JEC Composites show Paris 2011 Intelligence Report

JEC Composites Show 2011

Paris - Porte de Versailles

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SUMMARY
Abstract ................................................................................................................................................... 4
Introduction............................................................................................................................................. 5
Carbon fibre reinforced plastic composites ............................................................................................ 7
1.1
Carbon reinforced plastic composites for lighter and more efficient cars ............................. 7
1.1.1 Lamborghini ........................................................................................................................ 8
1.1.2 Audi ..................................................................................................................................... 8
1.1.3 BMW ................................................................................................................................... 8
1.1.4 Delta Motorsport .............................................................................................................. 10
1.2
Innovations in carbon fiber reinforced plastic composites ................................................... 12
1.2.1 Cutting Dynamics: Innovative aircraft seat back .............................................................. 12
1.2.2 Latécoère: Innovative aircraft door structure .................................................................. 13
1.2.3 Hexcel: Innovations in weaving technology ..................................................................... 13
1.2.4 Biteam: 3D carbon fiber woven profiles ........................................................................... 14
Vegetal fiber reinforced plastic composites.......................................................................................... 18
1.3
Vegetal fiber reinforced material for Building applications .................................................. 20
1.3.1 Innobat .............................................................................................................................. 20
1.4
Vegetal fiber reinforced material for Sport & Leisure applications ...................................... 21
1.4.1 Libeco – Lineo ................................................................................................................... 21
1.4.2 Porcher Industries ............................................................................................................. 23
1.4.3 Renards des mers.............................................................................................................. 25
1.5
Vegetal fiber reinforced material for Automotive applications ............................................ 26
1.5.1 Huntsman Advanced Material .......................................................................................... 26
1.6
Vegetal fiber reinforced material for other applications ...................................................... 27
1.6.1 RocTool – FiberShell.......................................................................................................... 27
Environementally friendly resins ........................................................................................................... 29
1.6.2 Reichhold: New environmentally friendly resins for composites ..................................... 29
1.6.3 Cray Valley: Fire resistant resins and gel coats ................................................................. 30
Light composite structures .................................................................................................................... 31
1.7
Sandwich structures .............................................................................................................. 31
1.7.1 Amorin: Cork cored composites ....................................................................................... 31
1.7.2 Biotopes: Bio-based wall panels ....................................................................................... 33
1.7.3 EconCore: Honeycomb cored structures .......................................................................... 33
1.7.4 Fraunhofer PYCO: Nap-core and polycyanurate foam containing structures .................. 37
1.8
Hexagonal structuring for light and stiff materials ............................................................... 38
Composite processing and assembly .................................................................................................... 39
1.8.1 Fraunhofer ILT: Laser beam welding of fiber reinforced thermoplastics ......................... 39
1.8.2 Fraunhofer PYCO: Recycling and repairing of CFRP and GFRP composites ...................... 40
1.8.3 Innovaltech: Magnetic Pulse System for cold welding ..................................................... 41
1.8.4 KVE Induct: Induction welding of carbon fiber reinforced thermoplastics ...................... 42
Conclusion ............................................................................................................................................. 44
A Propos de Veille Salon ........................................................................................................................ 45
Présentation de Viedoc Sarl .................................................................................................................. 47

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DISCLAIMER

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ABSTRACT
As it has been the case for many years now, the JEC Composite Show Paris 2011 has once again
gathered key players in the sector of the composite materials and has given opportunities to many
companies to showcase new products and innovations. The automotive sector was much
represented as carbon fiber reinforced plastics answer the growing need for more efficient and
lighter vehicles. On the vegetal fiber side, flax fibers are gaining ground as we now see technical
applications where linen replaces advantageously glass fiber. The need for lighter structures also
means that new light structure material building solutions are always being sought and that new
ways of assembling composite materials are now proposed. Consumer expectations and more
stringent reglementations on materials also mean that resin manufacturers are now proposing biobased resins for composite manufacture, leading the way towards composites with lower carbon
footprint.
Key words:
Fiber, reinforced, CFRP, plastic, epoxy, resin, gel coat, composite, carbon, BMW, Audi, SGL, flax, linen,
cellulose, automotive, rail, boat, construction, wall, window, bio-based, light, ski, sandwich,
honeycomb, steel, aluminum, wood, cork, Vault-Structure, cyanate, foam, repair, nap, core, airliner,
seat back, door, airplane, assembly, repair, welding, laser, induction, Eddy current, magnetic
***
Comme cela est le cas depuis de plusieurs années, le JEC Composite Show Paris 2011 a de nouveau
réuni des acteurs clés du secteur des matériaux composites, et a été l’occasion pour de nombreuses
entreprises de présenter leurs nouveautés et innovations. Le secteur automobile était extrêmement
bien représenté, les matières plastiques renforcées par la fibre de carbone permettant d’apporter
une solution à la demande croissante pour des véhicules plus légers et moins énergivore. Du côté des
fibres végétales, on a pu constater que les fibres de lin gagnent du terrain et que de plus en plus
d’applications techniques dans lesquelles le lin remplace avantageusement la fibre de verre, voient le
jour. Le besoin pour des structures plus légères signifie aussi que de nouvelles solutions sont
constamment recherchées et que de nouvelles façons d'assembler les matériaux composites sont
maintenant proposées. Les attentes des consommateurs et la réglementation de plus en plus stricte
signifient aussi que les fabricants de résines proposent maintenant des résines bio-sourcées ouvrant
ainsi la voie vers des matériaux composites ayant une empreinte carbone plus faible que ceux
actuellement produits et utilisés.
Mots clés:
Fibre, renforcé, CFRP, plastique, époxy, résine, gel coat, composite, carbone, BMW, Audi, SGL, lin,
cellulose, automobile, train, naval, construction, mur, fenêtre, bio-sourcé, léger, ski, sandwich, nid
d'abeille, acier, aluminium, bois, liège, Vault-Structure, cyanate, mousse, réparation, nap-core, avion,
dossier, portes, assemblage, réparation, soudage, laser, induction, courant de Foucault , magnétique


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INTRODUCTION
Manufacturers are to meet more and more production demands as human population has increased
3 fold over the past 50 years.
The composite industry, which is changing from low volume to high volume mass production, has
experienced over the past three decades long-term growth based on global economic development
and higher penetration into key markets to reach a world-wide market of 68 Bn€ and 7.9 Mt.
Between 2002 and 2010, the composite market – i.e. the final parts processed – grew at 4 to 5% per
year in value (3% in volume) according to a recent survey on the worldwide composite industry1.
The JEC Group, the largest composites industry organization in Europe and in the world with a
network of 250.000 professionals, organizes every year in early springtime a show in Paris to present
the latest trends and innovations from the composite sector.
The JEC Composites Show reflects the evolution of an industry that has penetrated into all
application sectors. Last year, it attracted 1,065 exhibitors, amongst which 75% came from abroad.
The show is very much end-user oriented as two out of three visitors are users of composite
solutions in the main application sectors as shows the picture below.

Breakdown of visitors at JEC Show Paris 2010
Source: JEC Composites

At this year’s show, we saw a real change amongst car manufacturers.
Carbon fiber reinforced plastics are not any more just for luxury and highend markets. Indeed, in the automotive sector, with the new regulations on
CO2 emissions and with the developments of electric powered cars,
composites are increasingly used to make lighter cars in order to compensate for the increased
weight of electronic equipment or batteries.
Fiber reinforced plastic composites traditionally use glass and carbon fibers. In the past few years, we
have seen new developments in composites on the vegetal fiber side, as manufacturers become
more aware of eco-designing and as the demand for more environmentally-friendly composite parts
grows.

1

Overview of the worldwide composite industry 2010-2015 – 2011 release – JEC Composites Publications


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These vegetal fiber reinforced plastics were until recently only used in non structural parts and for
interior elements. Things have changed.
Every year, new technical applications appear especially using flax fibers.
Indeed, flax fiber, which may well replace glass fiber in terms of mechanical
properties, is paving the way towards green composites having lower
carbon foot-print. This is even more true when bio-based resins are used.
The trend towards lighter materials is not just found in transportation sectors, but is indeed a trend
in nearly all sectors, as there is a greater awareness towards the impact on the environment of
products during the whole of their life cycle.
The search for cheaper and ever lighter solutions is therefore a priority in many
industries. Sandwich structures bring some answers. They are composed of a
core material covered with esthetic faces, and are already used in furniture,
railway interior design and construction for instance.
The need for lighter structures also means that new ways of assembling composite materials are now
proposed, besides adhesive bonding, laser beam or magnetic fields can be used in order to make do
without bolts and rivets and to reduce the global weight of structures.
Consumer expectations and more stringent regulations also mean that resin manufacturers are now
proposing bio-based resins for composite manufacturing, leading the way towards bio-based
composites structures with even lower carbon footprint.


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CARBON FIBRE REINFORCED PLASTIC COMPOSITES

Composites have a long history in the automotive sector and have been used as a material for nonstructural parts since the 1950’s.
Their inherent performance characteristics in terms of design flexibility and resistance for instance,
mean that composites are very attractive for many car parts even despite the fact that they have
higher raw material and process costs than steel or aluminum.

1.1

CARBON REINFORCED PLASTIC COMPOSITES FOR LIGHTER AND MORE EFFICIENT CARS

The use of composite materials reinforced with carbon fiber is becoming increasingly widespread in
the automotive sector. A study by Lucintel foresees a growth of 65% over the next 5 years2.

Source: Lucintel

Many manufacturers are working on developing and applying these technologies so they can build
lighter vehicles that make an important contribution to reducing fuel consumption and air pollution,
through improvements that include increasing the strength of the vehicle’s structures.
This year’s JEC Composite show displayed many examples of the changes taking place in the
automotive industry and showed that carbon fiber reinforced plastics are not anymore a material for
the higher end of this market as was the case until now.

2

Growth Opportunities in Carbon Fiber Market 2010-2015 – April 2010


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1.1.1 Lamborghini
Lamborghini's Aventador LP700-4's carbon fiber chassis was on display on the Italian company booth.

Lamborghini Aventador at Geneva

Lamborghini Aventador’s chassis at JECParis Show 2011

The carbon fiber reinforced composite was developed by Lamborghini, in conjunction with engineers
at Boeing. CFRC are also used in the construction of the wheels, frame, seats and a handful of other
parts on the Aventador.
But carbon reinforced plastics are not any more for high-eng market of the automotive industry.
Indeed, we saw this year two German car manufacturers displaying their developments on carbon
fiber reinforced plastics use for mass market.

1.1.2 Audi
The new, yet to be released Audi RS3, with carbon fiber fenders that were resin transfer molded by
Sora Composites (Change, France), got much attention as it was displayed in the Innovation display
area.
While fabrication details are not yet available, it is said by Sora that the thin, complex parts requires
attention to the performing process to achieve Audi’s exacting standards.

1.1.3 BMW
German carbon fiber manufacturer SGL Group announced a year ago their joint venture with BMW
Group and their plan to build a new carbon fiber manufacturing plant in Moses Lake (Washington,
USA) to produce material for the passenger cell of the forthcoming all-electric BMW i3 (dubbed
Megacity Vehicle at the time).

Forthcoming all-electric BMW i3

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BMW i3 will be the world’s first mass-produced vehicle with a passenger cell made from carbon.
With the innovative LifeDrive concept, the BMW Group engineers are developing the car’s
architecture from scratch and adapting it to the demands and conditions of future mobility. The goal
is to offset the additional weight of an electric vehicle – typically 250 to 350 kilograms. To this end,
the BMW Group is focusing on the innovative high-tech material, carbon-fiber reinforced plastic.
The LifeDrive concept consists of two horizontally separated, independent modules: the Drive and
the Life modules.

BMW LifeDrive concept consists of the Drive and the Life modules

The Drive module integrates the battery, drive system and structural and crash functions into a single
construction within the aluminum chassis.
The Life module, consists primarily of a high-strength, extremely lightweight passenger cell made
from CFRP.
CFRP offers many advantages over steel: while it is at least as strong as steel, it is also around 50%
lighter. Aluminum, by contrast, would save “only” 30% weight over steel. This makes CFRP the
lightest material that can be used in body construction without compromising safety. Furthermore,
the new vehicle architecture opens the door to totally new production processes which are simpler,
more flexible and use less energy.

SGL BMW i3 carbon fiber passenger cell displayed on SGL booth


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A completed passenger cell for the four-door BMW i3 was displayed on SGL booth. It featured blue
and white tape over the cell’s joints to hide some of the technology behind the cell.
SGL officials at this year’s show confirmed that the new facility in Washington State is on schedule for
completion this summer, to be followed in the third quarter by commissioning of the lines and
delivery of the first of the carbon fiber. The plant’s capacity will be 3,000 metric tons per year of 50K
standard-modulus carbon fiber.
The Moses Lake facility will be fed by polyacrylonitrile (PAN) precursor from a Mitsubishi/SGL joint
venture in Japan. Finished 50K tow will leave Moses Lake and arrive in Wackersdorf, Germany, where
it will be woven into noncrimp fabrics, which will then travel to Landshut, Germany, for stacking,
preforming, stamping, resin transfer molding (RTM) and machining for the passenger cell.
Similar technology may also be used in the just-announced hybrid-electric BMW i8, also due out in
2013. BMW is so committed to the use of carbon fiber composites in its cars that SGL Automotive
Carbon Fibers is already planning to expand the Moses Lake plant.
Also, on BMW booth this year was the electric version of the Mini with a CFRP roof. Although this
Mini roof was made especially for the show, it should be noted that BMW is already using carbon
fibers for the roofs of their M3 and M6 models.

Bmw M3 Coupe Carbon Fiber Roof

1.1.4 Delta Motorsport
Officially launched on March 7th at the European Automotive Industry Technology Roadshow, the E-4
Coupé is an all-electric road vehicle built using ACG’s innovative DForm® Deformable Composite
System (DCS) for structures, next generation Body Panel System (BPS) and tooling prepreg materials.
Delta worked with ACG on the carbon fiber integrated chassis and bodywork construction to
generate a class-leading, low-mass vehicle together with a clear road map towards effective mediumvolume production.
The four-seater road car has been developed using a combination of ACG’s DForm DCS and next
generation BPS, and has been engineered with a high level of parts integration in order to achieve
maximum weight reduction compared with traditional materials.


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The newly released Motorsport all electric E-4 Coupé

The Body in White (BIW) is manufactured from just fifteen bonded major composite panels and
weighs only 85Kg, including the front and rear aluminum sub-frames, and crash structures.
Closures have been manufactured using carbon DForm for the internal panels and either glass or
carbon BPS for the outer skins.
This approach dispensed with the need to attach additional trim covers, which would have added
weight to the vehicle and reduced that all-important mileage range.
The car also used a range of ACG’s prepregs systems for aesthetically pleasing seats. These prepregs
use a range of high performance resins combined with woven, stitched and unidirectional fiber
formats.

All electric E-4 Coupé carbon fiber seats

With assistance from its carbon fiber fabric weavers, ACG has developed a Special Visual Quality
(SVQ) material specification that maximizes the aesthetic impact of carbon fiber finishes, ensuring
that its products meet the exacting requirements set by the automotive interiors industry.
ACG’s in-house moulding facility and KS Composites, Delta’s moulding partner, manufactured the
prototype parts using ACG’s single-sided DForm tooling, a product which is custom-formatted to
produce the optimum, paint-ready surface finish direct from the mould.


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DForm composite tooling offers a number of advantages over standard long fiber woven fabric
prepreg, and random short fiber and infusion tooling systems, and can offer savings of up to 30% in
lay-up time. Its unidirectional fiber structure maintains dimensional accuracy and performance
predictability. DForm creates an extremely flat, print-through-free surface profile with no local
thinning, no loss of fiber orientation or variation in resin content.
External body panels have been manufactured using ACG’s latest glass and carbon body panel
systems, which utilize unidirectional fibers in their construction to eliminate the fiber print-through
associated with other woven-fabric based products. These materials have the ability to produce
exceptionally flat external surfaces ready for painting with a minimum of surface preparation, and
provide a desirable 65% mass saving compared with conventional steel body panels.
The first five cars will be on the road over the course of 2011 as part of a Government supported low
carbon vehicle demonstrator programme. For more information contact Steve Cope
(scope@acg.co.uk) or Mike Millward (mmillward@acg.co.uk).

1.2

INNOVATIONS IN CARBON FIBER REINFORCED PLASTIC COMPOSITES

At this year’s show we saw materials, equipment, tooling and process concepts, many of which
included automation, for producing composites faster and more efficiently — and out of the
autoclave.

1.2.1 Cutting Dynamics: Innovative aircraft seat back
Cutting Dynamics Inc. (CDI) has developed the most cost-effective means for
processing lightweight thermoplastic advanced composite components for
seatbacks used by the aerospace industry.
Cutting Dynamics received a JEC Innovation Awards 2011 for this innovation.
Their partners on this development were developed by A&P Technology (Cincinnati, Ohio), Ticona
(Florence, Ky.) and TenCate Advanced Composites (Morgan Hill, Calif.).
CDI uses a unique high-speed moulding process to produce a complex-geometry hollow structure for
seatbacks from braided thermoplastic slit tape.
The development phase at A&P began in early 2009 and more
than 18 months were necessary for the development of this seat
back which features a compression-molded pan that uses AS4
carbon fiber unidirectional tape from Hexcel. The tape was
prepregged by TenCate, using Ticona’s Fortron PPS
thermoplastic resin.
The market potential for CDI is approximately 400,000
thermoplastic seatbacks per year.
The key benefits are weight savings (critical for the future
development of aircraft parts), compliance with FST
requirements, increased mechanical performance, low cost due
to the quick throughput and repeatability of the manufacturing
process provided by the braided perform, non-toxic
manufacturing process and longer material lifespan.

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Thermoplastic materials are also recyclable, which is not the case with thermosets. The main
advantages of this new seat back are that it is lighter than aluminum made seat backs, it is easy and
quick to produce and that it does not have any corrosion problems.
The rim of the seat, which provides structural support against torsional forces, also comprises AS4
carbon fiber prepregged by TenCate, then split by A&P into strips 0.1875 inch/4.8 mm wide and
braided into a biaxial tubular shape to provide noncrimping conformity around the edge of the seat
back.
The rim is likely to be welded to the pan, although Cutting Dynamics also is considering an adhesive.
Cutting Dynamics molds the seat back in a cycle described as “minutes” long and expects to produce
several thousand for a major aircraft manufacturer.

1.2.2 Latécoère: Innovative aircraft door structure
Another impressive out-of-autoclave concept was an innovative aircraft door
structure with advanced stitched preforms using RTM process designed and
produced by Latécoère (Toulouse, France) together with its European partners.
The large and complex part with integral stiffening frames was made with a 3-D
preform stitched together with a new 1K (two-ply) carbon fiber sewing thread developed by Schappe
Technics (Blyes, France).
The part materials, which included dry carbon and fiberglass and metallic mesh for lightning strike,
was layed up in a complex multipart mold and infused, with assembly time reduced by 10 to 15
percent thanks to the preform and fewer steps required.
The finished part is reportedly 10 to 15 percent lighter compared to current door designs.

1.2.3 Hexcel: Innovations in weaving technology
PrimeTex™ is a range of carbon fabrics which have been processed for a smooth, closed weave and
uniform cosmetic appearance. The product was launched last year and is meant at applications
requiring a very even surface and outstanding visual quality.
In the patented PrimeTex process, the fiber tows are spread in both the warp and weft direction for
unique aesthetic appeal.
Hexcel’s Proprietary Spreading Technology allows the use of high K Tow fibers for lowest areal
weight, bringing a clear visual advantage to the final product, and enhancing laminate mechanical
properties.


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PrimeTex™ fabrics are more uniform as the filaments in each tow are spread out creating a thinner
and more closely woven fabric that provides better mechanicals and less porosity in a composite. It
can therefore also be used to lower the mass in a composite where lighter weight is the key
characteristic.
Product range:
- With 3K fiber from 160 to 245 gsm
- For PrimeTex™ using 1K and 24K fibers, consult Hexcel
PrimeTex can be made with larger tow fibers without any weight increase. The 12K 200gsm is being
used for both sport equipment and transport applications meeting the challenge of cost optimization
while providing a unique quality appearance.
The markets for these new carbon fabrics are:
- Automotive cosmetic applications
- Recreational (rowing boats, bicycles) and marine (hulls & spars)
- Industrial Machinery
- Aerospace thin laminates and sandwich structures

1.2.4 Biteam: 3D carbon fiber woven profiles
Address
Biteam AB
Sagostigen 9
SE-167 54 Bromma
Sweden
www.biteam.com

Contact
Fredrik Winberg
f.winberg@biteam.com
Phone: +46 708 256 804
Nandan Khokar
nandan.khokar@biteam.com
Phone: +46 709 271 736

Biteam's 3D woven beam-like profiled preforms are carbon textile reinforcements engineered for
strengthening composite materials required for use as primary load-bearing structural members,
jointing modules and stiffener elements. They have fully integrated 3D network architecture through
use of three sets of yarns that are arranged in mutually perpendicular XYZ orientations and in a
desired cross-section profile.
Such a structural integrity makes Biteam’s 3D woven profiled materials highly delamination resistant
and reliable single-piece preforms. These 3D woven beam-like profiled materials are advanced
preforms and sought for being used as structural members, stiffeners and jointing modules in crucial
aeronautical/aerospace, automotive, marine, building/construction applications. They have also
found use in certain medical products.

The worldʼs ﬁrst industrial 3D
-weaving machine for directly weaving 3D proﬁles was developed by
Biteam in collaboration with the Royal Institute of Technology of Stockholm.

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Enabling 3D-Weaving Technology
Thanks to Dual-Directional Shedding and Multiple Weft Insertion Systems, Biteam's 3D woven
profiled fabric has significantly low crimp. This is because the warps do not traverse between
opposite surfaces but interlace within their assigned planes in columns and rows with the vertical
wefts and horizontal wefts. As a consequence, the mechanical performance increases
correspondingly.
By way of comparison, the conventional 2D-weaving method employs the mono-directional shedding
system. This method cannot produce 3D structures and fabric properties similar to that producible by
Biteam's proprietary 3D-weaving technology

Engineering Performance
The mechanical performance of Biteam's 3D woven material stands further enhanced through
selection of weave patterns (plain, twill etc.) which can be different between and within the arranged
columns and rows of warps.
Further, different carbon fiber types can be combined in different directions and sections of the
same profile to realize the desired mechanical strength.


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Important Comparative Advantage
The structure of Biteam's 3D woven beam-like profiled preforms is characteristically different from
the laminated, pultruded and braided structures as shown. The most significant difference is that
Biteam's structure has fibers directly oriented in fabric's thickness and width directions whereas the
other structures have no fibers oriented directly in the stated directions. As a consequence, the
laminated, pultruded and braided profile structures display correspondingly lower mechanical
performance and reliability compared to Biteam's 3D woven profiles.

Combining Flexibly
The flexibility of Biteam's 3D-weaving process, which facilitates direct production of a wide range of
profiled preforms, makes it possible to readily produce, combine and join suitable different 3D
woven profiled preforms according to structural and constructional demands. Such a method of
assembling one component to the other in a quick, easy and cost-effective way, called modular
construction, is now practicable with composite material beams produced using Biteam’s 3D woven
profiled reinforcements. The possibility of combining different 3D woven profiled materials flexibly
gives freedom in designing, ease of constructing and reliability in material performance.

These proﬁles open up a new possibility for modularly joining different aircraft parts instead of the
traditional riveting.
EU Project MOJO
The 3D woven profiles have shown their applicability for the aeronautical industry through the EU
Project MOJO. The aim of MOJO project was to seek new methods for substantially lowering
construction costs and weight of aircraft. The other partners in this project included EADS - Premium
Aerotec, Dassault Aviation, Eurocopter, SABCA, DLR, EADS-IWF, VZLU, CRC-ACS, Secar and University
of Patras.
Biteam, together with its partners from the EU project MOJO (Modular Joints for Composite Material
Aircraft), received the JEC 2010 Award in the Process category during last year show in Paris.

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EU project CERFAC
Biteam has also recently been invited to the new EU project CERFAC (Cost Effective Reinforcement of
Fastener Areas in Composites) to contribute with its expertise in 3D-weaving process to produce 3D
woven profiled reinforcements for aircraft application.
CERFAC aims to develop cheaper, lighter and stronger damage-tolerant fastened joints. Its objectives
are to introduce innovative and efficient joining concepts combining some of the investigated
reinforcement solutions to further reduce the number of fasteners, while increasing the load bearing
capacity and damage tolerance of the assembly, with a significant step towards a reduced
manufacturing cost.
Biteam is be partnering on this project with Cenaero (Belgium), SABCA (Belgium), VZLU (Czech
Republic), DLR (Germany), EADS Innovation Works (Germany), Eurocopter (Germany), IFB Stuttgart
(Germany), Dassault Aviation (France), EADS (France), University of Patras (Greece), NLR
(Netherlands) and FNHW (Switzerland).


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VEGETAL FIBER REINFORCED PLASTIC COMPOSITES

Alongside carbon fiber, the other much publicized fiber at this year JEC Composite Show was flax.
Flax fiber is year after year gaining more and more ground for technical applications.
Flax is one of the few crops still produced in Western Europe, with nearly 130,000 acres under
cultivation annually.
Climatic conditions in this Western Europe are perfect for growing flax, and
increasing worldwide demand for linen makes it an important cash crop.
Linen growing cycle is short and sweet, with only 100 days between sowing in
March and harvesting in July.
The plant ripens by the end of June into golden yellow color, and then it flowers,
dotting the fields with blossoms of violet, blue and white.
Technical flax fibers combine specific properties and characteristics that allow for the design of
composite parts. In addition to low modulus and specific tensile strength close to glass fibers, flax
fibers present other interesting characteristics for composite applications, including vibration
damping, a coefficient of thermal expansion allowing compatible associations in hybrid structures
with carbon fibers, as well as electrical insulation properties.

Comparison of flax, glass and carbon fibers properties
Source: FiMaLin

One of the main challenges with selecting flax fibers lies in producing composites of a good and
homogeneous quality, owing to poor interfacial bond strength between the flax fiber and the
polymer matrix.
Therefore, the use of unidirectional flax fibers in epoxy composites usually leads to composites with
an acceptable tensile strength but a very poor compressive strength, mainly due to the kink band
present in the elementary fibers.


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European flax fibers production is mainly concentrated in northern France and Belgium

As northern-European flax production amounts to around 80% of global production, not surprisingly
initiatives to promote the use of this natural fiber for technical applications mainly come from
Europe with CELC (Confédération Européenne du Lin et du Chanvre) and more specifically from
France with FiMaLin (Fibres Matériaux Lin).
FiMaLin® is a French professional organization that brings together seed manufacturers, growers,
transformers, logisticians, manufacturers and research centers.
Founding members were Dehont Technologies (machines manufacturer),
Arkema (resins provider), Clextral (extrusion specialist), Dedienne Multiplasturgy
Group (composite materials manufacturer) and Terre de Lin (flax producer).
Since its formation in 2009, other members have joined FiMaLin.
Their aim is to make flax fiber the third fiber most used in high-tech composite material
manufacturing after carbon and glass fibers.
FiMaLin’s objectives to achieve this aim are:
- Production traceability
- Securing supplies quality and quantity
- Defining technical specifications
- Categorization and specifications adapted to the industry’s purposes and needs
- Input measure
- Repetitiveness with regards to specifications allowing performance levels to be maintained
By listening to the industry’s requirements in terms of mechanical properties for instance, and in
assuring consistent quality and quantity of produced fibers season after season, they are confident
that this natural fiber could well soon allow to make bio-based composite materials for a range of
technical applications from automotive to construction through to naval and sports & leisure
applications.
More information can be found on their website at www.fimalin.com or through mailing at
contact@fimalin.com.

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The European Confederation of flax & hemp – CELC – is an agro-industrial organization which brings
together the whole production chain for flax and hemp fibers, from farmers up to weavers, in 14
European countries.
The CELC’s Technical Uses Section acts as an interface, identifying the needs of
multiple industrial sectors and the industrialization capabilities of the flax and
hemp sector for technical applications.
The Section is at the centre of a European network of specialized technical
institutes, universities and companies, and has positioned itself as the European
hub to group all new applications for these two plant fibers.
Seven researchers, under the leadership of Prof. I. Verpoest from KU Leuven, are pooling their
knowledge to establish a state of the art in flax and hemp composites, as well as the necessary
developments required from the flax and hemp community.
These developments focus on perform production, the mechanical properties of fibers and the fibermatrix adhesion. A database gathering all the recent research projects involving the use of flax and
hemp fibers in composites is under development. More information can be found on their website at
the following address: www.mastersoflinen.com.
All these initiatives to promote flax as a technical fiber are starting to pay off, and new illustrations of
structures made of flax fiber composite materials are showing off every year.

1.3

VEGETAL FIBER REINFORCED MATERIAL FOR BUILDING APPLICATIONS
1.3.1 Innobat
Address
Innobat
CAP ALPHA avenue de l’Europe
34 830 Clapiers
France
Phone: +33 467 59 30 36

Contact
Michel MAUGENET
Director
contact@innobat.fr

Biopox 65 is a flax fiber reinforced bio-based epoxy resin composite material combining very good
thermal and mechanical properties while offering the required properties for window frames.
Biopox 65 characteristics are:
Flax fibers: 65%
Density: 1.4
Thermal conductivity: 0.28
Tensile modulus: 35 GPa

Based on these criteria, it can well compete with traditional raw materials such as PVC and
aluminum. This composite has a particularly low environmental footprint due to the use of bio-based
components.
The European market amounts to about 70 million windows, 700,000 metric tons of composites and
€7 billion a year. Innobat’s objective is to capture 3% of this market over 5 years.

P a g e | 21
PVC offers very good thermal insulation but a low modulus of elasticity, requiring PVC window
profiles to be reinforced with steel components.
Aluminum has a very good modulus of elasticity but very poor thermal insulation properties, which
means that aluminum window profiles need to integrate polyamide strips to ensure a thermal break.
Finally, both PVC and aluminum have a poor environmental footprint, mainly due to their production
process.
Therefore, Innobat with Biopox 65 provides the Construction Industry with a real alternative to PVC
and aluminum window framing.
Partners associated to Innobat on the 14 months development project of this environmentallyfriendlier material were: Amroy Europe Oy from Finland for the bio-based epoxy resin, Safilin SA
from France for flax fibers and Top Glass – Kemrock Group for the manufacturing process.

1.4

VEGETAL FIBER REINFORCED MATERIAL FOR SPORT & LEISURE APPLICATIONS
1.4.1 Libeco – Lineo
Address
Libeco Fabrics
Tieltstraat 12
8760 Meulebeke
Belgium
www.libeco.com

Contact
Dominique Andries
Sales Manager
Dominique.andries@libeco.be
Phone: +32 51 69 10 13

Libeco-Lagae is one of the world’s leading flax weavers. The group is composed of a variety of
companies all dedicated to the manufacturing and distribution of high end linen and linen products.
Lineo is focused on the use of flax fiber for the development of products with FlaxPly©, a relevant
solution for the manufacturing of high performance and eco-friendly composites.
Besides simple and well known plain weave, Libeco-Lagae has developed a complete range of hightech linen for composites made of 100% flax fibers and offers UD woven fabrics alongside basket,
twill and satin.
Plain and basket weave fabrics offer a constant tensile and compressive strength longitudinally as
well as transversely. They are suitable for large, flat surfaces but not ideal if an important
deformation is required.

Plain weave fabric

Basketweave fabric


P a g e | 22
Twill weave result in greater warp or weft concentration and therefore give directional properties to
laminates. Maximum strength is obtained with minimum weight of fabric. Compared to plain weaves,
twill weaves have better pliability and drapability and present lower resin absorption.

Twill 3/1 fabric

Twill 2/2 fabric

Eight harness satin weaves are most pliable for a minimum thickness and are used for the most
complicated curved surfaces and for small size components. Satin weaves improve surface
appearance, give higher bending strength while resin absorption is minimized with the highest fiber
concentration at the surface.

Satin 8

Satin 4

The patented and unique process of impregnation developed by Lineo presents several key
advantages:
- The process creates a very strong linkage between the natural fibres and the thermoset
resins. This enables composites which have mechanical properties equivalent to those of the
composites reinforced with glass fibres.
- The process limits the absorption of humidity of the natural fibres, preventing the fibres
degradation, moisture issues and drawbacks in composite processing.
- The pre-treatment of the flax fiber allows a temperature resistance until 250C, allowing the
use of flax fiber prepreg or fabrics in main processes used in composite manufacturing.
- The high number of yarns (more than 10,000 coming from different areas) used for the fiber
spinning limits the effect of culture conditions variations and ensures batch after batch the
homogeneous behavior of the prepreg.
Lineo combines flax/carbon/epoxy for its Flaxply® and Flaxpreg® products which are ideal for
vibration damping particularly in sports applications. Flaxply main benefit is to bring a new
functionality to composite materials.
Indeed, by combining FlaxPly with conventional material such as carbon or glass fiber, it is possible to
improve significantly the damping properties of materials while ensuring good mechanical
properties.


P a g e | 23
The vibration absorption provided by FlaxPly will reduce the stress of players using composite
sporting goods and improve the life span of composite parts in marine or aerospace market.

Lineo’s FlaxPly are used in the manufacturing of sporting goods made of epoxy resin and
carbon/glass fibres such as tennis, squash or badminton racquets, bike frames and accessories,
paddles, fishing rods, baseball bats, hockey sticks, golf shafts, and helmets.
After the tennis racquet developed for Oxylane and presented last year at JEC Show Paris 2010, Lineo
has now developed skis with improved vibration dampening where the FlaxPly is sandwiched
between carbon layers as presented above. These skis will be on sale in Decathlon stores next winter
season.
Also presented at the JEC Composite Show 2011 was the following prosthesis for a Paralympics
athlete.

Flax fiber composite made prosthesis

1.4.2 Porcher Industries
Porcher industries is an international group dedicated to the development and production of
innovative products, combining textiles and chemistry for multiple industrial applications. It has six
business units reflecting the scope of its markets: Automotive, Building & Industrial, Composites,
Electronics, Screen and Sport.


P a g e | 24
Address
Porcher Industries
ZI Le Mas des Chaumes
38 690 Le Grand Lemps
France
Phone: +33 4 76 06 55 68
www.porcher-ind.com

Contact
Marie-Angelique Puravet
Sales Manager
Marie-angelique.puravet@porcher-ind.com
Phone: +33 6 87 60 35 24

Porcher’s Greenlite is a new generation of high performance renewable reinforcements for the
composites industry.
These innovative materials are based on pure cellulose fibers. The combination of low density and
superior mechanical properties allows biocomposites to be made on an excellent weight to
performance basis.
Greenlite reinforcements are biodegradable and highly compatible with bio-based resins, making
them suitable for the production of 100% bio-based composites on a large scale.
With these new materials, Porcher Industries demonstrates a strong commitment to developing
renewable materials utilizing an ecofriendly process with minimal environmental impact.
Porcher Greenlite fabrics can be processed using standard equipment with no modifications to the
existing technology.
They are available in various styles for a wide range of composites parts, including sporting goods
and leisure applications.

Greenlite standard properties


P a g e | 25

Compared composite material properties with standard and bio-based thermosets
UP = unsaturated polyester resin
EP = epoxy resin
Bio 30% = 30% bio-based epoxy resin
Bio 55% = 55% bio-based epoxy resin

Cobra International, a manufacturer of composite Watersports
equipment from Thailand, won the 2009 JEC Innovation award for their
surfboard made with Procher greenlite material.
Although other prototypes have been made since the prize, no part
however has been produced since using this material.

1.4.3 Renards des mers
This year, the JEC Composite Show displayed the first-ever open-sea racing boat integrating
renewable flax fibres in the deck, hull, helm and toerail. Overall flax fibers account to 50% of the
boat’s structure.
The boat which has been called the “Araldite” is a 6.5m long, 3m wide, ergonomic, lightweight Mini
Transat racing boat prototype and is the smallest offshore racing boat allowed to cross the Atlantic.
Designed by Regis Garcia to showcase the possibilities of
incorporating flax fibres into the composite structure of an open sea
sailing prototype, the boat was built at the IDB Marine de Tregunc
shipyard in Brittany, France.
With acceptance and funding received from C.I.P.A.LIN, the French
Interprofessional Committee for the Agricultural Production of Flax,
the project has been completed in just over 12 months.
The ultimate goal was to adopt a cleaner production process whilst combining the renewable
properties of flax with the well-known, high-performance characteristics of carbon fiber, without
compromising the light weight or mechanical properties of the sailing prototype.

P a g e | 26
In order to achieve this, Lineo, a Belgium company
specializing in flax reinforcements, provided the diverse
fibres, specially treated to ensure perfect compatibility
between the flax and the Araldite warm curing system.
Lineo uses new technology to coat flax fibres with epoxy
resins in such a way that absorption of water from the
flax is prevented and strong bonds between the flax and
the epoxy resin are created, guaranteeing the quality of
the laminate.
Working closely in partnership, Huntsman research laboratories and Lineo issued the necessary
laminate mechanical properties used for designing the prototype’s diverse parts, including the deck,
hull, helm and toe-rails. In total, flax fiber constitutes 50 per cent of the boat’s structure, with the
remaining 50 per cent being reinforced by traditional carbon fibres.
The Araldite was launched on September 9, 2010 at a ceremony at the Maison du Nautisme at
Douarnenez, France. In its maiden competition, the boat competed in the Mini Empuries twohanded prototype race, sailing 300 miles around the Balearic Islands before crossing the finishing line
at L’Escala in Spain. This was followed by the Mini Barcelona solo race in October, another 300 mile
race which saw the “Araldite” sail from Barcelona and back to again.
This boat was presented at the JEC Composite Show 2011 by Renards des Mers (France), with its
partners Huntsman Advanced Materials GmbH (Switzerland), Cipalin (France), Lineo& Libeco Lagae
(Belgium), IDB Marine (France) and IFTH (France).
More information on this project is available at www.votreregard.fr or through mailing Thibault
Reinhart at www.thibaultreinhart.com.

1.5

VEGETAL FIBER REINFORCED MATERIAL FOR AUTOMOTIVE APPLICATIONS
1.5.1 Huntsman Advanced Material

This year, Huntsman Advanced Material unveiled on their booth the U-Box, an impressive work of
technical design proving it is possible to build an electrical car using environmentally sustainable
components and proposing innovative processes to fulfill large series-production demand.
This delivery vehicle was a showcase of the company’s composite materials expertise.
The U-Box bundles up differentiated materials, including the renewable properties of flax and basalt
fibres used to reinforce composite parts in combination with new toughened resins, as well as a new
halogenfree and fire-resistant resin designed for the infusion process, composite wheels and
composite bonders covering high strength or temperature resistance requirements to high flexibility.
The U-Box also integrates flexible organic light-emitting diodes (OLEDs) integrated in the composite
structure. Consuming up to 70% less energy than conventional light sources, the OLEDs are made
using high-performance, thin barrier (to water and oxygen) coatings designed by Huntsman.


P a g e | 27

Huntsman’s U-box vehicle incorporates flax fiber composite material

1.6

VEGETAL FIBER REINFORCED MATERIAL FOR OTHER APPLICATIONS
1.6.1 RocTool – FiberShell

Founded in 2000, RocTool’s main focus is to develop and improve molding technologies using
induction heating such as Cage System® and 3iTech® for the composite and plastic industries.
Address
RocTool Headquarters
Savoie Technolac
BP341 – Modul R
73375 Le Bourget du Lac Cedex
France
Phone: +33 479 26 27 07
www.roctool.com

Contact
Pamela Monget
FiberShell Project Manager
monget@fibershell.com
Phone: +33 479 26 59 33

FiberShell® is a trademark registered by RocTool launched at the
end of 2010. With FiberShell, RocTool complements its offer for
smartphone covers which already includes carbon fiber and textile
composite materials.
FiberShell cases are produced using a RocTool patented
manufacturing process. They are made of polyamide resinimpregnated composites reinforced with flax fibers. At the
moment, the resin used is PA 12 but other bio-based resins are
under investigation.
The manufacturing process goes as follows: First, the material is cut to size. Then, several layers of
the fabric are placed into the mold to obtain the thickness and strength desired.


P a g e | 28
The mold which is at room temperature is then heated to
a very high temperature by means of electromagnetic
induction.
The heat melts the resin and impregnates the fiber which
in turn guarantees the mechanical traits and perfect
surface quality of the finished cover.
The mold is then cooled down and the part is safely removed. Once the case is out of the mold, it is
trimmed, varnished and hand buffed. A video of the process is available at the following address:
http://www.fiber-shell.com/content/12-fabrication-process


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ENVIRONEMENTALLY FRIENDLY RESINS

Using a vegetal reinforcement is a first step towards bio-based composite materials having lower
carbon foot-print, but is not sufficient.
Indeed, choosing a resin with a high bio-based content means that less fossil material is used. We
could even eventually see 100% bio-based fiber-reinforced plastics that could be easier to dispose of,
the issue of composite end of life having not yet been dealt with.

1.6.2 Reichhold: New environmentally friendly resins for composites
Reichhold is one of the world’s largest suppliers of unsaturated polyester and vinyl ester resins for
composites applications.
aag+31307

47 1

Address
Reichhold
World Headquarters & Technology Center
Research Triangle Park
2400 Ellis Road Durham NC 27703 USA
Phone: +1 919 990 7500

Contact
Christian Oberleitner
christian.oberleitner@reichhold.com

During JEC Composite Show Paris 2011, Reichhold has introduced a new series of environmentally
friendly products under the name of Envolite, built on technologies developed in Brazil, North
America and Europe.
Reichhold’s recent product developments are in line with greater consideration for the environment
and of more efficient use of energy. These products address concerns specific to the thermoset
industry by allowing companies to reduce their carbon footprint.
This new product line of “green” resins is based on the following key concepts:
- low VOC
- renewable
- recyclable
- styrene-free
ENVIROLITE® is an unpromoted, medium reactive, low viscosity unsaturated polyester molding resin
derived in part from natural resources.
It incorporates new raw materials based on renewable resources. Specifically, this product is based
on Soya Oil resin.

P a g e | 30
The product is intended as a general purpose molding resin for RTM, SMC & BMC, Pultrusion,
Centrifugal casting and filament Winding as well as regular casting and Hand Lay up / Spray up
applications. The soy resin yields laminates with mechanical properties/performance that are similar
to standard resins.

1.6.3 Cray Valley: Fire resistant resins and gel coats
Address
Cray Valley
16/32 rue Henri Regnault
La Défense 6,
92062 Paris La Défense Cedex
FRANCE

Contact
composite.resins@crayvalley.com
Phone: +33 1 47 96 99 64

Environmental and safety concerns in the Railway and Building industries are strong drivers for
Composites, due to their lightweight, long service life time and fire retardancy.
However, new resins and gel coats were needed to offer a higher level of fire protection and a
greater ease of processing for composite part manufacturers.
A several years research program has enabled Cray Valley to recently launch on the market the
FireBlock technology, consisting of highly fire resistant resins and gel coats, that are easy to use in
many processes (RTM, hand lay-up, spray-up, pultrusion, BMC).
This solution allows to meet the highest ratings of most of fire standards in
the World, including the future European railway standard (TS EN 45545)
with a HL 3 rating, the French and Spanish standards with a M1F1 rating or
the ASTM E 84, with a Class 1 rating;
On the top of its fire performances, the FireBlock solution brings also some environmental benefits. It
has recently been labeled “Total Ecosolutions”, an environmentally friendly program of Total group,
due to reduced energy consumption and reduced greenhouse gas emissions, as compared to
standard fire retardant composite used in railway rolling stock.
Moreover, FireBlock is free of halogen and do not use any CMR substances. Details of the Life Cycle
Analysis are available upon request.
FireBlock won the JEC 2011 innovation award, in the material category. Cray Valley and its partners –
Mariskone, Crepim and Diseño e Innovacion – received their prize on Tuesday 29th of March at the
JEC Show in Paris.


P a g e | 31

LIGHT COMPOSITE STRUCTURES

Nowadays and due to new environmental guidelines, the demand for materials that are lighter,
cheaper and having excellent mechanical properties has lead to many developments over the past
years in the field of sandwich structures. These structures are now commonly used in transportation
and in construction, not to mention furniture manufacturing and shop fitting.

1.7

SANDWICH STRUCTURES
1.7.1 Amorin: Cork cored composites
Adresse
Armorim Cork Composites
Rua de Meladas, 260
4536-902 Mozelos VFR
Portugal
www.corkcomposites.amorim.com
www.corecork.amorim.com

Contact
Rui Palavra
Project Management/R&D
Phone: +351 227475300
rpalavra.acc@amorim.com

Amorim Cork Composites is committed to the development of cork-based materials suited to the
requirements of industries such as aerospace, aeronautics, the composites and the automotive
industry.
Recent studies in the Iberian Peninsula state that cork oak forest contributes with over 10 million
tons per year tons of CO2 sequestration, making it a significant world resource for the environmental
balance.

Each time cork is harvested, cork bark regenerates itself. Cork oak trees store CO2 in order to
regenerate, and therefore a harvested cork oak tree absorbs 3 to 5 times more than one which is not
harvested, thus benefiting the atmosphere.
Corecork materials are therefore an answer to ecologically concerned companies. They have

P a g e | 32
excellent recovery and insulation qualities and can be processed at up 150 C, with minor changes.

Corecork range

Corecork is a natural and sustainable core material, compatible with existing sandwich core
applications offering excellent FST (fire, smoke and toxicity) properties with good mechanical and
processing characteristics.
Their low density, their flexibility and excellent conformability make it possible to integrate them into
fast cycles of production.
Corecork can be processed by hand layup, vacuum bagging and infusion processes and will withstand
process temperatures up to 150°C.

Sandwich core applications made with Corecork meet or exceed the performance of similar FRP
made with synthetic non sustainable cores.
Comparative data measured on actual sandwich sample panels show that equivalent or better
mechanical resistance can be obtained with equal constructions.


P a g e | 33

Comparative chart showing properties of sandwich panels using different core materials

1.7.2 Biotopes: Bio-based wall panels
This flax and polyol foam sandwich structure can be quickly
installed and features multiple advantages: resistance to
weather conditions and UV rays, easy to handle and assemble,
fire resistant (M1).
The flax composite’s added value is to optimize the thermal
insulation and sound proofing of this “new generation”
material.
This wall 90% composed of bio-sourced, non-toxic materials can be used in the traditional
construction sector (passive homes, short- and long-term) and can meet event-based and design
constraints. The wall modules are light and easy to assemble though clipping. More information is
available through mailing at contact@biotopes.com.

1.7.3 EconCore: Honeycomb cored structures
EconCore provides core technologies for most economic honeycomb sandwich panels and parts and
supports customers and licensees in their application development.


P a g e | 34
Address
EconCore
Ambachtenlaan 17
3001 Leuven
Belgium
www.econcore.com
www.thermex.com

Contact
François de Bie
Sales Director
Phone: +32 16 381072
Francois.debie@econcore.com

EconCore technologies allow for production of ThermHex honeycomb cores from different
thermoplastic polymers via a coil of film or by direct extrusion and enable a direct further processing
in-line.
The range of polymers include, but is not limited to, Polypropylene, Polyethylene, Polystyrene,
Polyethylene
terephthalate,
Polyamide,
Polycarbonate,
Acrylonitrile-butadiene-styrene,
Thermoplastic polyurethane, Polyphenylene sulfide and Polyetherimide.

In combination with different skin materials EconCore honeycombs offer a wide range of application
possibilities. Low production costs of EconCore honeycombs enable substitution of other honeycomb
cores and homogeneous panel materials. EconCore develop panels and parts for automotive,
furniture, building and packaging markets.
After the successful global launch of ThermHex technology for packaging applications, EconCore is
now intensively exploring new material combinations, beyond single-material sandwich panel
concepts.
Next Generation Metal Composite Panels
EconCore now introduces a cost-efficient technology for producing the next-generation ThermHex
composite panels with steel or aluminum skins.

New-generation aluminum and steel composite panels


P a g e | 35
EconCore combines its thermoplastic ThermHex honeycomb core with metal skins into a well
balanced material system. Outstanding low weight of this solution compared to any solid metal sheet
is just one of its features.
After developing know-how and through optimization of interfacial bonding and efficient structural
design, EconCore explored both, Steel and Aluminum Composite Panel, demonstrating their excellent
mechanical performance-to-weight ratio.
ThermHex technology allows cost efficient production of panels, opening up new perspectives for
installing the technologies for production of panels for cost sensitive applications, replacing either
current, more expensive and heavier sandwich solutions or solid sheet products.
By utilizing the cutting-edge ThermHex technology, panel production costs can be reduced to a
minimum due to the continuous production process where a polymer film is extruded and directly
converted into a honeycomb core. In the following step of the online process, the metal skins are
applied and thermally bonded to produce a sandwich panel.

Due to ultra small size of honeycomb core cells, with cell diameters as small as 3 mm, a very smooth
surface of the sandwich panel is achieved, even if the metal skin thickness is below 300 μm. The 3
mm cell size allows for a 4-5 mm thick panel, but the same production process can make panels up to
40 mm in thickness.
High stiffness, low weight, good thermal insulation, magnetic properties (for steel faced panels) as
well as smooth surface (colored if needed) make the ThermHex product with metal skins a first line
candidate for use in many applications, including panels for interior and exterior cladding, visual
communication, solar energy, elevators, rolling stock, automotive and trucks, ship building and many
others.
Key advantages of these panels include:
- reduced production costs,
- high flexural stiffness,
- low weight,
- high aesthetics,
- high thermal insulation,
- eco-friendliness.
Lightweight Wood Panel Materials
EconCore has also introduced a range of ThermHex honeycomb panels with wooden skins bonded via
a thermoset adhesive layer.
HDF faced honeycomb core is a very attractive substitute for traditional materials in the
woodworking industry.


P a g e | 36
When referenced to a 18 mm thick chipboard, the 2 mm HDF faced ThermHex honeycomb shows
similar bending stiffness at less than half the weight. The flexural performance of a solid MDF board,
is met by a 21 mm thick HDF-ThermHex panel at half the weight. Thanks to the efficient honeycomb
spacer, only a small increase of weight (0.4 kg /m²) is noted when the ThermHex panel’s thickness is
increased from 21 mm to 25 mm while the stiffness increases by 40%.

Weight saving potential of the lightweight ThermHex boards

When compared to a mid range density solid plywood as shown in the chart below, the 18 mm
ThermHex honeycomb panel with 3 mm plywood skins shows up to 50% weight savings while a
flexural performance is equal. Bending stiffness of the Plywood-ThermHex board is doubled when
the panel thickness increases from 18 mm to 25 mm, although the weight increase for the
lightweight board in minimal.

Weight saving potential of the lightweight ThermHex boards

Next to saving weight, a key driver to this development is the overall tendency in the market to
reduce the amount of natural resources for manufacturing of panels for furniture. This objective is
achieved by combining low density honeycomb core and skins such as HDF, plywood or CPL.

Wood covered sandwich panels


P a g e | 37
Lightweight Wood Panels show very good mechanical performance whereas the low density spacer
on a basis of polypropylene offers a very good support also in high humidity environments, where
traditional paper based materials very fast show degradation and problems in application.
Although polypropylene is perfectly recyclable, ThermHex technology can be adjusted to work with
bio-based polymers such as PLA.
Looking at the current rate of development of lightweight material solutions in furniture and B&C
markets, hybridizing of PLA based ThermHex honeycomb with HDF and plywood skins would be
probably a next natural step – according to EconCore who are prepared to realize this concept.

1.7.4 Fraunhofer PYCO: Nap-core and polycyanurate foam containing structures
Chemists, physicists, engineers and technicians of Fraunhofer site in Teltow as well as of the Chair of
Polymer Materials of Brandenburg Technical University Cottbus (BTU) develop highly crosslinked
polymers (thermosets) for all applications with particular reference to aviation, IT-Technology and
instrumentation.
Today, their work is particularly focused on lightweight composites and on micro- as well as
optoelectronics: new (nano) materials, prepregs, core materials, laminates, all kinds of fiber
reinforced materials, sandwich structures, bistable displays, integrated optical devices and barrier
layers.
Address
Fraunhofer Pyco
Kantstrasse 55
14513 Teltow
Germany
www.pyco.fraunhofer.de

Contact
Rajko Wurzel
Phone: +49 3328 330 254
rajko.wurzel@pyco.fraunhofer.de

Nap-core as a core material
Nap-core has been known for several years but due to its properties only few applications were
possible. New developments have lead to advanced mechanical properties which now allow the use
of nap-core in a broad field of applications.
By varying the basic materials and the production processes the nap core can be customized to
different application purposes. The hitherto realized volume weight lies between 50 and 120 kg/m³.
Higher or lower volume weights and the mechanical properties are adjustable according to
requirements. Additionally to the use as core material the nap core can be customized as a crash
absorber. Combined applications, such as sandwich structure with crash-absorbing function are also
possible.

Sandwich structure with nap-core

The structure of nap-core offers several advantages in comparison to conventional core materials
such as foams, honeycombs and thermoplastic cores:

P a g e | 38







good acoustics (sound damping)
good top layer connection
drapability
cost-efficient production
drainage
wires are integrable

New polycyanurate foam for lightweight applications
The use of hard foams as core material is limited. Either hard foams are not flame-retardant enough
(e.g. polyurethane resins) or they are too brittle (e.g. phenolic resins).
Cyanate resins are intrinsic flame-retardant, heat resistant and the viscosity can be adjusted. They
are recyclable and therefore sustainable.
Cyanate resins can be foamed environmentally compliant because of their chemical mechanism.
Fraunhofer PYCO has developed and produced cyanate resin foams in the lab. They are currently
developing bigger scales production processes.

1.8

HEXAGONAL STRUCTURING FOR LIGHT AND STIFF MATERIALS

Vault-StructuringTM, originally invented and patent-protected for metals by Dr. Mirtsch GmbH, is an
innovative forming technique based on a self-organization process of materials and characterized by
hexagonal structures. In comparison to traditional forming no complicated forming tool is necessary.
This reduces costs and prevents the material/surface from damage due to only slight material and
very small laminar contact area with the forming tool.

InnoMat GmbH, together with Dr. Mirtsch GmbH, has enhanced this
originally metal-based process, so that Vault-Structuring is now applicable
to thin plastic materials and to fiber-reinforced plastic sheets, e.g.
prepregs and laminates.
The macro-structured sheets thus obtained can be used in applications
where structural stiffness and lightweightness are required (interior trim
for aircrafts, trains and boats, partitions and ducts in civil engineering,
interior design…).
For more information go to www.innomat-gmbh.de or mail at info@innomat-gmbh.de.


P a g e | 39

COMPOSITE PROCESSING AND ASSEMBLY
A prerequisite for the economic application of fiber reinforced thermoplastics is a drastic reduction
of the production cost and time in relation to conventional metal parts. The complexity of the
products has to rise as well to meet functional requirements.
Laser beam welding allows clean, fast and strong connections and can realize these structural
complex constructions. Another alternative to gluing and riveting is the use of magnetic field to joint
parts together as will be seen further down.

1.8.1 Fraunhofer ILT: Laser beam welding of fiber reinforced thermoplastics
With more than 260 employees and 10,000m² of usable floor space the Fraunhofer Institute for Laser
Technology is worldwide one of the most important development and contract research institutes of
its specific field.
The activities cover a wide range of areas such as the development of new laser beam sources and
components, precise laser based metrology and testing technology and industrial laser processes.
This includes laser cutting, caving, drilling, welding and soldering as well as surface treatment, microprocessing and rapid-prototyping.
Address
Steinbachstraße 15
52074 Aachen
Germany
Phone: +49 241 8906-0
www.ilt.fraunhofer.de

Contact
Dipl.-Ing. Andreas Roesner
Phone +49 241 8906-158
andreas.roesner@ilt.fraunhofer.de
Dr. Arnold Gillner
Phone +49 241 8906-148
arnold.gillner@ilt.fraunhofer.de

Method
The feasibility of the welding strongly depends on the optical properties of the welding partners.
The upper welding partner needs to be sufficiently transparent to guide the laser radiation into the
welding area. Therefore, only glass fiber reinforced plastics can be joined with this approach.
The lower welding partner needs to have a strong surface absorption to generate a heat source in
the welding area which melts both the lower and via heat conduction the upper welding partner.
Lower welding partners have to be filled with IR-adsorber, typically carbon black. Hence, carbon fiber
reinforced materials can be used as absorber as well.

Stringer structure of fiber reinforced PLA (left) and
samples of joined fiber reinforced PP and stainless steel (right)


P a g e | 40
Metal plastic connections are also feasible. Laser structuring of the surface of steel generates an
undercut structure in which the molten thermoplastics matrix and glass fiber near the welding area
can flow into during the joining process. After cooling the material is set and a connection is realized.
Results
Current results show that the connection strength of this process is above the strength of gluing or
resistance welding. However, appropriate system technology expands the range of weldable
materials and makes high demanding applications possible.
Applications
The request for energy efficient vehicles especially for electro mobility pushes manufacturers to
increase their effort in establishing lightweight components. Because of their inline production
ability, thermoplastic fiber reinforced materials are the preferred material in this industrial branch.

1.8.2 Fraunhofer PYCO: Recycling and repairing of CFRP and GFRP composites
Fellows at Fraunhofer Pyco develop highly crosslinked polymers (thermosets) for all applications with
particular reference to aviation, IT-Technology and instrumentation.
Their work is particularly focused on lightweight composites and on micro- as well as optoelectronics:
new (nano) materials, prepregs, core materials, laminates, all kinds of fiber reinforced materials,
sandwich structures, bistable displays, integrated optical devices and barrier layers.
Address
Fraunhofer Pyco
Kantstrasse 55
14513 Teltow
Germany
www.pyco.fraunhofer.de

Contact
Karina Klaube
Phone: +49 3328 330 254
karina.klauble@pyco.fraunhofer.de

Recycling and repairing of CFRP and GFRP composites
Commonly used thermosets for producing fiber-reinforced plastics are hardly recyclable and
repairable.
Existing recycling concepts are mainly based on milling and burning methods and sate-of-the-art
repairing concepts are complex and difficult to implement.
The new concept (already presented at the JEC Composite
Show 2010) developed by Fraunhofer PYCO makes it possible
to decompose the resin of fiber reinforced parts as well as to
decompose a selected area to be repaired.
The substances obtained from the decomposition can be
used as basic chemicals and the regained reinforcement,
which is not damaged or destructed, can be used for
producing new parts with the original properties.
Decomposing is initialized by a special chemical agent. An unintentional recycling process during life
time is not possible. The recyclable or repairable cyanate-based resins are adjustable for all common
manufacturing processes like prepreg, vacuum bagging, autoclave or RTM.


P a g e | 41

1.8.3 Innovaltech: Magnetic Pulse System for cold welding
Innovaltech includes four areas of expertise from design to completion:
1234-

Computer integrated manufacturing, machining speed and three-dimensional measurement
Design, rapid prototyping, duplication and digitalization
Implementation and plastics composites machining
Multi-lateral assembling

Haag

+31307 47 1

Address
Plateforme Innovaltech
Lycée Condorcet
Rond Point Joliot Curie
02100 SAINT QUENTIN
France
www.pft-innovaltech.fr

Contact
Dominique Haye
Technical Director
Phone: 03 23 08 44 89
PFT.innovaltech@u-Picardie.fr

Innovaltech has developed an innovative multi-material assembly based on magnetic force
generation for cold welding.
Magnetic Pulse System (MPS) is an energy efficient, ecological, reliable and fast substitute to
traditional processes of assembly. It enables the assembly of hybrid and multi sandwich with
dissymmetrical and composite materials.

Principle of the Magnetic Pulse System:
A stream of high energy is discharged through a coil surrounding the workpiece in an extremely
short time.
This high and extremely fast current creates a force between the magnetic coil and the part that
accelerates the outer part inward thus generating a cold weld very resistant.


P a g e | 42

Advantages of MPS:
• Reduced costs and components
• Ability to multi-material assemblies
• Assembly weight reduction
• Improved productivity ratios compared to other conventional methods
• Elimination of preparation and recovery
• Virtually no waste generated
• No need for metal or gas
• 30-50% lower energy consumption compared to conventional methods
• High quality
• Stable process with few incidents
• No heat affected zone
• No corrosion in the welded area
• Improved conductivity in the weld zone
• Improved aesthetics compared to other method of assembly
• Possibility of achievement assemblies hitherto impossible
• Energy efficient and environmentally friendly process (no gas)

1.8.4 KVE Induct: Induction welding of carbon fiber reinforced thermoplastics
KVE proposes an efficient assembly technology for carbon reinforced thermoplastic laminates.
KVE

COMPOSITES

GROUP

Laan van Ypenburg 56
2497 GB Den Haag
+31307 47 1

Address
KVE Composites Group
Laan van Ypenburg 56
2497 GB Den Haag
www.kve.nl
info@kve.nl

Contact
Lr. Jeroen de Vries
Commercial Manager
Phone: +31 (0)70 307 47 10
vries@kve.nl

Increasingly high performance engineering thermoplastics like PEEK, PEKK, PPS and PEI are combined
with continuous carbon fiber reinforcements. This is the case especially in the aerospace industry,
but medical, automotive and power industries are also turning to these materials.
The available assembly technologies like mechanical fastening and adhesive bonding are frequently
used, but for composites they are not always optimal.

P a g e | 43
The KVE Induct technology is both mechanical and cost wise very well suited to assemble carbon
fiber reinforced thermoplastic laminate (CF RTL) components.

KVE Induct technology generates Eddy currents in the electrically conductive carbon fiber of the
thermoplastic laminate. Eddy currents, generated by moving a coil over the weld line, heat up the
laminate from the inside.
This is a very efficient way to melt the thermoplastic matrix and weld two parts together. The two
parts are positioned in special tooling material, which is both ‘transparent’ for the EM field and has a
reasonable thermal conductivity.
The movement of the coil along the weld line can be achieved by commercially available systems like
for example an industrial robot. Material handling (parts, final component) can be setup as manual
labor in case of low volume manufacturing, or automated in case of high volume manufacturing
All process parameters which are influencing the quality of the induction weld can be controlled and
monitored.
Direct comparison of induction welding to other available assembly technologies for CF RTL shows
that:
- the option of assembling a component from many small parts instead of manufacturing this
component in one complex step give new and cost saving possibilities to the product designer.
- retaining the mechanical properties of CF RTL, the assembling technology offered by KVE
Composites Group allows the most efficient designs, balancing ease of manufacturing and assembly
with high quality CF RTL structures.
The availability of KVE Induct® opens up the possibility to manufacture large, complex component by
assembling many simple and small parts.
KVE Composites Group, Fokker Aerostructures, Gulfstream Aerospace, Royal Ten Cate and Ticona
have won the JEC Innovation Award 2010 in the category A1eronautics. This prestigious prize was
awarded for the first welded thermoplastic composite control surfaces of the all new Gulfstream
G650, using KVE’s patented induction welding technology.


P a g e | 44

CONCLUSION
Once again, the JEC Composite Show has been a great opportunity to see new developments and
trends in the ever evolving composite market.
Although many sectors now use composite materials, they still remain the material of choice for
transportation sectors which are precursors in terms of new technical developments.
Thanks to improvement on fiber reinforced plastics manufacturing, lighter structures can now be
produced in more efficient and cheaper ways allowing for instance CFRP to be used in near future in
mass produced cars.
We also see flax fibers tackeling glass fiber reinforced plastics on technical applications paving the
way to awaited technical bio-based composite materials with lower carbon foot-print than
conventional composites.
Development of bio-based resins for composite manufacture will thereagain open the way to even
more environmentally-friendly materials in line with the general trend towards preserving natural
resources and finding alternative solutions to fossil reserves.
The next issue to address however, and for which there is at the moment no viable solution, will be
the end of life and disposal of composite materials, as these hybrid materials are by nature not
recyclable as such…


P a g e | 45

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P a g e | 47

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P a g e | 48

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