle, especially in fully automated production workflows.

Source:

Zünd Systemtechnik AG

(c) ITM
22.06.2022

ITM: Techtextil Innovation Award 2022 für neuartige textile Herzklappenprothesen

Wissenschaftler:innen vom Institut für Textilmaschinen und Textile Hochleistungswerkstofftechnik (ITM) der TU Dresden sind am 21. Juni 2022 für ihre gewebten Herzklappenimplantate mit dem Techtextil Innovation Award 2022 in der Kategorie „New Product“ ausgezeichnet worden.

Im Rahmen eines Forschungsprojektes der Industriellen Gemeinschaftsforschung (IGF) entwickelten Wissenschaftler:innen des ITM neuartige textile Herzklappenprothesen. Die Implantate können exakt an die anatomische Form angepasst und minimalinvasiv im Herz platziert werden. Die textile Herzklappe ist integral gefertigt. Hierbei erfolgt die Integration des Ventils in situ während des Webprozesses. Somit besteht die strömungstechnisch optimierte Herzklappe aus einer einzigen textilen Struktur. Weitere Fügeprozesse, z. B. durch Nähen, sind nicht mehr erforderlich. Das reduziert den Fertigungsaufwand im Gegensatz zur heutigen Herstellung biologischer Herzklappenprothesen in Handarbeit enorm.

Wissenschaftler:innen vom Institut für Textilmaschinen und Textile Hochleistungswerkstofftechnik (ITM) der TU Dresden sind am 21. Juni 2022 für ihre gewebten Herzklappenimplantate mit dem Techtextil Innovation Award 2022 in der Kategorie „New Product“ ausgezeichnet worden.

Im Rahmen eines Forschungsprojektes der Industriellen Gemeinschaftsforschung (IGF) entwickelten Wissenschaftler:innen des ITM neuartige textile Herzklappenprothesen. Die Implantate können exakt an die anatomische Form angepasst und minimalinvasiv im Herz platziert werden. Die textile Herzklappe ist integral gefertigt. Hierbei erfolgt die Integration des Ventils in situ während des Webprozesses. Somit besteht die strömungstechnisch optimierte Herzklappe aus einer einzigen textilen Struktur. Weitere Fügeprozesse, z. B. durch Nähen, sind nicht mehr erforderlich. Das reduziert den Fertigungsaufwand im Gegensatz zur heutigen Herstellung biologischer Herzklappenprothesen in Handarbeit enorm.

Prof. Chokri Cherif, Institutsdirektor des ITM, freut sich mit seinem Team sehr über die kontinuierli-chen interdisziplinären Forschungserfolge, die am ITM in enger Kooperation mit technischen Webereien, Medizinern und Anwendern stetig erzielt werden. „Bereits vor zwei Jahren wurden wir mit dieser neuartigen Entwicklung als eines der drei Finalistenteams des Otto von Guericke-Preises 2020 geehrt. Die Auswahl für den Techtextil Innovation Award 2022 ist eine erneute Bestätigung für den Bedarf an unserer praxisorientierten Forschung und eine besondere Würdigung, aber gleichzeitig auch weiterer Ansporn für die zeitnahe Umsetzung unserer Forschungsergebnisse in die Industrie.“

Bislang stehen für die Behandlung defekter Herzklappen mechanische und biologische Klappen zur Verfügung. Die neuartigen gewebten Herzklappenprothesen sollen die Vorteile der beiden Typen vereinen: unbegrenzte Lebensdauer, keine lebenslange Einnahme von blutverdünnenden Medikamenten und minimal invasive Operation. Ferner können die textilen Herzklappen zeit- und kostensparend mit hoher Reproduzierbarkeit und Qualität gefertigt werden.

(c) AVK - Industrievereinigung Verstärkte Kunststoffe e. V.
24.11.2021

The AVK – Industrievereinigung Verstärkte Kunststoffe – presents its Innovation Awards 2021

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

Category “Research and Science”
First place in the “Research and Science” category was awarded to the German Aerospace Center (DLR) for its Bondline Control Technology (BCT). This innovative process is used for quality control and assurance of bonded joints. The core element is a porous fabric which is applied to a joining surface using an epoxy adhesive or matrix resin. Peeling away the fabric creates a chemically reactive and undercut surface and can also be used as a test to check adhesion to the substrate. BCT has potential in a variety of possible applications. For example, peel ply can be replaced by BCT fabric to produce composite components with an optimised joining surface. The cost-effective BCT peel test is suitable for coupon testing and process control. In addition, the combined adhesion test and surface pre-treatment can be used for quality assurance of bonded repairs on fibre composite structures.

Second place was taken by the Institute of Textile Technology (ITA) at RWTH Aachen University and its partners AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR with “StoneBlade – Lightweight construction with granite for the wind industry”. This innovation enables manufacturers to reduce the amount of non-recyclable materials used in rotor blade construction. At the same time, it reduces the weight of these components and improves the mechanical properties relating to the stability of wind turbines. The innovative approach replaces glass-fibre reinforced plastic in the blade components with hard rock – a natural, cost-effective and recyclable lightweight material. The slabs of rock are cut and ground to a thickness of just a few millimetres and embedded in a fibre composite laminate with carbon fibre, which stabilises them for alternating load cases. The pre-stressed material is pressure-stable in the composite and can absorb tensile forces in the event of continuously alternating loads without any loss of stiffness.

Third place went to the Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK) with its partner Mercedes Benz AG for the interdisciplinary development of a highly integrated inductive charging module for electric vehicles. The ultra-thin charging module was designed to make optimum use of space in the vehicle underbody without reducing ground clearance. An interdisciplinary approach was adopted for the development process. This involved the electrical, mechanical and process characterisation of high-frequency Litz wires, ferromagnetic foil and metal wire cloth as well as the creation of a simulation model. The result is a demonstrator for a charging system with a structural height of 15 mm and a total weight of 8 kg. It achieves a transmission efficiency of up to 92 percent at 7.2 kW nominal power and active air cooling. The hardware demonstrator was fabricated in a 3-step process using RTM and VARI techniques.

Overview of all the winners in the three categories:
Category “Innovative Products/Applications”
1st Place: “Traffic signs from Nabasco (N-BMC)” – Nabasco Products BV and Lorenz Kunststofftechnik GmbH, partners: Pol Heteren BV and NPSP BV
2nd Place: “Novel, ultratough vinyl ester resin for the construction of large marine vessels” Evonik Operations GmbH
3rd Place: “Air intake housing with a multi-material design for gas turbines” – MAN Energy Solutions SE, Leichtbau-Zentrum Sachsen GmbH and Leichtbau-Systemtechnologien KORROPOL GmbH.
Category “Innovative Processes”
1st Place: “In-mould wrapping” off-tool, film-coated, fibre composite components for exterior applications – BMW Group, Partner: Renolit SE
2nd Place: “Adaptive automated repair of composite structural components in the aviation sector” – Lufthansa Technik AG, Partner: iSAM AG
3rd Place: “Automated surface pre-treatment using VUV excimer lamps” – CTC GmbH
Category “Research and Science”
1st Place: “Bondline Control Technology (BCT)” – German Aerospace Center (DLR)
2nd Place: “StoneBlade – Lightweight construction with granite for the wind industry” – Institute of Textile Technology at RWTH Aachen University, Partners: AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR
3rd Place: “Interdisciplinary development of a highly integrated inductive charging module for electric vehicles” – Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK), Partner: Mercedes Benz AG

Submissions for the next Innovation Award can be made from the end of January 2022.

Source:

AVK - Industrievereinigung Verstärkte Kunststoffe e. V.

(c) Kai-Chieh Kuo
17.11.2021

ITA PhD student Kai-Chieh Kuo was awarded Best Master’s Thesis Award of Walter Reiners-Stiftung

Kai-Chieh Kuo, PhD student at the Institut für Textiltechnik (ITA) of RWTH Aachen University, was awarded the German Textile Mechanical Engineering 2021 Best Master's Thesis Award for his master's thesis entitled "Modification of the tube weaving process of fine yarns for the production of woven ultra-low profile stent grafts". The prize is endowed with 3,500€. Peter D. Dornier, Chairman of the Board of the Walter Reiners-Stiftung (Foundation), virtually presented the award on the occasion of the ADD International Textile Conference on 9 November 2021.

Kai-Chieh Kuo, PhD student at the Institut für Textiltechnik (ITA) of RWTH Aachen University, was awarded the German Textile Mechanical Engineering 2021 Best Master's Thesis Award for his master's thesis entitled "Modification of the tube weaving process of fine yarns for the production of woven ultra-low profile stent grafts". The prize is endowed with 3,500€. Peter D. Dornier, Chairman of the Board of the Walter Reiners-Stiftung (Foundation), virtually presented the award on the occasion of the ADD International Textile Conference on 9 November 2021.

Minimally invasive endovascular aortic repair (EVAR) with textile stent-graft systems is nowadays a clinically established therapy procedure for the treatment of abdominal aortic aneurysms (AAA) – pathological bulges of the aorta. Due to the thick profile of the folded stent graft systems, there is currently a high risk of injuring narrowed or highly angulated access vessels from the inside during implantation. Stent graft systems with smaller profiles could provide an improvement, which could overcome complicated access routes through a lower bending stiffness. One possible approach for reducing the system profiles is the use of thin-walled tubular woven fabrics made of ultrafine multifilament yarns (≤20 dtex) as graft material.

Up to now, it has not been possible to process the fine yarns with the required high thread density (>200 threads/cm) and the available weaving technology in order to guarantee sufficient tightness against blood.

In his master's thesis, Kai-Chieh Kuo made high-density tubular weaving of ultra-fine filament yarns possible for the first time by means of suitable modifications to a shuttle loom as well as adaptations in the weaving preparation. In particular, he developed a new innovative reed technology that reduces warp thread friction during the shedding process and thus improves the process stability of the dense tube weaving process of fine yarns.

With the help of the process modification, it was then possible to produce high-density, thin-walled tubular woven fabrics, which were positively evaluated with regard to their suitability for a stent graft. Above all the potential of these tubular fabrics lies in their extremely thin-walled fabric profile, which seals well against blood. By using these new types of tubular fabrics as graft material for stent grafts, the system profile of the folded stent graft system can be reduced without having to compromise the blood tightness of the implant. The technology developed by Mr Kuo is not only applicable to stent graft systems, but also offers great possibilities for use in all other endovascular implants such as trans catheter heart valves, covered stents and small-lumen vascular prostheses.

© ITM / TU Dresden
10.11.2021

Kreativitätspreis des Deutschen Textilmaschinenbaues 2021 geht an Irina Kuznik

Die Verleihung der Förder- und Kreativitätspreise 2021 der Walter Reiners-Stiftung des VDMA, Fachverband Textilmaschinen an Studierende und Nachwuchswissenschaftler:innen deutscher Universitäten für Spitzenleistungen in Studium und Promotion fand am 09. November 2021 im Rahmen der Aachen-Dresden-Denkendorf International Textile Conference 2021 statt. Die bundesweit ausgeschriebenen Förder- und Kreativitätspreise wurden erneut online durch Herrn Peter D. Dornier, Vorstandsvorsitzender der Walter Reiners-Stiftung, verliehen.

Frau Dipl.-Ing. Irina Kuznik vom Institut für Textilmaschinen und Textile Hochleistungswerkstofftechnik (ITM) der TU Dresden wurde mit dem 3.000 EUR dotierten Kreativitätspreis des Deutschen Textilmaschinenbaues 2021 für ihre exzellente Diplomarbeit „Entwicklung zur umweltfreundlichen Herstellung neuartiger Chitosanfasergarne unter Einsatz von ionischen Flüssigkeiten" ausgezeichnet.

Die Verleihung der Förder- und Kreativitätspreise 2021 der Walter Reiners-Stiftung des VDMA, Fachverband Textilmaschinen an Studierende und Nachwuchswissenschaftler:innen deutscher Universitäten für Spitzenleistungen in Studium und Promotion fand am 09. November 2021 im Rahmen der Aachen-Dresden-Denkendorf International Textile Conference 2021 statt. Die bundesweit ausgeschriebenen Förder- und Kreativitätspreise wurden erneut online durch Herrn Peter D. Dornier, Vorstandsvorsitzender der Walter Reiners-Stiftung, verliehen.

Frau Dipl.-Ing. Irina Kuznik vom Institut für Textilmaschinen und Textile Hochleistungswerkstofftechnik (ITM) der TU Dresden wurde mit dem 3.000 EUR dotierten Kreativitätspreis des Deutschen Textilmaschinenbaues 2021 für ihre exzellente Diplomarbeit „Entwicklung zur umweltfreundlichen Herstellung neuartiger Chitosanfasergarne unter Einsatz von ionischen Flüssigkeiten" ausgezeichnet.

In ihrer Diplomarbeit entwickelte Frau Kuznik einen völlig neuen Ansatz zur ökologischen und ökonomischen Herstellung von Chitosangarnen. Unter Nutzung ionischer Flüssigkeiten als gut geeignetes, neuartiges Lösungsmittel für Chitosan lässt sich Chitosan mit geringen Deacetylierungsgraden sowie reines Chitin erfolgreich auflösen. In einem Nassspinnverfahren können damit erzeugte Spinnlösungen zu neuartigen Chitosan- bzw. Chitinmonofilamenten mit sehr guten morphologischen Eigenschaften hergestellt werden. Des Weiteren lässt sich die ionische Flüssigkeit mittels eines Verdampfungsverfahrens aus dem Abwasser zurückgewinnen und wiederaufbereitet werden.

More information:
VDMA Textilmaschinen chitosan
Source:

Technische Universität Dresden
Institut für Textilmaschinen und Textile Hochleistungswerkstofftechnik (ITM)

(c) Tom Schulze. “IQ Innovationspreis Mitteldeutschland“, overall winner (from left to right) FibreCoat GmbH from Aachen, ITA graduate Dr Robert Brüll, Deutsche Basalt Fiber GmbH from Sangerhausen, Georgi Gogoladze.
28.06.2021

Overall prize of the “IQ Innovationspreis Mitteldeutschland“ for FibreCoat GmbH and DBF Deutsche Basalt Faser GmbH

FibreCoat GmbH from Aachen, Germany, together with DBF Deutsche Basalt GmbH, developed a completely new type of fibre material to shield electromagnetic radiation from digital end devices, medical technology or e-car batteries cheaply and effectively. The joint project was awarded the overall prize of the“ IQ Innovationspreises Mitteldeutschland“ on 24 June in an online event broadcast live from Leipzig.

The prize is endowed with €15,000 and was sponsored by the Halle-Dessau, Leipzig and East Thuringia Chambers of Industry and Commerce.

FibreCoat GmbH from Aachen, Germany, together with DBF Deutsche Basalt GmbH, developed a completely new type of fibre material to shield electromagnetic radiation from digital end devices, medical technology or e-car batteries cheaply and effectively. The joint project was awarded the overall prize of the“ IQ Innovationspreises Mitteldeutschland“ on 24 June in an online event broadcast live from Leipzig.

The prize is endowed with €15,000 and was sponsored by the Halle-Dessau, Leipzig and East Thuringia Chambers of Industry and Commerce.

Electromagnetic radiation from smartphones, hospital diagnostics and electric car batteries must be shielded so that they do not inter-fere with each other. To prevent mutual interference, they have so far been covered with metal fibre fabrics, a very time- and energy-consuming and thus expensive procedure. The new material from Basalt Faser GmbH and FibreCoat GmbH prevents this with a fibre core made of melted, thinly drawn basalt, which is coated with aluminium and bundled into the so-called AluCoat yarn. This yarn remains just as conductive and shielding, but is lighter, stronger, cheaper and more sustainable than previous alternatives. In addition, there are further advantages:

  • The number of process steps required is reduced from ten to one.
  • 1,500 metres of yarn are produced per minute instead of the previous five metres.
  • The energy required is only 10 per cent of the previous amount.

The result is a price that is twenty times lower.

The textile made of AluCoat fibres is versatile and flexible: as wallpaper it can shield 5G radiation in offices or medical rooms or encase batteries and thus ensure the smooth functioning of electric cars. AluCoat is already being used in some companies. A European fibre centre in Sangerhausen is being planned for mass production.

The two innovative companies DBF Deutsche Basalt GmbH and FibreCoat GmbH from East and West combine the two materials basalt and aluminium to protect against electromagnetic radiation. In doing so, they coat basalt with aluminium and, through this novel combination, create an inexpensive, sustainable and quickly produced alter-native for a market worth billions.

FibreCoat GmbH from Aachen is a spin-off of the Institut für Textiltechnik (ITA) of RWTH Aachen University; the managing directors Dr Robert Brüll and Alexander Lüking and Richard Haas have completed their doctorates at the ITA or are in the process of preparing their doctorates. Georgi Gogoladze, Managing Director of Deutsche Basaltfaser GmbH, also studied at RWTH Aachen University. The two managing directors Brüll and Gogoladze know each other from their student days.

Source:

ITA – Institut für Textiltechnik of RWTH Aachen University

 Künstliche Intelligenz für Maschinen hilft Mensch und Umwelt (c) SKZ
Vliesstoff-Kompaktanlage (DILO) zur Herstellung von Nadel-Vliesen aus Sonderfasern.
23.06.2021

Künstliche Intelligenz für Maschinen hilft Mensch und Umwelt

Der Maschinenbau ist eine Stärke der deutschen Industrie. In Leitbranchen, deren Produkte in einem globalisierten Umfeld starker Konkurrenz ausgesetzt sind, kann der Einsatz Künstlicher Intelligenz (KI) dazu beitragen, Industriekapazitäten und Knowhow in Deutschland zu halten, im Maschinenbau und nachgelagerten Branchen. Doch erst durch praxisnahe Anwendung in der Industrie kann KI seine Stärken für Unternehmen voll entfalten. Wie das mit dem Beitrag angewandter Forschung geht, zeigen Textilindustrie und -maschinenbau ebenso wie die Kunststoffbranche.

Mit der Corona-Krise sind Vliesstoffe über die Fachwelt hinaus bekannt geworden, denn sie bilden das Ausgangsmaterial für Schutzmasken. Die aufgetretenen Engpässe am Markt 2020 zeigten, wie stark Deutschland hier von Lieferungen aus dem Ausland abhängig ist. Zugleich ist Deutschland in anderen Vliesstoff-Segmenten und bei Maschinen für die Vliesstoffherstellung eine wichtige Größe auf den Weltmärkten. Damit das so bleibt, arbeitet die Branche an Innovationen. Ein zentraler Baustein dafür: Die Nutzung Künstlicher Intelligenz (KI).

Das Auge auf der lernenden Maschine

Der Maschinenbau ist eine Stärke der deutschen Industrie. In Leitbranchen, deren Produkte in einem globalisierten Umfeld starker Konkurrenz ausgesetzt sind, kann der Einsatz Künstlicher Intelligenz (KI) dazu beitragen, Industriekapazitäten und Knowhow in Deutschland zu halten, im Maschinenbau und nachgelagerten Branchen. Doch erst durch praxisnahe Anwendung in der Industrie kann KI seine Stärken für Unternehmen voll entfalten. Wie das mit dem Beitrag angewandter Forschung geht, zeigen Textilindustrie und -maschinenbau ebenso wie die Kunststoffbranche.

Mit der Corona-Krise sind Vliesstoffe über die Fachwelt hinaus bekannt geworden, denn sie bilden das Ausgangsmaterial für Schutzmasken. Die aufgetretenen Engpässe am Markt 2020 zeigten, wie stark Deutschland hier von Lieferungen aus dem Ausland abhängig ist. Zugleich ist Deutschland in anderen Vliesstoff-Segmenten und bei Maschinen für die Vliesstoffherstellung eine wichtige Größe auf den Weltmärkten. Damit das so bleibt, arbeitet die Branche an Innovationen. Ein zentraler Baustein dafür: Die Nutzung Künstlicher Intelligenz (KI).

Das Auge auf der lernenden Maschine

Am ITA Augsburg hat man dafür Grundlagen in einem Projekt gelegt, auf denen sich nun aufbauen lässt. Die Vision: Die Maschine zur Vliesstoffproduktion passt die Parameter entsprechend den Erfordernissen im laufenden Betrieb autonom an. Etwaig auftretende Fehler werden von der Maschine selbstständig diagnostiziert, die Drehzahlen entsprechend angepasst. „Wir haben im Projekt EasyVlies gezeigt, wie sich mit der Nutzung von Algorithmen für die Vliesstoffproduktion Material- und Energiekosten einsparen lassen. Zusammen mit Partnern aus der Industrie haben wir erreicht, dass die Maschine zentrale Parameter wie Drehzahlen und Abstände, von denen eine große Kombinationsmenge für das Erreichen der gewünschten Produktqualität notwendig sind, durch das entwickelte KI-Modell vorhergesagt werden. „Die Abstände der bis zu 40 Arbeitselemente in der Maschine bestimmen dabei in Kombination mit den Drehzahlen der beteiligten Walzen die Öffnung der Faserflocken bis zur Einzelfaser und die Bildung des Vlieses“, erläutert ITA-Augsburg Geschäftsführer Prof. Stefan Schlichter. Die naturwissenschaftlichen Zusammenhänge und Wechselwirkungen zwischen den Drehzahlen und den Qualitätsparametern der Vliesstoffproduktion sind nicht eindeutig bekannt. Gerade deshalb kann KI hier seine Vorteile ausspielen. „Denn Künstliche Intelligenz kann auch diffuse Zusammenhänge modellieren und simulieren“, betont Schlichter. Die Algorithmen dafür hat Maschinenbauingenieur Dr. Frederik Cloppenburg aus dem Aachener ITA-Stammhaus entwickelt, 280 Versuche wurden im Zusammenspiel mit der KI-Entwicklung durchgeführt.

In der unternehmerischen Praxis lernen die Algorithmen nun hinzu. Das zeigt  bei einem Vliesstoffbetrieb der Fahrzeugbranche bereits erste Erfolge in der betrieblichen Praxis. Im nächsten Schritt arbeiten die ITA-Forschenden daran, Messtechnik wie Kamerasysteme und strahlungsbasierte Messsysteme für die Gleichmäßigkeit des Vliesstoffs in die Maschinen zu integrieren. Ziel: Fehler so prognostizieren, dass sie gar nicht erst auftreten. Das Aufkommen an Vliesstoff-Ausschuss soll so um 30 bis 50 Prozent sinken. Angesichts von bislang jährlich allein in Deutschland anfallender Ausschussware im Wert von 150 Mio. Euro, das entspricht 10 Prozent des Branchenumsatzes, ein erheblicher Anreiz. „Die hoch qualifizierten Facharbeiter beaufsichtigen sozusagen die lernende Maschine“, erklärt Schlichter.

Industrie 4.0 wird in der Kunststoffbranche künftig auch benötigt, um das Ziel höherer Recyclingquoten zu erreichen. Denn eine weniger einheitliche Rohstoffbasis macht lernende Maschinen noch wertvoller. Das ist auch Ausgangspunkt des vom Bundesforschungsministerium (BMBF) geförderten Verbundprojekts CYCLOPS des Kunststoff-Zentrums (SKZ) und namhaften Partnern aus Wissenschaft und Wirtschaft. Durch den Einsatz von KI sollen Materialströme automatisiert klassifiziert werden, damit sie sich optimal verwenden lassen. „Die Maschinen sollen künftig eigenständig erkennen, in welche Anwendungen produzierte Materialien eines bestimmten Typs gehen können“ erläutert SKZ-Gruppenleiter Digitalisierung, Christoph Kugler. Ein Faktor: Die Fließfähigkeit des Kunststoffs, seine Viskosität. Je kürzer die Polymerketten des Materials, desto größer, vereinfacht gesagt, ihre Fließfähigkeit. Für diese Fließfähigkeit spielt andererseits auch das Druckniveau in der Maschine eine Rolle. Hier kommt wiederum die KI ins Spiel: „Durch Künstliche Intelligenz können Materialeigenschaften und selbst lernende Maschinensteuerungen sehr gut ineinanderwirken, so unsere Erwartung“, erklärt Kugler. Grundlage für die angewandte Forschung im Projekt CYCLOPS sind sowohl Prozessdaten aus den Maschinen, welche die Materialqualität beschreiben können, als auch Daten entlang des Lebenswegs von Material und Produkt. Im Rahmen des Projektes werden damit die Transparenz und die Informationsdichte erhöht, welche nach wie vor einige der größten Hemmnisse der Kreislaufwirtschaft sind.

Neue Expertisefelder wie Erklärbare KI erschlossen

Das SKZ baut mit dem Projekt auf KI-Expertise auf, die über abgeschlossene und noch laufende Projekte erarbeitet wurde. In der Vergangenheit lag der Schwerpunkt in der Entwicklung sogenannter Softsensoren aus Prozessdaten zur Berechnung komplexer Qualitätskennwerte wie z.B. Viskosität oder Vernetzungsgrad des Kunststoffs. Durch die Weiterentwicklung der Technologie werden neue Expertisefelder erschlossen, so z.B. Optimierung der Prozessmodellierung durch KI, Prognose von Materialverhalten unter Last oder auch erklärbare KI (XAI), sie beschreibt den Weg, auf dem Algorithmen zu ihren Ergebnissen gelangen. In den letzten Jahren wurde ebenfalls der Einsatz von digitalen Technologien und KI im Kontext der Kreislaufwirtschaft am SKZ forciert, so in den noch jeweils bis ins nächste Jahr hinein laufenden Projekten Di-Plast und DiLinK. Während Di-Plast ein EU-Projekt ist, wird DiLink ebenfalls vom BMBF gefördert. Mit dem FIR e.V. ist ein weiteres Institut der Zuse-Gemeinschaft im DiLink-Projektkonsortium vertreten, mit dem Fokus auf dem Thema Geschäftsmodelle. Denn diese verändern sich durch das Vordringen der KI in immer mehr Aspekten des Maschinenbaus.