“This is another world class approach to lay up space-grade carbon-fibre and then digitally model that for scale and repeatable design,” said iLAuNCH Trailblazer Executive Director, Darin Lovett. “As we make progress in developing sovereign capability for space applications, we know these products will also benefit defence, aerospace, and other sectors that require high-value, bespoke composite structures.”

This project will again utilise the design and advanced manufacture expertise of New Frontier Technologies (NFT) to create structures suitable for rocketry applications, along with the Australian National University’s (ANU) Australian Advanced Instrumentation Centre (AITC), and the X-ray Computed Tomography laboratory (CTLab) for testing.

Using an ANU high resolution CT scanner to assess and mature the manufacturing process the collaboration will build a functional digital twin of the rocket bodies to assess, qualify and enhance the fidelity of structural models for simulation.

“Our world class facilities, expertise in precision manufacturing and rigorous test and validation capabilities will help NFT mature and commercialise technology that will advance Australian manufacturing capability,” said the Australian National University’s Research School of Physics, Professor Patrick Kluth.

The application of x-ray computed tomography (CT) and 3D multiscale modelling at ANU will provide high-fidelity simulation. The CT will capture the detailed microstructure features, such as fibre alignment and voids, that can be reflected in the simulation models. 3D models will provide a detailed digital profile, with capability for performance simulation of every manufactured component, which is the foundation for digital certification.

The project lead, New Frontier Technologies has developed innovative design-for-manufacture (DfM) strategies for scalable, additive manufacturing of space-grade carbon-fibre structures using laser-assisted automated tape placement (ATP).

“This is the only ATP manufacturing capability of its kind in Australia and has been proven in European (ESA) projects for manufacture of high-performance composite structures for space applications,” said New Frontier Technologies Director and CEO, Paul Compston.

By joining forces, iLAuNCH, ANU and NFT will develop a qualified manufacturing process that will directly contribute to the development of rocket manufacturing in Australia through the optimisation of automated additive manufacturing technologies.

The Innovative Launch, Automation, Novel Materials, Communications and Hypersonics (iLAuNCH) Trailblazer is a $180 million program building Australia’s enduring space capability through the commercialisation of projects, a fast-track accelerator, and skills development to build the workforce of the future.

Cover photo: L-R ANU Prof Patrick Kluth, with New Frontier Technologies Paul Compston and Dr Victoria Zinnecker

In addition to these changes, Stan Deal, Boeing Commercial Airplanes President and CEO, will retire from the company and Stephanie Pope has been appointed to lead BCA, effective on March, 25th 2024.

“It has been the greatest privilege of my life to serve Boeing,” said Calhoun in a letter to employees. “The eyes of the world are on us, and I know that we will come through this moment a better company. We will remain squarely focused on completing the work we have done together to return our company to stability after the extraordinary challenges of the past five years, with safety and quality at the forefront of everything that we do.”

Kellner has served on the Boeing Board for 13 years and served as its chair since late 2019. As chair, he oversaw the establishment of a new board aerospace safety committee, and during his tenure led the recruitment of seven new independent directors, bringing deep engineering, safety, manufacturing and aerospace expertise to Boeing’s board.

“Boeing plays an essential role in our world, and serving this company, and our people, has been a true honor,” said Kellner. “After over a decade on the board and several years as its chair, I have been considering the right time for a transition of leadership on our board, and have been discussing that subject with Dave and the board in conjunction with Dave’s own planning about his succession timeframe. I want to thank Dave for his tremendous leadership of our company, and I know he will finish the job this year that he started in 2020 to position Boeing, and our employees, for a stronger future.  With Dave’s decision to step down as CEO at the end of this year, now is the right time for a transition to my successor. Steve is the ideal next leader to take on the role of board chair, and it is important that the CEO selection process be led by a new chair who will stay at the helm as a partner to the new CEO. With a strong board, an excellent management team and 170,000 dedicated Boeing employees, I am fully confident in our company’s future.”

Mollenkopf has served on the board of directors since 2020. He was previously CEO of Qualcomm. He has bachelor’s and master’s degrees in electrical engineering.

“I am honored and humbled to step into this new role,” said Mollenkopf. “I am fully confident in this company and its leadership – and together we are committed to taking the right actions to strengthen safety and quality, and to meet the needs of our customers. I also want to thank both Larry and Dave for their exceptional stewardship of Boeing during a challenging and consequential time for Boeing and the aerospace industry.”

Pope has been serving as chief operating officer of Boeing since January of this year. Previously, she was president and chief executive officer of Boeing Global Services, where she was responsible for leading the company’s aerospace services for commercial, government and aviation industry customers worldwide. Prior, she was chief financial officer of Boeing Commercial Airplanes, and has held positions in every Boeing business unit.  She begins her role as President and CEO of Commercial Airplanes immediately.

CCCS’ offices, located in Anaheim, Newbury Park, and San Diego, has operated in the region since 1993, and is staffed with experienced professionals who are familiar with the manufacturing landscape in the region, and has always had a goal of driving and supporting local manufacturing innovation that positively impacts the world. With the addition of Roboze, CCCS can expand its offering in the additive manufacturing space to address new markets by offering 3D printing solutions that solve common issues like process repeatability, accuracy, and the need to use high performance materials like super polymers and composites.

Offering the Roboze Plus Pro and the Roboze Production Series (ARGO 500/1000), three tiers of
polymer-based materials, a browser-based software slicing application, and the tried and true service, support, and training model, the partnership between Roboze and CCCS aims at helping manufacturers rethink production processes and save the user time and money.

Levi Smith, Global Director of Channel at Roboze: “At Roboze, we look for strategic partners who can extend our values and world class technical service and customer support. That is why I am extremely excited to announce our partnership with CAD/CAM Consulting Services, Inc. CCCS’ extensive knowledge in subtractive and metal additive manufacturing is well aligned to help customers navigate agnostic solutions to engineering problems. CCCS represents our first reseller in the Southern California market and their focus on localized manufacturing innovation is perfectly aligned with Roboze and our cutting-edge additive manufacturing solutions.“

Patrick Shelar, President of CCCS: “As we continue to look for new products that drive innovation that can be delivered to our customers, partnering with Roboze was an obvious choice. Their material portfolio and ability to print highly accurate large parts is a welcome solution for many companies that are trying to find new ways to lightweight their designs, cut down on lead times, and manufacture parts that simply cannot be traditionally machined. Additionally, their success overseas and vision for the future, along with their partnerships with high profile, high performing companies, ensures their trajectory as a disruptor in additive manufacturing. We are excited to be on this journey with them.”

“We are grateful for the Department of Energy’s continued support in our mission to advance wind energy technologies. With thousands of wind blades destined for landfill disposal, this funding allows us to explore the responsible recycling of these products, to reuse and repurpose them as feedstock materials for 3D printing“, said Habib Dagher, executive director of the ASCC.

The project proposes an innovative approach to recycle shredded wind turbine blade material as a cost-effective reinforcement and filler for large-scale 3D printing. By substituting short carbon fibers with shredded and milled material from wind blades, the team aims to achieve mechanical recycling of 100% of the composite blade material.

Research efforts will focus on developing new compounding methods to achieve the necessary adhesive bond strength of the composite material. Resulting pellets will serve as feedstock for large-format extrusion-based 3D printing, leveraging the ASCC’s advanced manufacturing capabilities.

In addition to the sustainability benefits of the research, the project could benefit the global precast concrete industry, which is valued at billions of dollars annually. By integrating shredded wind turbine blade material into the 3D printing process for precast concrete formwork, the team aims to significantly reduce material costs while providing geometric freedom for design and automating manufacturing processes.

This project also addresses the critical need for sustainable recycling of wind turbine blades and presents economic advantages for the construction industry by lowering formwork costs and reducing labor expenses.

The project aligns with UMaine ASCC’s broader environmental goals, aiming to reduce the environmental footprint of land and offshore wind energy and developing environmentally friendly feedstock for large-scale 3D printing processes.

A follow-on phase would enable the development of larger prototypes and deployment of case studies with industry partners, ultimately driving wider adoption of sustainable practices in wind energy recycling.

The WIND REWIND team members leading this project submission include faculty and researchers from the ASCC, the Department of Civil and Environmental Engineering, the Department of Mechanical Engineering, and industry (Dr. Roberto Lopez-Anido, Dr. Reed Miller, Dr. Amrit Verma, John Arimond, Dr. Habib Dagher, Hannah Berten, and Ed Pilpel). This project is led by Dr. Lopez-Anido with coordination support from Dr. Miller and Dr. Luis Zambrano-Cruzatty.

The ASCC is developing this novel approach of repurposing wind blade materials with its global recognition and leadership in composite materials, large-format advanced manufacturing and the floating offshore wind industry. ASCC is home to the world’s largest thermoplastic 3D printer with projects such as BioHome3D, the world’s only 100% bio-based 3D printed house, and 3Dirigo, the first ever 3D printed boat. With the largest team in the United States dedicated to floating offshore wind, ASCC is a global leader with the VolturnUS hull technology and commitment to innovation within the industry. 

Cover photo: Umaine

Collaborating closely with the TPRC and exchanging expertise will advance Composites One’s objective of better supporting its customers. As a leading supplier of high-performance composite materials across North America, Composites One serves over 9,000 customers across diverse sectors including marine, aerospace, wind energy, marble/solid surface, construction, industrial and ground transportation. Within these sectors, the company provides a comprehensive range of traditional and advanced materials that cover reinforcements, resins, process materials, gel coats, catalysts, core materials, shop supplies, and process equipment. Headquartered in Schaumburg, Illinois, USA, Composites One operates through a network of more than 40 locations in North America.

“We are thrilled to announce our participation in the TPRC Consortium, marking a significant step forward in our continued commitment to advancing aerospace technology and supporting our customers. This collaboration underscores our dedication to the innovative use of reinforced thermoplastic composites in aeronautic part design, offering unparalleled opportunities to enhance performance while also addressing important environmental challenges. By collaborating with TPRC, we aim to not only enhance the performance and efficiency of aerospace components but also to engage in meaningful initiatives around recycling and carbon emissions.” said Dave Smith, vice president of the marketing department at Composites One.

Sebastiaan Wijskamp, general manager of the TPRC said: “We are very happy with Composites One joining our research center. Composites One brings huge value to the TPRC with their extensive network and customer base in the various markets in which they operate. Their expertise on auxiliary materials and consumables needed for the processing of composites, both thermoset and thermoplastic, will open up new project opportunities for our research roadmap.”

Le projet, qui s’étend du 1er janvier 2024 au 31 décembre 2026, bénéficie d’un financement de 11,4 millions d’euros, y compris le soutien de l’Université de Northumbria, au Royaume-Uni. L’effort de collaboration, mené par 28 partenaires, vise à améliorer la durabilité des matériaux, des processus de production et des considérations relatives à la fin de vie des VE.

ZEvRA permet la collaboration de cinq grands équipementiers, soutenus par des universités européennes de premier plan et des acteurs-clés de toute la chaîne de valeur (et trois membres du partenariat 2ZERO). Le projet fera la démonstration d’une méthodologie de circularité harmonisée permettant l’interchangeabilité et la reproductibilité dans toute l’Europe. La méthodologie et les technologies de fabrication en matière de conception pour la circularité (DfC) seront soutenues par des outils numériques et validées sur une voiture circulaire complète, intégrant 8 composants prototypes couvrant 84% du mélange total de matériaux automobiles, y compris l’acier, l’aluminium, les composites, les plastiques et les pneus. Les innovations de ZEvRA visent à améliorer les approches zéro émission dans le cycle de vie et la chaîne de valeur d’au moins 59% des véhicules européens d’ici 2035.

Lors de la réunion de lancement du projet, qui a eu lieu au Fraunhofer IWU à Chemnitz, en Allemagne, du 23 au 25 janvier 2024, environ 75 participants ont eu un échange intensif entre eux et avec le responsable de projet de la Commission européenne.

Consortium du projet

• Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung EV
• University of Northumbria at Newcastle
• Fundacio EURECAT
• Bay Zoltan Alkalmazott Kutatasi Kozhasznu Nonprofit KFT.
• Alma Mater Studiorum – Universita di Bologna
• Skoda Auto AS
• RKW Sachsen GmbH Dienstleistung und Beratung
• RISE Research Institutes of Sweden AB
• Faurecia Automotive Composites
• EDAG Engineering GmbH
• Havel metal foam GmbH
• Raffmetal Spa
• Technische Universitaet Braunschweig
• Farplas Otomotiv Anonim Sirketi
• Benteler Automotive Raufoss AS
• Norges Teknisk-Naturvitenskapelige Universitet
• Toyota Motor Europe Nv
• Psa Automobiles Sa
• Automotive Parts Remanufacturers Association Europe
• Centro Ricerche Fiat Scpa
• Polymeris
• Endurance Amann GmbH
• Teknologian Tutkimuskeskus Vtt Oy
• Politecnico di Milano
• Turkiye Sise ve Cam Fabrikalari AS
• Continental Reifen Deutschland GmbH
• Volkswagen Aktiengesellschaft Wolfsburg
• Bax Innovation Consulting SL

Holders of GE common stock were entitled to receive one share of GE Vernova common stock for every four shares of GE common stock.

GE Aerospace Chairman and CEO H. Lawrence Culp Jr., said, “With the successful launch of GE Aerospace and GE Vernova as independent, public companies now complete – today marks the historic final step in the multi-year transformation of GE. I am tremendously proud of our teams, their resilience and dedication to achieving this defining moment.”

Culp continued, “Building on a century of learning and carrying forth GE’s legacy of innovation, GE Aerospace moves forward with a stronger balance sheet and greater focus to invent the future of flight, lift people up, and bring them home safely. With FLIGHT DECK, our lean operating model, as our foundation for connecting strategy to results, I am confident we will realize our full potential in service of our customers, employees, and shareholders.”

With an installed base of approximately 44,000 commercial engines and approximately 26,000 military and defense engines around the world, GE Aerospace launches as an established global leader in propulsion, services, and systems. The company generated approximately $32 billion of revenue in 2023, with 70% generated by services.

At the company’s Investor Day in March, GE Aerospace reaffirmed its 2024 guidance and presented a longer-term financial outlook, including achieving ~$10B of operating profit* in 2028. Additionally, GE Aerospace shared a capital allocation framework to invest in growth and innovation, while also returning approximately 70-75% of available funds to shareholders.

*Non-GAAP Financial Measure. The reasons GE Aerospace uses these non-GAAP financial measures and the reconciliations to their most directly comparable GAAP financial measures are included in their annual report on Form 10-K and their fourth quarter and full year earnings release.

Cover photo: Image par Vicki Hamilton de Pixabay

The agreement follows the significant development work by KECI and the customer to meet stringent supplier capability and quality requirements, allowing the customer to include an annual minimum volume commitment from the customer to KECI. The parties have agreed not to disclose the contract value.

KECI will be delivering the carbon fibre planks from its new factory near Goa, India, currently in final stages of construction. Deliveries are expected to begin in the second half of 2024, subject to the customer’s product approval protocols and subsequent issuance of purchase orders under the agreement.

“We are pleased with the progress and confidence placed by the customer in KECI. By utilizing KECI’s new factory in India, the customer will be able to avail themselves of state-of-the-art carbon fibre planks produced competitively in India”, says Shekhar Sardessai, Managing Director of Kineco Exel Composites India.

“The agreement marks an important milestone in the development of our capabilities to better support wind turbine manufacturers. We are in the process of further improving these capabilities to be able to serve the various needs of different customers seeking carbon fibre planks and other composite products for their wind turbines”, adds Paul Sohlberg, President and CEO of Exel Composites.

Exel Composites and KECI offer wind turbine manufacturers a comprehensive range of glass fibre and carbon fibre composite components required for the manufacturing of modern on-shore and off-shore blades.

Recognized for Quality Excellence, Toray was instrumental in aiding Northrop Grumman with manufacturing and distribution goals as the industry works to support Department of Defense customers and other commercial entities.

“We take immense pride in serving the nation as a leading material supplier in the US and delivering excellence at every turn,” said Jered Wagner, Vice President of Aerospace Sales for Toray Advanced Composites. “We are deeply committed to providing the highest quality carbon fiber, thermoset, and thermoplastic composite materials, ensuring every component meets stringent standards for mission-critical success. We look forward to continuing our support with Northrop Grumman and advancing national security solutions.”

Windform composites have undergone rigorous dielectric constant and dielectric strength tests, essential for evaluating material electrical performance, particularly in applications requiring electrical insulation. In today’s automotive industry, characterized by hybrid or fully electric vehicles, the use of insulating plastic materials is paramount due to the reliance of the entire propulsion system on electricity.

The dielectric constant test

The dielectric constant, often denoted by the symbol ε₀ (epsilon zero), is a fundamental constant in physics that represents a material’s ability to resist the formation of an electric field within it.

During the test, the Glass fibre reinforced Windform thermoplastic composites Windform LX 3.0, Windform GT, and Windform FR2 exhibited a dielectric constant close to 4, with Windform LX 3.0 and FR2 slightly above 4, and Windform GT slightly below. The tests were conducted at the standard frequency of 1 kHz.

The dielectric strength test

The dielectric strength test evaluated the maximum electric potential difference the materials can withstand before conducting electricity. Windform LX 3.0, Windform GT, and Windform FR2 demonstrated exceptional performance, enduring peak voltages of at least 2.5 kV/mm without any signs of deterioration. Specimens with a thickness of approximately 1.6 mm were subjected to sinusoidal voltages alternating at 50 Hz and amplitudes up to 4000 V without discharge.

These results are significant for electrical applications, where maintaining a dielectric constant around 4 is crucial, especially in fully electric vehicles with high voltage. Insulating plastic materials play a vital role in ensuring safety, efficiency, and proper operation of the electrical system. Examples include battery housings, power converter housings, cooling and air conditioning system components, and charging connector housings.

The ability of glass fibre reinforced Windform thermoplastic composites to withstand voltages of at least 2.5 kV/mm ensures reliability and safety in environments with high electrical voltages, such as in the electric power and telecommunications sectors. Windform thermoplastic composites emerge as a suitable choice for applications demanding high-quality electrical performance and reliability.

Cover photo: CRP Technology

Le centre technologique espagnol AITIIP, coordinateur du projet et fort de son expérience dans le secteur aéronautique, travaille sur le pré-traitement et la préparation des composites avant l’étape de recyclage. La préparation de ces composites nécessite tout d’abord de découper les pales d’éolienne et de les débarrasser des traitements de surfaces qu’elles ont subis lors de leur élaboration.  

Plus d’une année de travaux a permis de développer une solution automatisée portable pour l’intégration de la découpe au jet d’eau. La découpe au jet d’eau est un procédé industriel puissant et polyvalent qui utilise un courant d’eau à haute pression ou un mélange d’eau et de matériaux abrasifs pour découper les pales d’éolienne. Le premier prototype sera opérationnel cet été.

La surface des pales est souvent recouverte de résines protectrices, qui peuvent entraver l’efficacité du recyclage des composites. AITTIP travaille en parallèle sur différentes méthodes de traitement de surfaces mécaniques et chimiques afin de déterminer la solution la plus efficace en prenant en compte son impact environnemental. Cette solution sera également prête pour une mise à l’échelle préindustrielle au cours de cet été.

Pari réussi pour Blackleaf qui vient de conclure un tour de table majeur de 7M € avec l’accompagnement et le soutien d’un pool bancaire regroupant Bbifrance, le CIC, BNP Paribas et le Crédit Agricole Alsace Vosges. D’abord auprès de la Team Cajuba, emmenée par Michel Hussherr, qui rassemble une cinquantaine de business angels locaux engagés dans la création d’emplois durables dans le secteur de l’innovation. Cette communauté d’entrepreneurs-investisseurs qui privilégie le mentorat et le partage de réseau a su se mobiliser pour rassembler les 2/3 de la levée avec de la “smart monnaie”. On retrouve également au tour de table l’industriel nantais Armor Group, qui, après HoloSolis et Equium, continue sa démarche d’ouverture en menant des partenariats industriels stratégiques.

« Après une pre-seed réussie en 2021, je me réjouis du succès de cette nouvelle opération. La confiance accordée par nos partenaires financiers est grande. En outre, pour la première fois, nous sommes rejoints dans l’aventure Blackleaf par un industriel de taille, Armor Group, qui au-delà de sa participation financière, nous fera bénéficier de son expertise industrielle en formulation d’encres et en process industriel », déclare Yannick Lafue, CEO de Blackleaf.

« Je suis extrêmement heureux du lien qui unit désormais Blackleaf et Armor Group. Il existe de vraies synergies industrielles entre nos deux sociétés. Le graphène est un matériau qui est clef pour nos activités de collecteurs de courant pour batteries ainsi que pour notre toute nouvelle filiale de films intelligents ARMOR SMART FILMS. Cette nouvelle participation apporte une preuve supplémentaire à notre engagement pour une industrie à impact social et environnemental positif », confie Hubert de Boisredon, Président-Directeur général d’Armor Group.

Une croissance protéiforme

Issue du terreau universitaire strasbourgeois, Blackleaf est l’une des start-up les plus prometteuses du moment. Son ambition : révolutionner la production de graphène, matériau stratégique aux multiples applications, clef pour la transition écologique. La levée qui vient d’être bouclée va permettre de soutenir la croissance dans laquelle l’entreprise est engagée. D’une équipe actuelle de 12 personnes, Blackleaf projette de nombreux recrutements pour arriver à un total d’une quarantaine de collaborateurs d’ici à 2025. En outre, l’objectif de la start-up est à la fois de mettre en place une vraie capacité de production industrielle et, en parallèle, de développer des solutions et produits mettant en œuvre du graphène. Elle se concentre actuellement sur les revêtements chauffants (aéronautique, habitat, transport ou industrie) et la production d’encres, mais prépare à terme d’élargir son activité au béton bas-carbone et à l’intégration du graphène dans la fabrication de systèmes de stockage d’énergie.

« Notre objectif est à la fois de mettre en place une vraie capacité de production industrielle et, en parallèle, de développer des solutions et produits mettant en oeuvre du graphène. Jusqu’à présent, l’approche dominante a été de se focaliser sur la production de graphène, or le marché est orienté « solutions » et c’est cette approche que souhaite privilégier Blackleaf – de manière à raccourcir les délais de prises de commandes », détaille Yannick Lafue.

Une 1ère usine opérationnelle en 2024

Spin-off de la recherche académique française, Blackleaf est une start-up deeptech qui, seulement 4 ans après avoir quitté le CNRS, construit aujourd’hui son pilote industriel pour faire du graphène un matériau-commodité. Avec son projet de ‘Manufacture Graphene’, Blackleaf est lauréat de l’appel à projets « Première Usine », opéré par Bpifrance dans le cadre du plan d’investissement France 2030. A travers cet appel à projets, le Gouvernement entend faire de la France un leader de l’innovation et de la production industrielle.

« Matériau stratégique, le graphène est un intrant de première importance pour l’industrie française. Parfait candidat à la décarbonation, le graphène est attendu dans de nombreuses filières comme l’aéronautique, la chimie, les nouvelles générations de batteries, le béton bas-carbone, ou encore les peintures et encres conductrices. Avec la construction de notre site industriel et une capacité de production de 120 tonnes en 2025, Blackleaf figurera comme l’acteur de référence européen au service la souveraineté industrielle. », conclut Yannick Lafue.

DCIM much faster than previous LCTS solution

The decision to use DCIM (Direct Compounding Injection Molding) technology was made shortly after the initial contact with KraussMaffei, after less than six months. At the time, Fiber Dynamics needed to expand production and faced an even greater challenge with the production of propeller blades for the advanced air mobility market.

The existing Lost Core Tooling System (LCTS) solution was taking too long, had formulation limitations and was too costly using traditional methods. Injection molding was an obvious solution, but producing the proprietary and highly customized formulations posed an additional challenge. “KraussMaffei was able to quickly understand our problem and offer us a unique solution with its DCIM technology. In addition, KraussMaffei was able to demonstrate and implement the solution quickly,” says Darrin Teeter, CEO of Fiber Dynamics, praising the collaboration.

In-house formulation brings clear advantages

In addition to cycle times that are up to eight times faster compared to the previous LCTS technology, Fiber Dynamics sees the main advantage of DCIM technology in its own recipe control. “The ability to test a variety of different formulations and quickly develop new ones is crucial to the success of our program. Externally compounded formulations are generally not practical for our work and jeopardize the proprietary nature of our solutions,” explains Darrin Teeter. The ability to also produce technical thermoplastic molded parts and thermoplastic composites also opens up a whole new dimension of versatility and added value for the company.

Close cooperation with leading research institute NIAR

An important partner in this project is the NIAR Institute ATLAS (Advanced Technologies Lab for Aerospace Systems) also located in Wichita, Kansas. With 1,400 employees and an annual research budget of more than USD 240 million, NIAR (National Institute for Aviation Research) is the leading research institute in the field of aviation in the USA. Since mid-2023, ATLAS has been operating a GX 450-1400 from KraussMaffei in its 150,000 square meter research pilot plant, which is also designed for the FiberForm and ColorForm processes. Darrin Teeter: “When we discovered the potential to produce our LCTS materials by thermoplastic injection molding, we were able to use the laboratory machine at ATLAS to carry out important validation processes. The results were excellent, so we quickly decided to purchase the DCIM system.”

The GX 1100-4300 DCIM system with a clamping force of 11,000 KN is scheduled to start production in Wichita in May. Initially, it will produce tooling mandrels for composites articles in aircraft, such as propeller blades, wings and landing gears. Fiber Dynamics also sees great future potential for DCIM technology in the automotive and sporting goods industries.

DCIM from KraussMaffei – economical and sustainable

The DCIM process combines injection molding and compounding in a single process. A single-screw extruder handles the material preparation, making the process particularly cost-effective for smaller components with a shot weight of 50 g to 2000 g. Material savings of up to 50 percent per kilogram can be achieved.

The entire process takes place in one heat, as the compounded melt enters the plasticizing process of the injection molding machine without any intermediate stops or cooling. This reduces polymer degradation, saves energy costs and reduces the CO₂ footprint. 

Cover photo: iStock – Advanced air mobility: Fiber Dynamics sees great potential for DCIM in the air taxi market

Ils imaginent, étudient et optimisent vos produits et systèmes. Aussi, ils réalisent des pièces en composites hautes performances par thermocompression, estampe et sur-moulage.

Spécialisé dans les composites et polymères (PEEK, PEKK, PEI, PPS…) et plus particulièrement dans :

• Calcul de structure
• Simulation procédé
• Estampage
• (Sur)Moulage
• Impression 3D (FGF/FFF)

« L’autonomie exceptionnelle, l’efficacité énergétique et le confort des passagers de l’A350 en font un choix idéal pour notre réseau mondial », a déclaré Jason Yoo, directeur de la sécurité et de l’exploitation et vice-président exécutif de Korean Air. “Nous sommes convaincus que l’introduction de l’A350 dans notre flotte améliorera l’efficacité opérationnelle ainsi que l’expérience de voyage globale de nos passagers.”

Benoit de Saint Exupéry, EVP Sales, Commercial Aircraft, Airbus a déclaré : « Cette commande de Korean Air est une nouvelle reconnaissance majeure pour l’A350 en tant que leader mondial des long-courriers. La compagnie aérienne bénéficiera de nouveaux niveaux d’efficacité dans l’ensemble de ses opérations, avec une consommation de carburant et des émissions carbone considérablement réduites. L’A350 sera également la plate-forme idéale pour que le transporteur puisse propulser ses offres à bord et ses services de classe mondiale vers de nouveaux sommets. Nous remercions Korean Air pour sa confiance continue dans Airbus et ses produits, et nous sommes impatients de voir l’A350 voler avec les couleurs emblématiques de l’entreprise“.

La gamme A350 constitue la plus moderne au monde pour les gros-porteurs. Elle est fermement établie comme leader mondial en matière de vols long-courriers, avec certaines versions passagers capables de voler jusqu’à 9 700 nm / 18 000 km sans escale. Propulsée par des moteurs Rolls-Royce de dernière génération, la cellule utilise 70 % de matériaux avancés tels que des composites, du titane et des alliages d’aluminium modernes pour créer un avion plus léger et plus rentable. Tout cela se traduit par une réduction moyenne de la consommation de carburant et des émissions carbone d’environ 25 % par rapport aux avions de taille similaire de la génération précédente.

Fin février, la famille A350 totalisait 1 240 commandes provenant de 59 clients dans le monde.

A new design philosophy for McLaren Automotive

Drawing on sixty years of motorsport heritage while embracing the imperative of modernising its vehicles, McLaren has just unveiled its new design philosophy. It revolves around five pillars, “Epic, Athletic, Functional, Focused, and Intelligent,” defined by the new Chief Design Officer, Tobias Sühlmann, who has previously worked at Bentley, Aston Martin, Bugatti, and Volkswagen. “Racing is in our DNA, and beauty flows from this relentless pursuit of performance. We are deeply inspired by six decades of McLaren history, but we are not rooted in our past. Our Design DNA will build McLaren into a brand that delivers 60 years of motorsport heritage in incredible lightweight supercars and beyond. A new era, with new vehicles, more product differentiation, and with Performance by Design at the heart of it,” explains Tobias Sühlmann.

The McLaren Composites Technology Centre is at the heart of the group’s new strategy

Beyond the potential diversification of the range and the electrification efforts, McLaren remains focused on performance, particularly through increasingly precise work on aerodynamics and weight reduction using advanced materials. “Our vehicles are designed and finished with innovative and ultralight materials, and we develop them for new uses, making them lighter, stronger, more durable, and expanding their functions,” he emphasizes, clearly referring to the McLaren Composites Technology Centre’s (MCTC) ultralight carbon architecture (MCLA): “The MCLA is designed, developed, and manufactured at the McLaren Composites Technology Centre (MCTC) in the Sheffield region of England, using a unique process in the world, and will be the flagship of the brand’s electrified future.” The McLaren Composites Technology Centre, which represented a £50 million investment, was inaugurated in 2018. At the forefront of research, its mission is to develop and produce the carbon fibre monocoque chassis for McLaren vehicles, which are assembled at the group’s renowned technological center in Woking, Surrey, designed by famous architect Norman Foster.

Cover photo: McLaren F1LM 2024

Un nouveau langage stylistique pour McLaren

Conciliant soixante années de sport automobile et un impératif de modernisation de ses véhicules, McLaren vient d’ailleurs de dévoiler sa nouvelle philosophie de design. Elle s’articule autour de cinq piliers, « Epic, Athletic, Functional, Focused et Intelligent », définis par le nouveau chief design officer, Tobias Sühlmann, qui a auparavant travaillé chez Bentley, Aston Martin, Bugatti ou encore Volkswagen. « La compétition est dans notre ADN, et la beauté découle de cette poursuite incessante de la performance. Nous sommes profondément inspirés par six décennies d’histoire de McLaren, mais nous ne sommes pas enracinés dans notre passé. L’ADN du design qui nous appartient fera de McLaren une marque offrant 60 ans d’héritage du sport automobile dans d’incroyables supercars ultralégères, mais pas seulement. C’est le début d’une nouvelle ère, avec de nouveaux véhicules et une plus grande différenciation des produits, tournant autour de la notion de Performance by Design », déclare ainsi Tobias Sühlmann.

Le McLaren Composites Technology Centre au cœur de la nouvelle stratégie du groupe

Au-delà de la possible diversification de la gamme et du chantier de l’électrification des modèles, McLaren reste focalisé sur les performances, notamment grâce à un travail toujours plus pointu sur l’aérodynamisme, et l’allègement, via les matériaux. « Nos véhicules sont conçus et finis avec des matériaux innovants et ultralégers et nous les développons pour de nouvelles utilisations, en les rendant plus légers, plus résistants, plus durables et en élargissant leurs fonctions », souligne-t-il en faisant clairement référence à l’architecture ultralégère en carbone (MCLA) de la maison « britannique » : « La MCLA est conçue, développée et fabriquée au sein du McLaren Composites Technology Centre (MCTC) dans la région de Sheffield en Angleterre, selon un procédé unique au monde, et sera le fer de lance de l’avenir électrifié de la marque ». Le McLaren Composites Technology Centre, dont la construction a représenté un investissement de 50 millions de livres, a été inauguré en 2018. A la pointe de la recherche, il a pour mission de développer et produire les châssis monocoques en carbone des véhiucles McLaren, qui sont assemblés dans le célèbre centre technologique du groupe de Woking, dans le Surrey, œuvre de l’architecte Norman Foster.

Photo en-tête : McLaren F1 LM 2024

“Our GreenGirt® CMH™, GreenGirt® CMH™ Clips, and GreenGirt® CMH™ Delta have been popular in Canada for years, across provinces including British Columbia, Alberta, Ontario, Nova Scotia, and beyond,” stated G. Matt Krause, Founder and CEO, Advanced Architectural Products. “This partnership with KLAD Envelope Solutions will deepen our impact and bring our advanced building enclosure and continuous insulation systems to more Canadian projects and contribute to meeting the nation’s ambitious emission reduction targets.”

“KLAD Envelope Solutions is excited to be working with Advanced Architectural Products across Canada.  A2P’s innovative engineered products are perfectly suited to help designers and contractors meet Canada’s drive to energy efficient, high-performance buildings,” stated Robert Jahnsen, Principal, KLAD Envelope Solutions. “In partnering with A2P, KLAD continues to add to our ability to provide building envelope technical solutions for architects, contractors, engineers, and building owners.”

To expand the market for Advanced Architectural Products’ building enclosure and continuous insulation systems in Canada, Cole Hansen, Business Development Manager, will focus in British Columbia and the Northern regions; Russell Macdonald, Manager of Inside Sales, will focus in the Prairies; and Lyrrad Pittard, Vice President, will lead expansion efforts in Eastern Canada.

Composite Recycling accumule les récompenses

C’est dans cet esprit que le forum Monaco Smart Yacht Rendezvous organise un vaste concours de start-up, avec 350 candidatures et 40 start-up et scale-up retenues pour les délibérations finales d’un jury international composé d’une vingtaine de professionnels de l’industrie et d’investisseurs. Dans la catégorie des start-up, Composite Recycling a obtenu le prix qui a été remis à Guillaume Perben, co-fondateur et dirigeant de l’entreprise. Un prix qui viendra garnir une étagère de trophées déjà bien remplie, Composite Recycling ayant notamment obtenu un Start-up Booster Award lors de JEC World 2023, ainsi qu’une distinction lors de Metsrade 2023, aux côtés de ses partenaires Beneteau et Chomarat.

Tendre vers une économie circulaire et collaborative

« Ce prix a une saveur particulière car ma famille a des liens profonds avec Monaco et quiconque aime naviguer comprendra qu’être distingué par le prestigieux Yacht Club de Monaco représente un formidable accomplissement », commente Guillaume Perben, en remerciant aussi les représentants de M3 – Monaco Marina Management et de la Fondation Prince Albert II de Monaco, et en se réjouissant d’avoir pu rencontrer Mike Horn, présent lors de l’événement.

Pendant le forum, le dirigeant de Composite Recycling a aussi participé à une table ronde sur le thème de la « synergie entre les chantiers de construction et de refit par une approche collaborative », aux côtés Bob Wagemakers, directeur et architecte naval Virtue Yacht Refit Management, de Marcello Maggi, président de Wider Yachts, de Laurent Thiebaut, directeur général Solution France de Rolls Royce/MTU et de Rob Papworth, directeur général de MB92 La Ciotat.

Notons enfin que dans la catégorie « scale-up », c’est aussi une société bien connue de JEC qui a été primée, à savoir Greenboats, spécialiste des structures en composites à fibres naturelles, qui était représentée par son business developer Loris Schimanski.

Photo en-tête : yacht Lexus 2027 – copyright Toyota Lexus

Rafael Mellado, managing director and CEO of Global Composites, says: “A company like INCOM with which we share the same values ​​is key to the successful development of this collaboration. We know the markets, we offer high value-added products and services that our customers appreciate, and now we have the opportunity to expand our portfolio by incorporating more products and services of high quality”.

Carlos Vidal, Founder of INCOM, highlights: “Although the development and supply of composite materials kits has historically been our main objective, technical and supply chain solutions have come to occupy a prominent place in our portfolio, giving rise to a whole new variety of products designed to create added value for our customers”.

Luis Azorín, general director of INCOM, states: “I am totally convinced of the synergy that we can contribute between both companies to the existing value chain, and where this combination of both commercial and technical resources from InCom and Global Composites, together with a strong belief in offering an efficient service to our customers, will ensure that we succeed in projects and opportunities that are more difficult to access separately, in sectors full of many challenges and where we are forced to adapt in an agile and competitive way”.

Foton Bus and Coach Company, a subsidiary of the Chinese BAIC company, manufactures a wide range of commercial vehicles, including trucks, buses, vans, and construction vehicles. In line with industry trends, Foton has shifted its focus to electric and hydrogen vehicle manufacturing, particularly in the bus and coach sector. 

Exel will produce a series of structural composite profiles for many different bus models. These profiles, including fiber reinforced plastic (FRP) side panels, skirt panels, and fake roofs, are manufactured using pultrusion technology with glass fiber composites. These offer greater tensile strength and durability while reducing density by 30 per cent, compared to traditional aluminum profiles. 

“Exel’s profiles improve our design process in ways that are only achievable with composite materials,” explained Mr. He, head of group R&D for Foton Bus and Coach Company. “The geometric possibilities are key for complex-shape structural components and weight savings of fiberglass compared to aluminum reduces strain on both the chassis and the battery. What’s more, composite panels don’t rust and can last for decades.” 

“Having refined the pultrusion manufacturing process over many decades, we can produce complex geometric profiles that match the strength of traditional aluminum, while being much lighter,” explained Kathy Wang, executive VP for industrial solutions business unit at Exel Composites. “At the same time, the finished profile has a smooth surface finish, which eliminates the need for further processing. 

Furthermore, unlike aluminum extrusions, which are limited to 0.3 m in width and require multiple connections for larger panels, our composite profiles can extend up to 1.2 m wide and 12 m long. This ensures structural integrity and solidarity.” 

Exel Composites can also use pultrusion for applications including interior air ducts, luggage racks, side shields, and flooring – and pull-winding for small diameter tubes, further reducing the energy consumption and weight of buses.  

For the new FlowTech 1 Single Fin, the partners selected Ixef^® PARA 1022, a 50% glass fiber reinforced compound that exhibits very high strength and rigidity, outstanding surface gloss and excellent creep resistance.

“We are very pleased to provide a thermoplastic compound that helps Kohola bring a more sustainable solution to the surfing industry with no compromises in product performance, aesthetics or durability. Indeed, unlike traditionally used subtractive manufacturing processes, using  Ixef^® PARA 1022 (a 50% glass fiber reinforced compound that exhibits very high strength and rigidity, outstanding surface gloss and excellent creep resistance) enables our customers to improve material usage efficiency as well as, waste and recycling challenges’.“, says Meghan Powers, Global Marketing Manager for Syensqo Specialty Polymers.

“Our longboard fins require a material that supports the dynamic maneuverability and minimized resistance enabled by the natural whale pattern design, which improves flow control by cutting through turbulences and reducing side-to-side wobbling for a more stable forward ride as well as safer, tighter turns. Apart from offering the mechanical characteristics to meet those needs, extensive testing showed that Syensqo’s Ixef^® PARA also ensures the durability to handle marine conditions with extensive exposure to sun and saltwater.”, says David E. Shormann, founder of Kohola Flow Tech Company.

“The new Kohola fins are a game changer in the surfboard market. By replacing a phenolic thermoset material with Ixef^® PARA and taking full advantage of the injection molding process, we arrived at a high-performing high-end product with better resource efficiency and superior finish straight from the mold, eliminating the time and cost for secondary trimming and polishing.”, says Bryan Quance, Sales & Applications engineer at Drake Plastics.

Following the success of the FlowTech 1 Single Fin, Kohola is also considering to specify Ixef^® PARA for the company’s advanced FlowTech 3 Thruster Set. This new design will further maximize drive and stability through turns with controlled release for the ultimate combination of speed, power and flow when surfing. In addition, the patented fin design has potential in other markets where wing-like structures are used, from ceiling fans and aircraft to marine propellers.

Located in the middle of the Subang factory, the center has been expanded through two renovation projects to model and furnish space and incorporate soundproofing in the workspace to accommodate new engineering functions for the Malaysia engineering team, including 24-hour engineering service to Spirit factories around the globe. The center is equipped with state-of-the-art engineering technology, high speed networks, and engineering software.

Black said that Spirit’s engineering team in Malaysia is already a significant player in the design of the A350XWB Section 15 Freighter, A350XWB Ultra Long Range and a key partner to A220 Wing program.   

“Expanding engineering services in Malaysia gives Spirit the ability for around-the-clock support for our global manufacturing locations and development programs, improving engineering turn-around time, so we can provide service to meet our growing customer demand,” Black said. “Additionally, an expanded engineering office in Malaysia will enhance supply chain communications in the Asia-Pacific region by providing operations within the same time zone, as well as culture and language advantages.”

Black added that upgrading engineering capabilities for the company’s Malaysia facility creates future opportunities for Spirit to offer design-and-build capabilities in that region.

“A stronger engineering workforce in Malaysia helps Spirit have better agility and capacity to serve our global customers,” Black said.

“We are thrilled to welcome Andy as president of ASTM International,” says Bill Griese, 2024 chair of ASTM’s Board of Directors. “Andy has spent years supporting ASTM International in a variety of volunteer roles and is exceptionally well-suited to lead the organization forward. He brings a strong commitment to ASTM’s mission, values, and membership. Kathie’s dedication and engagement have made it possible for us to find the right leader for ASTM’s future, and we are delighted she will help to ensure a smooth transition as Andy assumes the role in May.”

Kireta is president and CEO of the Copper Development Association and has been with the not-for-profit trade association since 1992, serving the past two decades in an executive management capacity. He has been an ASTM International member since 1998, and joined the board of directors in 2014, serving as chair of the audit and finance committee in 2017, vice chair in 2018 and 2019, and chair of the board in 2020. Kireta also previously served as vice chair and chair of the board of SEI International, an ASTM affiliate.

“I am honored and excited to serve as the new president of ASTM International,” says Kireta. “I have great respect for ASTM’s mission, staff, members, and partners, and I am humbled to lead an organization that has made such a meaningful impact on industry and society over its 125-year history. I am eager to work with the ASTM community to build upon that success as we advance our mission of helping our world work better.”

In his role as president, Kireta will lead one of the oldest and largest standards organizations in the world, overseeing 35,000 global members who work to develop and refine more than 12,900 technical standards and solutions that represent over 90 industry sectors.

The task of the Chief Sustainability Officer is to develop solutions to reduce the DITF’s energy and resource consumption, promote renewable energies and implement efficient energy use. The management team, the operational organizational units and all employees are involved in the process.

The CSO also acts as a driving force for both the Executive Board and the research departments to promote sustainability issues.

The DITF consider these tasks to be an important part of the process of becoming an energy-efficient and climate-neutral research institution.

Célébration du partenariat à Shap’in

L’annonce de ce partenariat se tiendra le mardi 26 mars à 14h au centre d’innovation Shap’in à Saint-Aignan-de-Grandlieu, près de Nantes. L’événement comptera sur la présence de Philippe Varin, Président de C’Possible et Vincent Chanron, Directeur de la Transformation et Performance RH chez Daher. Une visite de Shap’In précédera la présentation du partenariat pour illustrer l’importance de la synergie entre le secteur industriel et l’éducation pour le développement des talents de demain.
Shap’in, le centre d’innovation de Daher en Loire-Atlantique, est un pilier dans le domaine des composites avancés pour l’aéronautique, répondant aux enjeux de décarbonation et de cadences du secteur. A proximité immédiate, l’usine de Nantes se distingue par son engagement dans le recyclage des chutes de production en composites thermoplastiques, avec un objectif de 80% de chutes traitées à terme.

Engagement durable et développement du partenariat

La convention signée entre Daher et C’Possible symbolise un engagement durable, marqué par un soutien financier de Daher. Ce partenariat ambitionne non seulement l’intégration professionnelle des jeunes dans des domaines spécialisés comme les composites mais envisage également une extension à d’autres régions où Daher opère, répondant aux défis de formation dans l’aéronautique.
Pour Jérôme Leparoux, Secrétaire général de Daher : « La collaboration avec C’Possible illustre notre engagement envers l’éducation et l’insertion professionnelle des jeunes. Notre ambition est de forger un lien durable avec l’avenir de l’industrie aéronautique, en mettant l’accent sur la transmission de nos savoir-faire techniques. Ce partenariat souligne aussi notre volonté de préparer la prochaine génération à relever les défis de demain. »
Pour Philippe Varin, Président de C’Possible : « Je suis particulièrement heureux de ce partenariat avec Daher qui incarne l’indispensable mobilisation des entreprises pour préparer les jeunes des lycées professionnels aux métiers de demain. Je suis convaincu que c’est par ce type d’approche concrète que les jeunes peuvent trouver du sens à leur formation, se projeter vers l’emploi et renforcer leur confiance dans l’avenir. Les équipes de C’Possible s’investissent au quotidien pour faciliter ces interactions terrain lycées-entreprises. »

The A350-1000 aircraft that Korean Air will introduce is the largest aircraft in the A350 family. It is usually equipped with 350 to 410 seats. More than 50% of the fuselage is made up of carbon composite materials, increasing fuel efficiency and reducing carbon emissions by 25% compared to existing aircraft of similar class.

Meanwhile, Korean Air is accelerating the modernization of its aircraft for safe operations. Including this contract to purchase 33 Airbus aircraft, the company plans to introduce a total of 143 new aircraft, including 50 Airbus A321neo.

By applying pressure and temperature above the melting point of the resin when laminating, the layers can be welded. It can be used as a material for auto tape laying (ATL), press or autoclave molding process. As an example, Fig. 2 shows a pipe-shaped laminate made by ATL, using SHIMTEQ™ TP CA140ST with fiber orientation in four directions (0°, 90°, +45°, -45°). In addition to this example, there is another actual case in which slit tape was used as braided configuration, and then pipes were formed. After lay-up in this way, the laminate is heated and pressurized for resin impregnation, and cooled and demolded to obtain high-strength and high-rigidity molded composite products.

The unique feature of SHIMTEQ™ TP CA140ST is its very thin configuration as less than 0.04mm thickness. Thinner laminates are more easily heated, therefore continuous welding process like ATL can be stable. The products are available in standard widths of 3, 5, and 10 mm, but can be designed by 0.1 mm increments upon customer’s request. Furthermore, the winding method of slit tape can be selected record or traverse winding, as shown in Fig.3 or Fig.4 respectively.

The tape shown here uses PA6 as the resin, but it can be changed according to the characteristics required for the product, and the type of carbon fiber, thickness, and Vf (fiber volume fraction) can be also customized. The material design flexibility enables customers to achieve new solutions.

Cover picture (Fig. 1): Thin ply thermoplastic prepreg slit tape SHIMTEQ™ TP CA140ST – Shindo

In recent tests, the YangWang U9 reaches a top speed of 309.19 km/h and can sprint from 0 to 100 km/h in just 2.36 seconds, with 0-400 m acceleration in only 9.78 seconds. Besides, after rigorous track testing, the U9 has fine-tuned its thermal management system to better resist high temperatures, resulting in a 100% increase in maximum cooling capacity. The Blade Battery facilitates discharging and cooling functions and Dual Plug-in Ultra-fast charging technology boasts a maximum charging power of 500 kW. Additionally, YangWang U9 is equipped with 12 sets of active and passive aerodynamic packages to reduce drag coefficient and enhance heat dissipation efficiency.

The YangWang U9 boasts the “Super Carbon-Fiber Cabin, a structure made of different materials”, and the next-generation CTB technology. “And it contributes to unprecedented torsional stiffness of 54425N·m/deg and the single-side compressive load of the roof exceeds 11 tons, ensuring comprehensive travel safety“, says BYD.

The parties have agreed to customary exclusivity undertakings, while the parties finalize their discussions and Polyprocess consults with their employee representatives on the proposed transaction. The contemplated transaction is expected to sign and complete by the end of April 2024 and envisages also the transfer to the Polynt Group of Polyprocess’s production plant located in Saint-Jean-d’Illac, France.

Rosario Valido, Chief Executive Officer of the Polynt Group stated: “Polyprocess will complement the offering product portfolio of the Polynt Group.  The synergy of Polyprocess technology and experience combined with the innovation leadership of Polynt Group will contribute to the further growth in our industry, confirming our role of key-players in this industry”.

Matthieu Castet, manager GMV, GMV CEO of Polyprocess, added:  “This project will give a new dimension to Polyprocess, particularly worldwide. It allows us to secure supplies but also to continue to develop new ranges of products, combined with our recognized know-how and that of the Polynt Group, to maintain our high standards of quality and innovation for the coming years.”

Les parties se sont engagées à respecter les clauses d’exclusivité habituelles, en attendant de finaliser leurs discussions et de consulter les représentants du personnel de Polyprocess quant à l’opération envisagée. La réalisation de l’opération est prévue pour fin avril 2024 et implique également le transfert au groupe Polynt de l’usine de production de Polyprocess située à Saint-Jean-d’Illac, en France.

Rosario Valido, Directeur Général (Chief Executive Officer) du Groupe Polynt, a déclaré : « Polyprocess complétera le portefeuille de produits du Groupe Polynt.  La synergie entre les technologies et l’expérience de Polyprocess et le savoir-faire en matière d’innovation du groupe Polynt contribuera à la croissance de notre industrie, confirmant ainsi notre rôle d’acteurs clés dans ce secteur. »

Matthieu Castet, Président de Polyprocess, a ajouté : « Ce projet va donner une nouvelle dimension à Polyprocess, particulièrement au niveau mondial. Il nous permet de sécuriser nos approvisionnements mais aussi de continuer à développer de nouvelles gammes de produits, associées à notre savoir-faire reconnu et à celui du Groupe Polynt, afin de maintenir nos hauts standards de qualité et d’innovation pour les années à venir. »

This far-reaching transformation has led Plastic Omnium into becoming OPmobility. The new name  is an affirmation of its fundamental principles as an agile industrial Group, close to its customers  and taking bold technological choices to drive mobility. 

Conveying an optimistic vision of the future, OPmobility’s visual identity embodies the Group’s  historical roots, its values and its drive for continuous growth. Opened to all forms of mobilities,  OPmobility will continue to support their transition towards decarbonization. 

Laurent Burelle, Chairman of OPmobility, comments “Almost 80 years after its creation, OPmobility  marks a major milestone in the Group’s history. This name pays tribute to our past and our values,  while projecting us into the future. OPmobility accurately translates our profitable growth strategy  in sustainable mobility, bringing together our historic automotive activities and our technological  diversification, whether in electrification, hydrogen, lighting, or software“. 

“In recent years, the Group has undergone a deep transformation, expanding its activities  worldwide and diversifying its customer base, including newcomers in electric mobility. With this  new name, we are addressing all the players in sustainable mobility, in every geography. It is a  powerful brand name, synonymous with technological and industrial excellence for exploring new  horizons“, explains Laurent Favre, Chief Executive Officer of OPmobility. 

For Félicie Burelle, OPmobility’s Managing Director: “OPmobility is the affirmation of the vision of an  industrial Group valued by all our employee in the 28 countries in which we operate. By changing  its name while keeping its distinctive logo, the Group is building on its roots to accelerate into the  future. OPmobility expresses our ambition to play a key role in energy transition and the  transformation of mobility, in full alignment with our purpose: Driving a new generation of mobility“. 

Picture: OPmobility – Factory

La transformation de ses activités conduit naturellement Plastic Omnium à devenir aujourd’hui OPmobility. Ce nom réaffirme ses fondamentaux, ceux d’un Groupe industriel agile, proche de ses clients et qui prend des paris technologiques audacieux au service de la mobilité.

Porteuse d’une vision optimiste du futur, l’identité visuelle d’OPmobility incarne à la fois les racines du Groupe, ses valeurs et sa dynamique de croissance continue. Ouvert à toutes les mobilités, OPmobility est déterminé à accompagner leurs transitions sur la voie de la décarbonation.

Laurent Burelle, Président d’OPmobility, déclare : « Près de 80 ans après sa création, le Groupe franchit, avec OPmobility, une étape majeure de son histoire. Ce nom rend hommage à notre passé et à nos valeurs, tout en nous projetant dans l’avenir. OPmobility exprime avec justesse notre stratégie de croissance rentable dans la mobilité durable, en faisant la synthèse entre nos activités historiques dans l’automobile et notre diversification technologique, que ce soit dans l’électrification, l’hydrogène, l’éclairage ou encore les logiciels ».

« Ces dernières années, le Groupe a entrepris une vaste transformation en développant ses activités dans le monde entier et en diversifiant son portefeuille de clients, avec notamment les nouveaux entrants dans la mobilité électrique. À travers ce changement de nom, nous nous adressons à tous les acteurs de la mobilité durable, dans toutes les géographies. C’est une marque forte, porteuse d’excellence technologique et industrielle pour explorer de nouveaux horizons », explique Laurent Favre, Directeur Général d’OPmobility.

Pour Félicie Burelle, Directrice Générale Déléguée d’OPmobility : « OPmobility, c’est l’affirmation de la vision d’un Groupe industriel qui est cher à tous nos collaborateurs, dans les 28 pays dans lesquels nous sommes présents. En conservant son logo distinctif tout en changeant de nom, le Groupe prend appui sur ses origines pour se projeter dans l’avenir. OPmobility exprime notre ambition de jouer un rôle clef dans les transformations de la mobilité et dans la transition énergétique, en pleine résonance avec notre raison d’être, ‘Driving a new generation of mobility’ ».

Photo : OPmobility – Usine

The start of this first phase marks a solid step in the construction of Tianhe Group’s Guangdong project, and the completion of the project will further strengthen Tianhe Group’s development model to shine throughout the region. The group will use its research institute as an incubator to continuously consolidate its industrial base and deploy a comprehensive system around its production bases in Nantong and Lianyungang in Jiangsu province, in Zhejiang province and in Guangdong province.

The project includes an expansion of 1,300 square meters in a new energy-efficient building and represents a €10 million investment over the past 3 years. This project comes less than a year after inaugurating the “Dry Room” laboratory for lithium batteries, reaffirming the Bollate Research Center’s pivotal role in developing new applications for high-tech industries’ evolving needs.

It will enhance Syensqo’s offering of specialty polymers solutions that are crucial for green mobility, energy efficiency, sustainable sourcing, and more. The new laboratories also boost the research center’s scientific workforce by 30%.

The ADL research center in Bollate is working in close collaboration with Syensqo’s other application development labs all over the world, such as the ones in Alpharetta in the U.S, Seoul in Korea, Fuji in Japan, Shanghai in China and Brussels in Belgium. 

“Research and Innovation lies in Syensqo’s DNA with over 2.000 scientists working together worldwide. We are thrilled to inaugurate this new project, which is a concrete demonstration of our ambition to be the prime innovation partners of our customers. We want them to benefit from our innovation power and work hand in hand with them on the new technologies that will enable a more sustainable world.”, says Ilham Kadri, CEO of Syensqo.

“Our ADL is a network of professionals and state of the art R&I facilities leveraging local excellence to deliver sustainable global solutions.”, says Francesco Triulzi, Head of Application Development Labs Global.

Arkema fabrique ces produits oléochimiques biosourcés à Marseille en France et/ou à Singapour et les commercialise dans le monde entier dans diverses applications dont les lubrifiants, les produits cosmétiques et de soins, les arômes et les parfums.

Ils sont produits à partir de graines de ricin renouvelables, qui ne concurrencent pas les cultures destinées à l’alimentation (l’huile de ricin n’étant pas comestible), ne provoquent pas de déforestation et ont une empreinte carbone négative, c’est à dire qu’ ils consomment plus de CO₂ atmosphérique pendant la croissance des cultures que l’équivalent en CO₂ émis pendant la fabrication.

Cette certification a été attribuée après vérification du contenu biosourcé par un organisme tiers dans le cadre du Programme BioPreferred^® de l’USDA qui cherche à accroître le développement, l’achat et l’utilisation des produits biosourcés. Ces derniers contribuent à la lutte contre le changement climatique en offrant des substituts renouvelables aux produits à base de pétrole : ils piègent le dioxyde de carbone et réduisent ainsi la concentration des gaz à effet de serre dans l’atmosphère.

Le label de produit biosourcé certifié par l’USDA affiche le contenu biosourcé d’un produit, à savoir la part d’un produit provenant d’une source renouvelable, telles que des matières premières végétales, animales, marines ou forestières. L’utilisation de matériaux biosourcés renouvelables élimine le recours aux produits chimiques non-renouvelables issus du pétrole.

« Nous félicitons Arkema d’avoir obtenu le label de produits biosourcés certifiés par l’USDA », a déclaré Vernell Thompson du Programme BioPreferred^® de l’USDA. « Ce label vise à stimuler le développement économique, à générer de nouveaux emplois et à créer de nouveaux marchés pour les produits agricoles. En outre, le label permet aux consommateurs ainsi qu’aux acheteurs du gouvernement fédéral de trouver plus facilement des produits biosourcés et d’envisager des options plus respectueuses de la planète lors des décisions d’achat. Suite à la certification de l’USDA sur la teneur biosourcée de ses produits, Arkema se joint à une liste grandissante d’entreprises qui luttent contre les allégations marketing inexactes et la pratique de l’écoblanchiment, tout en contribuant à une bioéconomie prospère qui réduit notre dépendance au pétrole. »

Le Programme BioPreferred^® de l’USDA, conçu pour accroître le développement, l’achat et l’utilisation de produits biosourcés, a été introduit pour la première fois dans le cadre du Farm Bill [loi agricole] de 2002 avant d’être de nouveau autorisé en 2018. À ce titre, les agences et sous-traitants fédéraux sont tenus de privilégier les achats de produits biosourcés.

Photo en-tête : Arkema – Graines de ricin moyennes

“Today, XB-1 took flight in the same hallowed airspace where the Bell X-1 first broke the sound barrier in 1947,” said Blake Scholl, founder and CEO of Boom Supersonic. “I’ve been looking forward to this flight since founding Boom in 2014, and it marks the most significant milestone yet on our path to bring supersonic travel to passengers worldwide.” 

Flown by Chief Test Pilot Bill “Doc” Shoemaker, XB-1 took off from the Mojave Air & Space Port and flew in the same airspace that hosted many historic first flights, including the flights of the Bell X-1, the North American X-15, and the Lockheed SR-71 Blackbird.

“Everyone on the XB-1 team should be incredibly proud of this achievement,” said Bill “Doc” Shoemaker, Chief Test Pilot for Boom Supersonic. “It has been a privilege to share this journey with so many dedicated and talented professionals. The experience we have gained in reaching this milestone will be invaluable to Boom’s revival of supersonic travel.”

Test Pilot Tristan “Geppetto” Brandenburg flew the T-38 chase aircraft which monitored XB-1 in the air. Chase planes accompany new aircraft on their maiden flights to observe how the test plane is handling and verify things like altitude, airspeed, and airworthiness during flight.

“Being in the air with XB-1 during its maiden flight is a moment I will never forget,” said Boom Test Pilot Tristan “Geppetto” Brandenburg. “The team has been working hard to get to this point, and seeing today’s flight through mission completion is a huge accomplishment for all of us.”

XB-1 met all of its test objectives, including safely and successfully achieving an altitude of 7,120 feet and speeds up to 238 knots (273 mph). While XB-1 was in the air, the team performed an initial assessment of the aircraft’s handling qualities, including airspeed checks with the T-38 chase aircraft, and assessing the aircraft’s stability in the landing attitude (at a high angle of attack).

Two decades after Concorde’s retirement, the first flight of XB-1 marks the return of a civil supersonic aircraft to the skies and paves the way for the revival of mainstream supersonic travel onboard Overture, Boom’s sustainable supersonic airliner. 

The XB-1 program provides the foundation for Overture’s design and development, while establishing a safety-first culture in engineering and manufacturing. XB-1 validates key technologies and Boom’s own innovations, including:

• An Augmented reality vision system
• Digitally-optimized aerodynamics
• Carbon fiber composites: XB-1 is almost entirely made from carbon fiber composite materials, enabling it to realize a sophisticated aerodynamic design in a strong, lightweight structure
• Supersonic intakes

It is fitting that XB-1 took off for the first time from the Mojave Air & Space Port, in airspace known as the home of many firsts in the world of aviation and aerospace. This region in the Mojave Desert is the proving grounds for the aerospace industry, where an aircraft broke the sound barrier for the first time in 1947 and where speed and altitude records are set.

Now that XB-1 has successfully completed its first flight, the team will systematically expand the flight envelope to confirm its performance and handling qualities through and beyond Mach 1. When XB-1 is ready for its first supersonic flight, Test Pilot Tristan “Geppetto” Brandenberg will be at the controls.

The inaugural flight of XB-1 takes place as Overture continues to advance toward production, with a growing global network of Tier 1 suppliers and an order book including 130 orders and pre-orders from American Airlines, United Airlines, and Japan Airlines. 

The latest generations of supercars are becoming increasingly high-performing

“The new Artura is absolutely the complete next-generation supercar, whichever model you choose. We have upgraded the powertrain and the chassis systems to deliver more power, more dynamic performance and even higher levels of connection with the driver – without any compromise in everyday driving. And now alongside the new Artura coupe we have the Artura Spider, a new convertible that has all of these improvements and brings another dimension of open-air McLaren supercar exhilaration to our range”, underlines Michael Leiters, CEO, McLaren Automotive.

McLaren knows how to make the most of carbon fiber

It’s part of McLaren’s DNA, but weight reduction was one of the priorities in the Artura’s specifications, particularly for the wiring, reduced by 25%, and for the retractable roof, a crucial module for a spider. « The new Artura Spider has a dry weight of just 1,457 kg, with a curb weight (DIN) of only 1,560 kg, just 62 kg more than the Artura Coupé. These figures make the new Spider the lightest vehicle among its convertible competitors, by 83 kg », highlights a spokesman for the group, emphasizing that the Artura Spider is based on the McLaren Carbon Lightweight Architecture (MCLA). The engine and battery pack are positioned at the rear of the vehicle, mounted on a carbon fibre floor.

The retractable hard top (RHT) in composites is truly impressive

As a central element for a convertible vehicle, the RHT is a showcase of high technology. Firstly, the complete structure of the roof in composites, along with its mechanism and eight small electric motors, which are very silent by the way, adds only 62 kg compared to the Coupé version! Secondly, this retractable hard top deploys or retracts in just 11 seconds. « Furthermore, the shape of the roof has been designed to channel air towards the outlet, known as the « chimney », specially repositioned to accelerate the flow of hot air from the powertrain », concludes a spokesperson for the group, noting that the first deliveries of the Artura Spider are expected in mid-2024. In the United States, the supercar is offered in standard version at $273,800. In France, it starts from €272,250.

Cover picture: A new laboratory for lightweighting, the McLaren Artura Spider leverages the full potential of carbon fibre. – All pictures: McLaren

A first drawing shows the ” slim part” of the new innovation and seminar complex (on the right) at BYK in Wesel. In the planning, particular importance is being attached to efficient energy consumption. Heating and cooling, for instance, will be entirely fueled by heat pumps and photovoltaic systems. “With regard to sustainability, safeguarding the future, and ecology, we wish to equip the building – and further adjacent laboratory buildings – with heat recovery, as well as meeting the full energy needs of this new innovations construction with 100 percent renewable energies,” Dr. Jörg Hinnerwisch continued. Added to which, sustainable materials will be deployed throughout the entire project.

An old laboratory building will make way for the approximately 47 x 18 x 14.5 meters construction with a total area of 5,100 square meters so that it can be fully integrated into the existing structure at the BYK campus in Wesel. BYK Marketing & Commercial Managing Director Dr. Stefan Mößmer: “This will be of especial benefit to our customers who seek to develop their project solutions here on site with BYK experts. It was therefore logical to plan a further story where we will soon be able to host customer events, visits, and seminars. At around 25 million euros construction costs, a particular intention of the innovation complex is to provide modern, state-of-the-art laboratories for the BYK end uses while at the same time allowing more breathing space for existing end use, applications labs, and R&D facilities.” BYK estimates a total project implementation period of around four years. Completion is envisaged in the second quarter of 2028.

Picture : BYK – A first drawing shows the ” slim part” of the new innovation and seminar complex (on the right) at BYK in Wesel.

During the inauguration ceremony attended by Mr. Tatsuo Igarashi, mayor of Tsukuba City, the EH216-S pilotless eVTOL completed its first flight in the Kanto region for aerial sightseeing.

The establishment of the UAM Center is the result of a strategic partnership between EHang and AirX Inc. (AirX), a Japanese air mobility digital platform company. Situated on the site of the former Helicopter Control and Command Center owned by Ibaraki Prefectural Government, the UAM Center houses hangars with capacity for approximately 25 units of EH216-S aircraft. The shared landing platform, used by both helicopters and eVTOLs, covers an area of around 30,000 square meters. Developed by AirX in collaboration with Tsukuba Airlines, the UAM Center is designed to meet the evolving needs of next-generation air mobility that encompasses pilotless eVTOL aircraft, helicopters and private jets.

EHang has been actively expanding its presence in the global market. To date, the EH216-S pilotless eVTOL aircraft has conducted flights across 12 cities in Japan, showcasing its versatility in various use cases, including aerial sightseeing, island transportation, aerial logistics, and emergency services.

In 2023, EHang became a member of Japan’s Public-Private Committee for Advanced Air Mobility. This recognition underscores EHang’s pivotal role in driving the advancement of Japan’s innovative air transportation initiatives, particularly as the unique pilotless eVTOL provider among the 56 committee members.

Tezuka Kiwamu, founder and CEO of AirX, commented, “Through the establishment of this UAM Center, our goal is to showcase air mobility flight experiences to the public. In the future, we plan to offer aerial sightseeing services with the cutting-edge EH216-S eVTOL aircraft at this location. Looking ahead, AirX is gearing up to launch additional UAM Centers in Tokyo, solidifying our commitment to spearheading the development of UAM and transforming the future of transportation in Japan.”

Huazhi Hu, founder, chairman, and CEO of EHang, remarked, “Congratulations on the inauguration of Japan’s first UAM Center. This is a key milestone in UAM, bringing us one step closer to introducing a new era of transportation to the public. EHang will continue collaborating with our partners in promoting safe, autonomous, and environmentally friendly UAM solutions in Japan, as we aim to offer our pilotless eVTOLs to a global audience and enhance the lives of people worldwide.”

The fuselage of the EH216-S is made of carbon fiber composite.

“EzCiclo” was invented in 2021 and solved the problem of non-recyclability of thermosetting epoxy resin since its invention in 1935, according to Swancor. It has also dispelled the negative stigma surrounding FRP or composite materials, once viewed as a “necessary evil”. Currently, EzCiclo recyclable products in commercial circulation include 100-meter wind turbine blades, carbon fiber bicycles, and shoe materials. Products undergoing testing encompass dry-type transformers, copper clad laminate (CCL), and EMC packaging materials.

Swancor is committed to further promoting the application of “EzCiclo” across various industries, and pledges to collaborate closely with its partners to advance the cause of sustainable development on the planet.

Picture: Swancor

In 2023, RUAG International transformed itself into a space market-focused international supplier by selling its aerostructures business. The financial year was characterized by an inflationary market environment and strained supply chains. At the same time, investments were made in the expansion of production and the digital future of the space business. Adjusted for divestment and foreign currency effects, sales increased by CHF 62 million compared to the previous year. Reported earnings before interest and taxes (EBIT) amounted to CHF 28 million.

Due to substantial company divestments in 2023 and 2022 (including RUAG Ammotec), the key figures can only be compared to a limited extent. However, they reflect the continuous progress of the divestment strategy adopted jointly with the owner, the Swiss Confederation. The number of employees fell accordingly from 2,963 to 1,989 worldwide. Net sales, 96% of which came from civil activities, fell to CHF 620 million (previous year CHF 945 million) and EBIT to CHF 28 million (CHF 178 million). Adjusted for divestment and foreign currency effects, sales increased by CHF 62 million compared to the previous year.

Space business on a growth track

The Space segment (Beyond Gravity), with around 1,600 employees, increased sales by 8 per cent to CHF 383 million (previous year: CHF 356 million). Despite massive investments in the expansion of production and digital infrastructure, EBIT recovered from CHF -5 million to a black zero (CHF 0 million), thus laying the foundation for profitable growth. At CHF 408 million (CHF 439 million) and CHF 729 million (CHF 744 million) respectively, order intake and order backlog remain at a very high level. André Wall concludes: “Beyond Gravity can proudly point to full order books. This underlines the company’s strong position as a key player in the global space market.”

Aerostructures business successfully sold

With the sale of the entire Aerostructures segment, RUAG International has reached an important milestone: all shares and around 1,000 employees of RUAG Aerostructures Germany & Hungary have been transferred to the German family-owned company Mubea, while Pilatus Aircraft Ltd has taken over all machines and 230 employees of RUAG Aerostructures Switzerland. RUAG Aerostructures Switzerland AG will continue to exist as a company for the time being and will finalize existing customer commitments with non-Pilatus customers. Another divestment related to the sale of the company site in Zurich-Seebach to the City of Zurich, with RUAG International leasing the site back until at least 2030.

In the Aerostructures segment, which employed a good 1,300 people, sales increased to CHF 240 million in 2023 (previous year: CHF 235 million). However, EBIT fell significantly from CHF 43 million to CHF -17 million. The result suffered from delays in international supply chains, changing customer requirements and production volumes as well as extraordinary expenses in connection with the divestment projects. The reversal of provisions and value adjustments in 2022 must also be taken into account.

Transforming into a genuine space company

André Wall, CEO RUAG International, looks back on another successful and eventful financial year: “With the further completion of the privatization, we continue our course towards a promising future and look forward to reaching the next milestones in space research and development. The focus is now on exploiting the opportunities in the expanding space market. I see us as pioneers in innovative technologies and services. Our aim is to push the boundaries of what is possible and realize pioneering projects in space together with our customers. I am confident that this strategic realignment and our investments in modern production facilities and development processes will help to drive growth in the space market even faster while ensuring the success and sustainability of the company.”

Expanding the production sites in the USA and Sweden

Following the major order from Amazon in 2021 for the production of satellite dispensers and launch vehicle structures for the Kuiper satellite project, the production sites in Linköping (Sweden) and Decatur (USA) are being massively expanded and modernized. In Linköping, the company will rely on automated manufacturing processes (“Automated Fibre Placement” technology) in the new production building. In Decatur, where payload fairings for the Vulcan Centaur launch vehicle are manufactured, a new facility with an annual production capacity of 25 payload fairings (50 half-shells) is being built. This corresponds to twice the capacity of the current plant. The opening of both plants is already planned for 2024.

Investing in the digital future

RUAG International invested heavily in the digital transformation of the Space division during the reporting period. The “EZYone” project aims to build a strong digital core for Beyond Gravity, harmonize processes, create a solid database, and implement a uniform system landscape. These measures will enable smooth collaboration across different locations, promote faster innovation cycles, reduce administrative costs, and lay the foundations for the increased use of artificial intelligence, augmented reality and other forward-looking technologies.

Outlook

Strong growth in both the institutional and private space market is expected to continue in the coming years. With the ramp-up of the new production capacities in Decatur and Linköping and the gradual rollout of “EZYone” from 2024, Beyond Gravity will have a powerful basis for profitably capitalizing on the expected growth in the industry. Even in view of the privatization of Beyond Gravity by the end of 2025 at the latest, RUAG International’s focus remains on systematically continuing the transformation of all business areas into digitally networked and economically viable units.

Picture: RUAG

Une expertise et un outillage de pointe recherchés

« Dans un premier temps, nous avons réalisé le moule sur le site de Lorient avec un suivi très particulier concernant les contrôles géométriques. Ensuite, nous avons commencé le drapage sur le site de Port-la-Forêt avec une extrême précaution dans le découpage des opérations », détaille Stéphane Digard, le Directeur Général de CDK Technologies, dont les équipes, sous la responsabilité de Michel Ollivier, ont, une nouvelle fois, réalisé un véritable travail d’orfèvre, mettant à profit leur expertise ainsi que leurs outils, et en particulier l’autoclave classe 120° / 6 bars, d’une longueur de 50 mètres et d’un diamètre de 1,80 mètre.

« Ce tube long – l’un des plus grands d’Europe – fait partie de l’outillage de pointe dont dispose CDK Technologies et qui nous permet de produire des pièces composites hautes performances de très grandes tailles et de faire des cuissons dans les règles de l’art sur des éléments hors-normes », poursuit-il. Les équipes de CDK Technologies ont naturellement dû respecter un certain nombre de paramètres afin de répondre aux critères de jauge de l’America’s Cup. « Historiquement, les mâts des bateaux de la Coupe sont conçut en Nouvelle-Zélande. C’est aujourd’hui la première fois qu’un espar destiné à cette compétition est réalisé dans un chantier en Europe et c’est une grande marque de confiance pour CDK Technologies », ajoute Stéphane Digard.

La confiance au cœur du projet

« Notre politique de transparence absolue et notre système qualité robuste représentent assurément de forts atouts. Nous cherchons perpétuellement à faire les choses le plus rigoureusement possible. Des soins extrêmes ont été apportés à chacune des étapes de la construction, mais finalement, ce que nous avons fait pour l’équipe britannique correspond à nos standards habituels d’exigence, même si certains matériaux utilisés ont forcément été un peu plus délicats en termes de mise en œuvre », souligne le dirigeant du chantier breton, qui a travaillé main dans la main avec les membres de INEOS Britannia, présents dans les locaux depuis le lancement du projet. « Nous avons véritablement œuvré en bonne intelligence », conclue Michel Ollivier qui, après la livraison de ce premier mât ce lundi 26 février, doit en fournir un second, parfaitement identique, à l’équipe britannique.

Apart from a few types of cement, carbon-negative composites are scarce, according to David Heldebrant, an organic chemist who is one of the project’s principal investigators. The composite decking his team has developed “is one of the first composite materials to be demonstrably CO₂ negative over its life cycle,” he says.

The materials and processes that go into constructing buildings account for 11% of all energy-related carbon emissions, according to the World Green Building Council. Significant efforts have gone into developing building supplies that can offset these emissions, such as using recycled or plant-derived products. However, in many cases, these sustainable alternatives are more expensive than traditional materials or can’t match their properties, such as strength or durability.

One type of construction material — decking — is a multibillion-dollar industry. Decking boards made from a wood plastic composite are a popular alternative to lumber boards because they are less prone to damage from ultraviolet radiation and can last longer. Composite decking is typically made from a blend of wood chips or sawdust and plastic, such as high-density polyethylene (HDPE). To make these composites more sustainable, one alternative is to use fillers that are waste products or would otherwise be burned.

Composite decking material, such as boards used to make this deck, may one day be carbon negative and less expensive than traditional materials.

That’s an approach Heldebrant’s colleague Keerti Kappagantula was taking: using low-quality brown coal and lignin, a wood-derived product left over from papermaking, as the filler in decking composites. To make the pulverized coal and lignin particles mix with and stick to plastics, the research team needed to add ester functional groups to the particles’ surfaces. Heldebrant, who works at Pacific Northwest National Laboratory (PNNL) and develops specialized liquids to capture CO₂, found out about this work while chatting over coffee with Kappagantula.

Satish Nune, another project investigator, and Heldebrant were excited when they heard about this. “Esters are essentially carboxylic acids, which are a captured form of CO₂,” Heldebrant explains. So, the team wanted to do the same thing and put CO₂ onto the surface of the particles in the composite to make the material even more environmentally friendly while improving the composites’ mechanical performance.

To test the feasibility of this approach, the team turned to a classic chemical reaction to form a new chemical bond between CO₂ and a functional group called a phenol, which is abundant in wood products like coal and lignin. After undergoing the reaction, the lignin and coal particles contained 2–5% CO₂ by weight.

The team then mixed varying ratios of these particles with HDPE to form brownish-black composites, and they tested the resulting properties. A composite containing 80% filler maximized the amount of CO₂ content while demonstrating strength and durability that meet international building codes for decking materials. It was manufactured via friction extrusion using PNNL’s shear assisted processing and extrusion (ShAPE^TM) machine. The researchers used this material to form 10-foot-long composites that look and feel similar to any standard wood composites found in decking or lawn furniture.

In addition to their favorable physical properties, the new composite boards offer a substantial price and sustainability advantage. They are 18% cheaper than standard decking composite boards. They also store more CO₂ than is released during their manufacture and lifetime, Heldebrant says. If the 3.55 billion feet of decking sold in the U.S. every year were replaced with the researchers’ CO₂-negative composite decking, he says, 250,000 tons of CO₂ could be sequestered annually, which is equivalent to the yearly emissions from 54,000 cars.

Next, the researchers plan to make additional composite formulations and test the properties. They envision that carbon-negative composites could be developed for a range of building materials, such as fencing and siding. In the meantime, the team is working to commercialize its decking boards. This new carbon-negative decking could be available at building supply retailers as soon as next summer.

The research was funded by the United States Department of Energy Office of Fossil Energy and Carbon Management (FWP 78606) and the Southern California Gas Company (SoCalGas).

Picture: Sleigh by Design/Shutterstock.com – Composite decking material, such as boards used to make this deck, may one day be carbon negative and less expensive than traditional materials.

Prior to joining ASK Chemicals, Luiz Totti worked at renowned companies such as Akzo Nobel and PPG, where he held various leadership positions.

Totti’s appointment is a strategic decision by ASK Chemicals to leverage his extensive experience and innovative vision to drive sustainable growth and strengthen the company’s leadership position in its markets.

The Board of Directors and the entire ASK Chemicals team warmly welcome Luiz Totti in his new role as CEO of the group and look forward to achieving new milestones and creating sustainable value for all stakeholders.

Dans le cadre de cette mission lunaire, Stratasys fournira des échantillons imprimés en 3D qui seront acheminés jusqu’à la surface lunaire par un atterrisseur sans pilote dans une structure porteuse imprimée en 3D par Stratasys. Trois matériaux feront l’objet de deux expérimentations différentes menées par Northrop Grumman.

La première expérimentation cherchera à évaluer les performances d’un échantillon imprimé en filament Antero^® 800NA FDM^® de Stratasys renforcé de tungstène. L’Antero 800NA est un thermoplastique haute performance à base de PEKK possédant d’excellentes propriétés mécaniques, une grande résistance chimique et de faibles niveaux de dégazage. L’ajout de tungstène vise à fournir une protection contre les rayonnements nocifs, notamment les rayons gamma et les rayons X.

La deuxième expérimentation passive est conçue pour évaluer le comportement de certains matériaux d’impression 3D dans l’espace. Parmi ceux-ci se trouve le filament Antero 840CN03 FDM, compatible avec les composants électroniques en raison de ses propriétés ESD, et qui a été utilisé sur le vaisseau spatial Orion. L’expérimentation portera également sur un nouveau photopolymère ESD fabriqué par Henkel, partenaire de Stratasys, destiné à être utilisé avec les imprimantes 3D Origin^® One de Stratasys et conçu pour les environnements à haute température. Les échantillons de matériaux d’impression 3D seront exposés à la poussière lunaire, ainsi qu’aux basses pressions susceptibles de provoquer un dégazage et aux variations rapides de température résultant de la quasi-absence d’atmosphère sur la Lune.

« La fabrication additive est une technologie importante pour les missions spatiales, où chaque gramme compte et où une haute performance est essentielle, a déclaré Rich Garrity, directeur des affaires industrielles. Cette série d’expérimentations nous aidera à comprendre comment tirer pleinement parti de l’impression 3D pour assurer la sécurité des personnes et des équipements lors de nos voyages sur la Lune et au-delà. » 

Les pièces seront acheminées jusqu’à la surface lunaire par un atterrisseur sans pilote dans une structure porteuse imprimée en 3D par Stratasys dans un thermoplastique ULTEM™ 9085, un matériau couramment utilisé dans les intérieurs d’avions commerciaux.

Photo en-tête : Stratasys – Boîtier d’expérimentation sur les rayonnements imprimé en Antero 840CN03 FDM® de Stratasys pourvu d’un couvercle rouge en ULTEM 9085 de Stratasys portant la mention « Remove Before Flight » (Retirer avant le vol), destiné à protéger les échantillons de test pendant leur transport vers la Lune et à permettre leur installation à la surface du satellite.

Zund Australia is under the leadership of Managing Director Dale Hawkins: “Being associated with the Zund products in Australia for 15 years I am excited to head up Zund Australia. We are currently in the process of establishing a team of highly experienced technical personnel along with a new headquarters in Melbourne.”

With Zund Australia, the Swiss company will further strengthen its market position in Australia and open new areas of application in the medium term.

Oliver Zünd, CEO of Zünd Systemtechnik AG: “With Zund Australia, we can support our existing and new customers directly and competently. The close cooperation with the new branch allows us to strengthen our market position in Australia. Zund Australia enables us to continue to offer our Australian customers the best possible care in the long term. The team on site has a lot of experience with our cutting solutions. This will enable us to further improve advice and customer service.”

Toute son activité repose sur un savoir-faire “français” et professionnel depuis 20 ans.

A Unified Vision for Enhanced Customer Solutions

Adam Fenton, CEO of National Composites, expressed enthusiasm about the new addition to the company portfolio: “We are excited to welcome Northern Plastics into the National Composites Family. This acquisition strategically increases our capacity and capability within the Thermo/Vacuumform plastic market, providing our customers with a one-stop shop solution, even beyond composites.”

Expanding Horizons In Thermoplastics

The acquisition is seen as a complementary expansion of National Composites’ existing expertise in composites and metals. “Thermoform plastics is a great complement to our current offering. Although thermoforming is a core competency of ours, the addition of Northern Plastics is just the first of many planned expansions into the thermoplastics space,” Fenton added.

Strategically Broadening Capabilities

National Composites is recognized for its commitment to growth and innovation, as demonstrated in its recent strategic partnership with Laval, a premier North American compression mold maker. This new acquisition of Northern Plastics further solidifies National Composites’ dedication to providing comprehensive solutions and staying ahead of industry demands. Northern Plastics brings to National Composites a wealth of experience and a strong market position in the Thermo/Vacuumform plastic domain, enhancing the combined entity’s offerings to a diverse customer base. This acquisition is a clear signal of National Composites’ forward-thinking approach and unwavering focus on customer-centric services and quality products. With this expansion, National Composites reinforces its mission to deliver comprehensive solutions from initial design to final delivery, ensuring a seamless experience for all stakeholders involved.

Nick Smith, Technical Director at SHD Composites talks us through his insights on bringing sustainable solutions into this sector. “Pressure is on the automotive industry from multiple angles to measure and improve all aspects of sustainability over the whole life of vehicles from manufacture to end of life and onwards to the next generation of vehicles by recycling materials for reuse.

Lightweight and high-strength composites

The automotive industry has long recognized the importance of lightweight materials for improving fuel efficiency and reducing emissions. Green technologies have ushered in a new era of lightweight and high-strength composite materials that replace traditional materials like steel and aluminium.

Carbon fibre-reinforced composites, for instance, are being increasingly used in the construction of vehicle components, including body panels, chassis, and interiors. These materials offer a remarkable strength-to-weight ratio, enhancing both fuel efficiency and overall performance.

Sustainable composite materials

Traditional automotive materials, such as fiberglass and certain plastics, can have significant environmental drawbacks. Green technologies have introduced sustainable composite materials derived from renewable resources like natural fibres, biopolymers, and recycled composites.

Manufacturers are now incorporating materials like flax, hemp, and recycled plastics into composites for various automotive applications. This shift not only reduces the reliance on non-renewable resources but also minimizes the carbon footprint associated with vehicle production.

Smith said: “Flax fibres are a valuable tool in CO2 reduction. Flax sequesters CO2 from the atmosphere hence the material is carbon negative before processing. For non-structural parts, flax is also less dense than carbon or glass so for a like-for like thickness, the use of flax will reduce weight. For structural parts, intelligent design and hybrid structures can yield equivalent mechanical properties with a much reduce CO2 burden.”

Recycled and recyclable composites

The automotive industry is increasingly adopting circular economy principles by incorporating recycled and recyclable composites into vehicle design. Post-consumer recycled materials, including recycled carbon fibre and plastics, are being used in the manufacturing of automotive components.

Recyclable composites enable easier end-of-life vehicle disposal and reduce the overall environmental impact of the automotive industry. This approach aligns with the growing emphasis on sustainability and resource conservation.

“At SHD, when developing materials for sustainability, every effort is taken to consider sources of environmental impact in the manufacture and use of the product,” says Smith.

“For example, not only the use of natural fibres such as flax and the use of bio-based resins but also modification of the formulation to remove the need for frozen storage and optimisation of the material to use without an autoclave. Also, the reduction of packaging material and use of recycled materials has an impact that needs to be accounted for.”

Green resins and binders

The resins and binders used in composite manufacturing have traditionally been petroleum-based, contributing to environmental concerns. Green technologies have introduced bio-based resins derived from plant-based sources, such as soybeans and corn, as well as eco-friendly binders.

These sustainable alternatives not only exhibit similar mechanical properties to traditional resins but also reduce the carbon footprint of composite production. Green resins contribute to a more environmentally friendly manufacturing process without compromising the performance of composite materials.

Energy-efficient manufacturing processes

Green technologies are not limited to material composition; they extend to the manufacturing processes themselves. Advanced techniques such as automated manufacturing, 3D printing, and innovative curing methods are reducing energy consumption and waste in the production of composite automotive components.

These energy-efficient processes not only contribute to environmental sustainability but also lead to cost savings for manufacturers. As the automotive industry adopts these technologies, the overall ecological impact of vehicle production is diminished.

Driving to a green future

As consumers and regulatory bodies increasingly prioritize sustainability, automakers are under pressure to adopt green technologies in their manufacturing processes. The progress in the use of green technologies in composites for the automotive industry not only aligns with these evolving expectations but also paves the way for a more eco-friendly, efficient, and innovative automotive sector.

Smith says: “Achieving a sustainable vehicle build requires a holistic approach. Simply swapping synthetic composites for a green equivalent will not yield true sustainability.

“All aspects of the life cycle of the selected materials must be considered before selecting material along with the mechanical performance, durability, weight and recyclability. Only a design considering all of these aspects will deliver a truly sustainable design”

The integration of green technologies into composites for the automotive industry represents a pivotal step toward a more sustainable and environmentally conscious future. From lightweight and high-strength materials to sustainable composites, recycled content, green resins, and energy-efficient manufacturing, these advancements are reshaping the automotive landscape.

The paper, Network structure enabling re-use and near full property retention in CNT sheets recycled from thermoset composites, was recently published in a special issue of prestigious journal Carbon.

It represents a significant advance in the field of sustainable nanostructured materials and in the viability of fibres, sheets, and textiles made of carbon nanotubes to play a key role in the future green energy transition.

“This research represents a crucial step towards manufacturing and usage of sustainable and recyclable CNT fibres and sheets,” explained Dr. Anastasiia Mikhalchan, Senior Research Associate at IMDEA Materials and Co-PI of the project.

“These will be able to displace widespread CO₂-intensive materials, such as conventional carbon fibres and some metals like copper, decreasing our future CO₂ emissions footprint”.

“Our work demonstrates that high-performance materials made from carbon nanotubes are recyclable and can be reused in the same application as structural reinforcement or electrical conductors. This is due to the fact that neither their continuity, alignment and mechanical properties nor their conductivity is affected by recycling”.

“This is the first attempt in this direction, addressing a critical need in the society,” she added.

The work utilizes carbon nanotubes that are rapidly grown and directly assembled into freestanding network materials by means of floating catalyst chemical vapour deposition (FCCVD) synthesis process.

IMDEA Materials Institute is one of the world leaders in the field and is currently the only research centre in the European Union capable of synthesising high-quality nanotube macromaterials.

These CNT fibres and sheets possess high structural toughness and flexibility as well as high mechanical, electrical and thermal properties. This enables their usage in structural reinforcement in composite laminates, as well as printable strain/stress sensors, electrical conductors, and flexible battery anodes, among other applications.

In addition to the demonstrated recyclability in the macroscopic sheet-format, the researchers envision the future possibility of next-level disintegration of the recycled sheets to their building blocks – CNTs – in liquid crystalline solutions, which could then be re-spun into a new high-quality fibre.

“This prospective is similar to breaking down a LEGO model into its individual bricks, and then re-building the original model with the same shape, robustness, and quality,” explained Dr. Mikhalchan.

“This is never possible with conventional carbon fibres because their crystalline structure is formed by fused crystallites in the graphitisation process, so they cannot be “broken down” into individual crystallites and re-graphitized again into a continuous fibre filament”.

“In contrast, carbon nanotubes are capable of dissolution in superacids and can be re-spun into a fibre, which is a matter of future confirmation”.  

This pioneering work is supported by the Rice University-led Carbon Hub Initiative. IMDEA Materials’ Multifunctional Nanocomposite research group, led by Dr Juan J. Vilatela, is an active member of the initiative, alongside some of the world’s most prestigious research institutions such as the University of Cambridge, Stanford University, Georgia Tech, and MIT.

Carbon Hub is targeting a zero emission future, and together with the stakeholders from the oil&gas industry, pursue the new paradigm of sustainable co-production of clean hydrogen and advanced carbon nanostructured materials from natural gas and oil.

Instead of burning hydrocarbons to generate energy while releasing gigatons of CO₂ into the atmosphere, the Initiative proposes the innovative transformation of hydrocarbons into high-performance value added nanocarbons (such as CNT fibres and sheets) with cogenerating net clean energy as (turquoise) hydrogen.

Presently, the world’s CNT production capacity is in the order of 10 kt/year, a rate which is increasing at roughly 30% annually. However, this could accelerate to the megatone scale if the Carbon Hub efforts are successful and nanocarbons start displacing metals.

The work demonstrated by IMDEA Materials researchers is another milestone in this trajectory, confirming that value-added carbon nanotube materials are, by their nature, recyclable and can be re-used in the same application.

Their network structure and inherent toughness, similar to ductile polymers, makes them extremely tolerant to defects and therefore suitable for re-use and re-processing as high added value materials.

“Even three years ago, there was little interest in recycling CNT-based materials, but now it is becoming a far more relevant topic”, Dr. Mikhalchan stated. “We believe our research will stimulate the scale-up of manufacturing high-performance CNT materials and their faster adoption by industry, knowing that such materials offer sustainability and recyclability and are capable of reducing component weight and industry’s CO₂ footprint”.

Those behind the recent breakthrough, alongside Dr. Mikhalchan, include former IMDEA Materials intern Sergio Ramos Lozano, IMDEA Materials PhD student Dr. Andrea Fernández Gorgojo, Prof. Carlos González and Dr. Vilatela.

Recycling is recognised in the UN’s Sustainable Development Goals 2030. Each year the « Seventh Resource » (recyclables) saves over 700 million tonnes in CO2 emissions and this is projected to increase to 1 billion tons by 2030. Needless to say, this is one of the cornerstones of the circular economy.

The young composite materials industry, poised for sustained growth in the coming years, has embraced this challenge in recent years, as seen in sectors like boating, for example. Despite technical difficulties that may need to be overcome, market players in the composites industry are organising themselves and initiating numerous efforts to standardise recycling and scale it up, while also exploring the potential of upcycling and reuse.

To celebrate Global Recycling Day, the JEC teams present a selection of interesting projects and actions that offer new and inspiring perspectives for the future.

Biobased composite bodywork vehicle wins Africa Eco Race 2024

The 15th edition of Africa Eco Race (AER) ended on January 14th in Dakar, and was the inaugural race of APH-01 vehicles, the new-generation hybrid and sustainable side-by-side vehicles (SSV) developed by Apache Automotive (Belgium), subsidiary of GCK Performance (Auvergne, France). Due to strong weight limitations and its environmental-friendly approach, APACHE Automotive was aiming for bio-based composite-based bodyworks, and thus chose to collaborate with VESO Concept (Occitanie, France). Once the design of the bodywork parts validated, APACHE Automotive put a total trust in VESO Concept for the part prototyping and production : reinforcements, polymers and processes have been defined by the VESO Concept team using an eco-conception approach, to finally deliver a first prototype and two bodyworks in one year.
More information: www.veso-concept.com

ORNL develops a new process which allows full recovery of starting materials from tough polymer composites

In a win for chemistry, inventors at the Department of Energy’s Oak Ridge National Laboratory have designed a closed-loop path for synthesizing an exceptionally tough carbon-fibre-reinforced polymer, or CFRP, and later recovering all of its starting materials. A lightweight, strong and tough composite material, CFRP is useful for reducing weight and increasing fuel efficiency of automobiles, airplanes and spacecraft. However, conventional CFRPs are difficult to recycle. Most have been single-use materials, so their carbon footprint is significant. By contrast, ORNL’s closed-loop technology, which is published in Cell Reports Physical Science, accelerates addressing that grand challenge.
More information: www.extracthive-industry.com

JEC Composites Magazine Special Issue: Composites Sustainability

JEC Composites Magazine editorial team produces every autumn: the Composites Sustainability Report. Compiling highlights about the part composite materials are playing in creating the sustainable European economy of the future. The purpose of this annual work, rather than results, which quickly become obsolete, is to give examples of approaches contributing to and moving towards sustainability. In the past, JEC Group published special issues about end users industries such as smarter cities, mobility, sports, health, and leisure, all these issues being available to all JEC Composites Magazine subscribers.
More information: www.jeccomposites.com

Xenia® Materials unveils XEGREEN® 23-C20-3DP: 100% recycled PET-G carbon fibre reinforced grade for high-performance additive manufacturing

Xenia® Materials, global player in high-performance fibre-reinforced thermoplastic composites production, proudly announces the debut of XEGREEN® 23-C20-3DP at JEC World 2024. This innovative material marks a significant leap in additive manufacturing, bringing forth unmatched performance, sustainability, and versatility. XEGREEN® 23-C20-3DP, a PET-G (polyethylene terephthalate glycol-modified) with 20% carbon fibre reinforcement, represents a meticulous engineering effort to meet the demands of applications requiring superior strength, minimal warpage, and environmental responsibility.
More information: www.xeniamaterials.com

IMT Nord Europe receives €10 million to complete the ECOHYDRO project

IMT Nord Europe announces that it has received a €10 million grant from the European Commission to implement the Economic Manufacturing Process of Recyclable Composite Materials for Durable Hydrogen Storage (ECOHYDRO) project. Funded as part of the HORIZON EUROPE funding program for research and innovation for a four-year period, this international project aims to develop a new recyclable thermoplastic resin with specific functionalities (self-repairability, fire resistance), a new, more cost-effective filament winding process to manufacture hydrogen tanks, digital models to predict the residual life of tanks using Structural Health Monitoring technology via built-in sensors and artificial intelligence algorithms and new composite recycling technology to recover carbon fibers from tanks at the end-of-life and reuse them to manufacture new parts.
More information: www.imt-nord-europe.fr

Acciona Energía highlights the recycling of composites

At the end of 2023, the Spanish group drew attention to composite material recycling in a unique way. They collaborated with the brand El Ganso to develop sneakers made largely from recycled wind turbine blades. Through an innovative process of reducing glass and carbon fibres and epoxy resins, a powder is obtained and combined with rubber to create a shoe sole. The sneakers branded El Ganso feature the graphic symbol of a wind turbine. The shoes are derived from a 23-meter-long wind turbine blade from the Aibar wind farm in the Navarre region of Spain. This blade has been in service since 1998, producing an estimated 12,500 MWh.
More information: www.acciona-energia.com

JEC Composites Innovation Awards 2024: here are the 11 winners

Annually, the JEC Composites Innovation Awards recognize successful initiatives and collaborative efforts within the composites industry. Over the past 26 years, the program has engaged over 2,000 companies globally, honoring 225 companies and 573 partners for their outstanding achievements in composites innovation and effective partnerships. Criteria for the awards include partner involvement in the value chain, project complexity, and commercial potential. The competition is open to any company, university or R&D Center with a compelling collaborative innovation or concept to showcase. The success of participants is closely tied to partnerships and collective intelligence. Beyond being a ceremony, these awards serve as a platform to spotlight potentially undisclosed projects, offering inspiration and motivation to an expert audience eager to explore new frontiers.
More information: www.jeccomposites.com

DOE announces phase one prize winners to boost recycling for a circular wind energy economy

The U.S. Department of Energy announced 20 winners of the first phase of the Wind Turbine Materials Recycling Prize. The $5.1 million, two-phase competition funded by the Bipartisan Infrastructure Law helps develop a cost-effective and sustainable recycling industry for key wind turbine materials not currently recycled commercially. Robust, domestic recycling options for fiber-reinforced composites and rare earth elements will help the environment by lowering the United States’ need to extract and process raw materials. The reuse of more critical materials would also decrease dependence on imports, which would make domestic supply chains less susceptible to price volatility and disruptions. By creating a circular economy for wind energy systems, the Wind Turbine Materials Recycling Prize supports the Biden-Harris Administration’s goals of achieving a carbon-pollution-free power sector by 2035 and net-zero emissions by 2050.  
More information: www.energy.gov

Thermolysis launches fully recyclable products using recycled carbon fibre at JEC World 2024

Introduced the RCF brand, a sustainable initiative committed to complete recycling, in pursuit of the goal of zero waste. To dispel the misconception that composite materials cannot be recycled, Thermolysis is dedicated to developing a range of products that can be entirely recycled, utilizing recycled materials as a foundation. They are pleased to announce the establishment of a socially responsible green brand, “RCF”. This brand designs and produces a range of bicycle accessories and daily necessities, using carbon fiber recycled by Thermolysis. The product lineup of the RCF brand comprises bicycle accessories, including bottle cages, pads, seats, cycling shoe boards, light stands, and fenders. All these products are crafted from Thermolysis’ recycled carbon fiber, ensuring not only their lightweight characteristics but also retaining excellent mechanical strength.
More information: www.thermolysis-asia.com

BÜFA Composite Systems introduces sustainable product portfolio and new environmental label BÜFA®-future

BÜFA Composite Systems, Europe’s leading distributor and manufacturer of polyester resin specialties, announces the launch of its comprehensive sustainable product range and the innovative sustainability label BÜFA®-future. The company, recognised for its innovation and commitment to sustainability, is setting a new standard in the composites industry. With more than a century of experience in the chemical industry, BÜFA has become synonymous with innovation, quality and sustainability. The introduction of the sustainable product range is a further step in the company’s journey to make a positive impact on the environment while meeting the needs of the market.
More information: www.buefa-composites.com

Toray Carbon Fibers Europe to supply bio-circular Torayca carbon fibre for HEAD’s prototype racquets

Toray Carbon Fibers Europe S.A. announced that HEAD Sports GmbH (HEAD) is developing prototype tennis racquets and pickleball paddles made with Toray’s bio-circular carbon fibre using the mass balance approach as certified by the ISCC PLUS standard. Toray Carbon Fibers Europe and HEAD are leaders in producing premium high-performance products and are committed to reducing the carbon footprint of their activities. The decision to build a partnership to develop new racquets was also based on Toray’s ability to provide bio-circular carbon fibre (mass balance approach) for this project. Toray Carbon Fibers Europe recently obtained ISCC PLUS certification in September 2023 and is able to supply bio-circular carbon fibre using the mass balance approach. Therefore, products manufactured with bio-circular carbon fibre will emit less CO2.
More information: www.toray-cfe.com

A life on the ocean waves with flax technical innovations

The adoption of composite parts based on flax fibres by the Marine Industry continues to grow, with major OEMs as well as smaller shipyards now aiming to take advantage of the reduced carbon impact and impressive mechanical properties they can provide. As a member of the Alliance for European Flax-Linen and Hemp, Bcomp, headquartered in Fribourg, Switzerland, has this year been working with Northern Light Composites (nlcomp), based in Monfalcone, northern Italy, on the creation of what is billed as the first fully recyclable nine-metre-long sailing boat – the ecoRacer30.
The boat is based on nlcomp’s proprietary rComposite technology – a combination of thermoplastic resins and BComp’s ampliTex high-performance natural fibre reinforcement fabrics and patented powerRibs technology.
More information: www.allianceflaxlinenhemp.eu

Through this Contract GKN will support Safran with its significant future demand and will start up new Shaft production at GKN Aerospace’s global center of excellence in Kongsberg, Norway. The first shafts are expected to be delivered from GKN Norway to Paris in the second half of 2024. 

GKN Aerospace and Safran have worked together closely for more than 35 years, with long-term partnerships in place for the industry-leading CFM56 and GE90 engines, as well as on the next-generation RISE technology development program.

Alexander Andersson, Senior Vice President of GKN Aerospace’s Engines business, said: “This is a significant agreement and another important milestone in our partnership with Safran.  The LEAP is at the forefront of the industry and we are proud to increase our presence on the engine today, while continuing to explore new technology development for the next-generation RISE engine.”

Dominique Dupuy, Senior Vice President, Purchasing for Safran Aircraft Engines, said: “We are satisfied with our partnership with GKN, which began several decades ago and continues with the manufacture of rotating parts for the LEAP programs.”

More than 5,000 LEAP engines are currently in service, with a backlog of 10,000 more engines on order.  With more than 30 million flight hours to date, the LEAP engine has achieved the fastest order and flight hour ramp up in commercial aviation history.

Ce projet est en collaboration avec 14 partenaires académiques et industriels issus de 7 pays :

·  Belgique (Basaltex NV, Chemical & Intermodal Logistics, Katholieke Universiteit Leuven, Promat Research and Technology Centre)
·  France (Airbus, Centre Technologique Nouvelle-Aquitaine composites & materiaux avancés, Mahytec sarl, Arkema)
·  Italie (D.P. Materials design and processing srl)
·  Luxembourg (Haesaerts, Luxembourg institute of science and technology)
·  Pologne (Politechnika Wroclawska)
·  Royaume-Uni (Electra Commercial Vehicles Limited)
·  Turquie (FEV TR Automotive and Energy Research and Engineering ltd, Temsa Skoda Sabanci Ulasim Araclarianonim Sirketi)

Chung-Hae Park, Professeur à IMT Nord Europe au sein du Centre d’Enseignement, de Recherche et d’Innovation (CERI) Matériaux et Procédés, est le chef de file qui assurera la bonne coordination de cet important projet.

Découvrez-en plus sur le site de l’actualité scientifique de l’Institut Mines-Télécom : I’MTech.

Dannozzle‘s legacy spans decades, marked by the continuous development of long-lasting Climate Solutions, among which installations throughout Scandinavia. As a market leading actor in Climate Solutions, Dannozzle anticipates substantial growth in the years ahead.

For nearly a decade, Comaxel has been an integral collaborator with Dannozzle, serving as the supplier of composite structures. Over the past ten years, Comaxel has manufactured hundreds of thousands of square meters of composites, establishing itself as a leading Tier One producer renowned for innovation and prototyping.

Comaxel Engineering, an independent entity, plays a pivotal role in supporting both Comaxel and its clientele. It serves as the hub for new developments, where innovative concepts take shape, models and molds are meticulously planned, and detailed engineering is executed using state-of-the-art Siemens NX platforms. Additionally, programming and operational support for milling centers, featuring Kuka Robots and CNC machines, are expertly managed from this division.

Picture: Danozzle – Comaxel

Elixir Aircraft, the French aircraft manufacturer designing and producing 4th generation aircraft, has finalized its financing for the next five years with the closing of a €13 million capital increase, led by Innovacom and Bpifrance via its new Amorçage Industriel fund, to ensure its industrial development. 

This capital increase comes on top of the 13 million euros in subsidies already announced by the French President at the Paris Air Show 2023, from the “Produce in France low carbon Aircraft ” calls for projects operated by Bpifrance as part of France 2030. Elixir Aircraft now has a further 26 million euros to continue its adventure. The remaining balance will be financed by bank loans. The majority of these funds will be allocated to production, with the hiring of 500 new employees over the next six years, the acquisition of new machinery and tooling, the creation of a new factory in La Rochelle, and the fitting out of buildings reserved for sales, marketing and customer support.  

The timing is perfect. Never before has the air transport sector needed so many pilots, and therefore so many training aircraft, with economic and environmental issues converging.

The renewal of the training fleet with 4th-generation aircraft, such as the Elixir, will lead to a division of the aircraft operating costs by a factor of four and a 70% reduction in greenhouse gas emissions.

Continued industrialization for more carbon-free aviation

Arthur Léopold-Léger, President of Elixir Aircraft, commented: “After a decade of hard work, Elixir Aircraft has reached a turning point. Design, certification and first deliveries have been achieved. Now it’s time for mass production. The decarbonization of aviation can only be achieved by replacing the more than 230,000 older-generation single-engine piston aircraft. With this total financing of 40 million euros, Elixir Aircraft is giving itself the means to achieve its objectives: nearly 400 aircraft produced per year by 2030, thanks to several hundred employees. I see Elixir Aircraft getting stronger and more structured. In the last two months, we’ve delivered six aircraft – a record for our company! With this financing, we’re going to continue our efforts and become one of the leaders in global general aviation!” 

­Jérôme Faul, President of Innovacom, declared “the renewal of the industry, in all sectors, depends on the development of innovative projects served by talented entrepreneurs. The private investors of which we are a part of are proud to support the Elixir Aircraft team, and to contribute to a value-creating return to the forefront of general aviation in France.”

Raphaël Didier, Director of the Bpifrance Amorçage Industriel fund, commented: “Bpifrance is proud to support Elixir Aircraft in the next stages of its development, by committing to multiple financing levers in its fundraising: with the Bpifrance Amorçage Industriel fund, and with the various innovation support schemes, notably within the framework of France 2030. This investment illustrates the ambitions of the Startups and Industrial SMEs plan supported by Bpifrance, which aims to enable the opening of one hundred new factories a year by 2025.  In addition to the reindustrialization, innovation and export support we are supporting, the Elixir Aircraft team illustrates the excellence of the French aeronautical industry, and helps it to meet the challenge of low-carbon aviation”. 

Recruitment, innovation and the environment: key issues 

Alain Rousset, President of the Nouvelle-Aquitaine Region, declared: “To combat global warming and preserve its future, the aeronautical industry is accelerating its transition to low-carbon aircraft. It’s a huge technological challenge, requiring breakthrough innovations. This is what Elixir Aircraft has achieved with its 4th generation  two-seater, designed using composite materials. This aircraft will be powered in the future by low-carbon fuels, and even hydrogen. As evidenced by NACO’s successful fund-raising campaign, this La Rochelle-based company, which the Region has supported from the outset, has everything it takes to become the leader in “green” flight training aircraft. More generally, New Aquitaine has the ecosystem to establish itself as the champion of low-carbon aircraft. It can rely on the strength of major groups (Dassault, Thales, ArianeGroup…), as well as excellent technological SMEs and research laboratories (Pprime, ICMCB…). Not to mention major e-kerosene production projects, such as the Elyse Energy project in the Lacq basin, which will mobilize an investment of 1 billion euros. The Region has been a step ahead of the game by launching its “Maryse Bastié” plan in 2019, with the aim of stimulating innovation towards decarbonized aircraft.”

A highly dynamic market 

Stéphane Mayer, an aeronautics industry executive and member of the Elixir Aircraft Board of Directors, commented: “Thanks to its innovative design, the Elixir aircraft provides a pertinent response to the demands of a buoyant market. I’m delighted to be supporting a dynamic team, alongside the investors, in this new phase of the company’s development.”

13 millions d’euros levés en capital

Elixir Aircraft, constructeur aéronautique français concevant et produisant des avions de nouvelle génération, a finalisé son financement des cinq prochaines années grâce à la clôture d’une levée de fonds de 13 millions d’euros, menée par Innovacom et Bpifrance via son nouveau fonds Amorçage Industriel, afin d’assurer son développement industriel.  Cette augmentation de capital arrive en complément des 13 millions d’euros de subventions déjà annoncés par le président de la République lors du Salon International de l’Aéronautique et de l’Espace 2023, issus de l’appel à projets Produire en France des aéronefs bas carbone opéré par Bpifrance dans le cadre de France 2030. Elixir Aircraft dispose au total maintenant de 26 millions d’euros pour poursuivre son aventure. Le solde des besoins nécessaires sera financé par de la dette bancaire. La majorité de ces moyens sera consacrée à la production, avec l’embauche de 500 nouveaux collaborateurs au cours des six prochaines années, l’acquisition de nouvelles machines, la création d’une nouvelle usine à La Rochelle ou encore l’aménagement de bâtiments réservés au support client. Le moment est opportun. En effet, jamais le secteur du transport aérien n’a eu autant besoin de pilotes et donc d’avions de formation, avec une convergence des enjeux économiques et environnementaux. Le renouvellement de la flotte de formation par des appareils de 4^e génération, tel que l’Elixir, entraînera une division des coûts d’opération par quatre et une diminution de 70% des émissions de gaz à effet de serre.   

Poursuivre l’industrialisation pour une aviation plus décarbonée

Arthur Léopold-Léger, président d’Elixir Aircraft, a déclaré « Après une décennie à travailler d’arrache-pied, Elixir Aircraft est arrivé à un tournant. Conception, certification et premières livraisons sont atteintes. Il faut maintenant produire en masse. La décarbonation de l’aviation ne pourra passer que par le remplacement des plus de 230 000 avions monomoteurs à pistons d’ancienne génération. Avec ce financement total de 40 millions d’euros, Elixir Aircraft se donne les moyens d’atteindre ses objectifs : près de 400 avions produits par an d’ici 2030, grâce à plusieurs centaines de salariés. Je vois Elixir Aircraft se structurer, se renforcer. Sur les deux derniers mois, nous avons pu livrer six avions, un record à notre échelle ! Avec ces financements, nous allons poursuivre nos efforts et devenir l’un des leaders de l’aviation générale mondiale !  » 

­Jérôme Faul, président d’Innovacom, a déclaré « Le renouveau de l’industrie, dans tous les secteurs, passe par le développement de projets innovants servis par des entrepreneurs talentueux. Les investisseurs privés dont nous faisons partie sont fiers d’accompagner l’équipe d’Elixir Aircraft et de contribuer à un retour au premier plan de l’aviation générale en France qui soit créateur de valeur. » Raphaël Didier, directeur du fonds Bpifrance Amorçage Industriel, a déclaré « Bpifrance est fière d’accompagner Elixir Aircraft dans les prochaines étapes de son développement, en s’engageant par des leviers multiples de financement dans sa levée de fonds : avec le fonds Bpifrance Amorçage Industriel, et avec les différents dispositifs d’aide à l’innovation, dans le cadre de France 2030 notamment. Cet investissement illustre les ambitions du plan Startups et PME industrielles porté par Bpifrance, dont l’objectif est de permettre l’ouverture de cent nouvelles usines par an d’ici 2025.  Au-delà des enjeux de réindustrialisation, d’innovation et de soutien à l’export que nous soutenons, l’équipe d’Elixir Aircraft illustre l’excellence de l’industrie aéronautique française et l’aide à relever le défi d’une aviation décarbonée. » 

Le recrutement, l’innovation et l’environnement : des enjeux clés 

Alain Rousset, président de la Région Nouvelle-Aquitaine, a déclaré « Pour lutter contre le réchauffement climatique et préserver son avenir, la filière aéronautique accélère aujourd’hui sa transition vers l’avion bas carbone. C’est un immense défi sur le plan technologique, qui nécessite des innovations de rupture. C’est ce qu’a réussi Elixir Aircraft, avec son biplace de 4^egénération, conçu avec des matériaux composites. Un biplace, qui sera motorisé demain avec des carburants décarbonés, voire de l’hydrogène. Comme en témoigne cette belle levée de fonds à laquelle participe NACO, cette société rochelaise, que la Région soutient depuis ses débuts, a tout pour devenir le leader de l’avion d’école « vert ». Plus globalement, la Nouvelle-Aquitaine a l’écosystème pour s’imposer comme le champion de l’avion décarboné. Elle peut s’appuyer aussi bien sur la puissance de grands groupes (Dassault, Thales, ArianeGroup…), que de belles PME technologiques, mais aussi d’excellents laboratoires de recherche (Pprime, ICMCB…). Sans oublier de grands projets industriels de production d’e-kérosène, comme celui d’Elyse Energy sur le bassin de Lacq, qui mobilisera un investissement d’1 milliard d’euros. La Région a eu un temps d’avance en lançant dès 2019 son plan, « Maryse Bastié », avec l’objectif de stimuler l’innovation vers l’avion décarboné. » 

Un marché très dynamique

Stéphane Mayer, dirigeant de l’industrie aéronautique et membre du conseil d’administration d’Elixir Aircraft, a déclaré « Grâce à sa conception innovante, l’avion Elixir apporte une réponse pertinente aux demandes d’un marché porteur. Je suis très heureux d’accompagner une équipe dynamique, aux côtés des investisseurs, dans cette nouvelle phase de développement de l’entreprise. »

The collaboration will extend beyond product supply, encompassing joint efforts in design practices, material characterization, tooling to part interaction, material processing, new material development, as well as market penetration strategies.

Austin Schmidt, President and Co-Founder of AES, commented, “This is a logical agreement between two market leaders in the LFAM space and we are thrilled to further our existing relationship with Airtech.” Andy Bridge, Director of Business Development at AES, added, “I have been impressed with the level of material testing, especially tool-part interaction evaluation that Airtech focuses on.”

Gregory Haye, Director of Additive Manufacturing at Airtech Advanced Materials Group, emphasized the company’s dedication to supporting AES and its clients, “Airtech is excited to expand their relationship with one of the first commercial adopters of LFAM in North America. AES is dedicated to this technology and delivering meaningful problem-solving solutions to their customers. We look forward to supporting AES customer project success by providing our industry-leading material solutions and technical support capabilities.”

The exclusive partnership between Airtech Advanced Materials Group and Additive Engineering Solutions holds significant promise for the Large Format Additive Manufacturing sector. By pooling their expertise and resources, both companies aim to deliver enhanced product quality, streamlined processes, and innovative solutions. With a focus on driving real-world results and customer satisfaction, this collaboration signifies a practical step forward in addressing industry challenges, new market penetration and meeting evolving customer needs.

Founded in 1995, WhirlWind Propellers manufactures composite constant-speed and ground-adjustable propellers for the light-sport, experimental and unmanned aircraft markets. The Company also designs proof of concept propellers for emerging applications. Hartzell Propeller plans to retain the WhirlWind brand and product offerings.

JJ Frigge, President of Hartzell Propeller, commented, “The acquisition allows Hartzell to further expand WhirlWind’s rapid propeller development capabilities for the design, tooling and manufacturing of advanced carbon composite propellers.”

Hartzell will retain the services of Jim Rust, former President of WhirlWind Propellers. Rust’s technological expertise with rapid prototyping composite propeller systems further enhances Hartzell’s existing capabilities. 

Rust added, “I am excited to be part of the Hartzell Propeller team and eager to see the WhirlWind brand continue to thrive under Hartzell’s leadership.”

Picture: WhirlWind Propellers

The showcase was attended by Member for Chisholm Dr Carina Garland MP, one year on from the federal government announcing their Rebuilding Australian manufacturing agenda to revitalise Australia’s industrial capability and manufacturing.

Swinburne Chief Scientist Professor Virginia Kilborn says the university is proud to be one of Australia’s leading partners in the research and development of advanced manufacturing.

“Swinburne continues to deliver ground-breaking digital techniques to push Australia to the forefront of manufacturing carbon fibre composite components. Our tech-led approach promotes widespread adoption of Industry 4.0 standards and digital twins, to help secure Australia’s manufacturing future.”

Based at CSIRO’s Clayton facility, the Swinburne-CSIRO National Industry 4.0 Testlab supports innovative research and development for Swinburne’s Aerostructures Innovation Research (AIR) Hub, Victorian Hydrogen Hub, ARC Research Hub for Future Digital Manufacturing, and collaborations with CSIRO’s Data61 arm.

Industry 4.0 Testlab Research Director Professor Boris Eisenbart is thrilled to share the incredible work of Swinburne and CSIRO through the National Industry 4.0 Testlab.

“Testlab is already supporting groundbreaking projects in areas like aerospace, automotive, 3D printing and digital twinning. This is only the start for this world-leading facility, and I am excited for what we can do next to continue to build our partnership with CSIRO and our industry network.”

The Global Innovation Linkages program project is another key initiative of the facility. Developing a highly automated, flexible approach to the manufacturing process, the project integrates world-first 3D fibre printing technology with a unique composite curing process and digitisation technologies. This will achieve a leap forward in increasing the production rates and quality of composite part manufacture, while significantly lowering the cost of production.

CSIRO’s Chief Scientist Professor Bronwyn Fox is an integral part of the Swinburne and CSIRO community. Since holding previous positions as Swinburne’s Deputy Vice-Chancellor of Research and Enterprise and Director of Swinburne’s Factory of the Future, she is now also supervising PhD students undertaking projects with the Testlab.

Professor Fox is one of the many world-leading experts who will use this facility for innovative education, research and development outcomes in manufacturing for years to come.

“Australia’s future depends on having a world class advanced manufacturing capability and Testlab has been purpose-built on the cutting edge of what we need to succeed in the era of Industry 4.0,” she says.

“It is a facility that gives us the ability to generate, translate and accelerate research, training and technology into opportunities and competitive advantage for Australia.”

“Testlab’s real power is collaboration – it brings together the people, the capabilities and the intention to deliver benefits for the nation through generous collaboration between Swinburne, CSIRO and other key players in Australia’s research and innovation system.”

Picture: Swinburne University of Technology – The Testlab has showcased its world-first fully automated industrial-scale production facility using a 3D-printing approach to composite component creation.

La résidence Taikang est un lieu idéal, imaginé et dédié, aux personnes âgées. Elle comprend un centre de santé, des espaces de vie collectifs et individuels, ainsi qu’une zone réservée au bien-être.
L’objectif de la résidence était d’harmoniser l’architecture du bâtiment, en privilégiant des environnements ouverts et lumineux qui assurent une sensation de sécurité, de détente et de confort à ses résidents. Ainsi, les espaces deviennent de véritables îlots de bien-être, où l’expérience sensorielle se mêle à l’expérience émotionnelle.
Le toit est un véritable chef-d’œuvre d’ingénierie. Revêtu d’une membrane GF-6006 en PTFE signée Serge Ferrari, il bénéficie d’un système d’éclairage innovant de 6000 lumières, créant un effet visuel époustouflant, rappelant la lumière du soleil sur une goutte d’eau.

Une goutte d’eau signée Serge Ferrari

Illuminé, le toit de la résidence Taikang donne l’impression de flotter dans le ciel nocturne, grâce à un système d’éclairage intégré de manière transparente dans l’enveloppe textile. Cette atmosphère est rendue possible par la membrane en PTFE de Serge Ferrari, qui amplifie la transmission de la lumière grâce à ses propriétés réfléchissantes. La résidence bénéficie alors d’une abondance de lumière naturelle durant la journée et d’un éclairage adéquat la nuit.

Fiche projet

Projet : Résidence Taikang
Localisation : Beijing, Chine 
Toile Serge Ferrari installée :  GF-6006 en PTFE
Superficie : environ 9500 m²
Architectes : Fangwei-Architects
Construction: Août 2023
Installateur: Vector-foiltec China
Client : Taikang Healthcare Industry Investment Holdings Co., Ltd
Photos: Topia

The facility acquired by Joby will be fitted out to support initial manufacturing operations in Dayton, which are expected to begin later this year. The facility will be used for the manufacturing of aircraft parts in support of Joby’s Pilot Production Line in Marina, California.

Joby’s acquisition of the on-airport facility is the first step in the Company’s plan to develop facilities capable of building up to 500 aircraft per year in Dayton, which is expected to include the design and construction of a larger greenfield factory.

“We’re pleased to be able to acquire an underutilized facility at Dayton International Airport and repurpose it as a modern, high-tech manufacturing center to serve as our initial manufacturing footprint in the region. Later this year, we expect to begin subtractive manufacturing of titanium and aluminum aircraft parts as we continue to grow our workforce in Dayton,” said Didier Papadopoulos, President of Aircraft OEM at Joby. “I am deeply appreciative to the Dayton community, and Ohio more broadly, for the warm welcome we have received as well as the high level of interest in joining our team. We look forward to continued collaboration and to growing our presence in the Miami Valley region as we build the future of flight in the birthplace of aviation.”

Joby announced in September 2023 that it had selected Dayton, Ohio, as the location for its scaled manufacturing facility, capable of producing up to 500 electric vertical take-off and landing (eVTOL) aircraft per year, with plans to invest up to $500 million and create up to 2,000 high-quality, clean manufacturing jobs in the region.

Joby’s electric air taxi is designed to carry a pilot and four passengers at speeds of up to 200 mph, offering high-speed mobility with a fraction of the noise produced by helicopters and zero operating emissions.

Picture: Joby Aviation photo – Joby’s pilot production line in Marina, California, with two of the company’s prototype aircraft.

Utah’s aerospace & defense thought leadership in advanced materials

The JuggerBot 3D’s pellet extrusion system can efficiently fabricate key components at low cost with high-performance materials. The printing system ensures a controlled and consistent environment for additive manufacturing accurately while simultaneously tracking key performance parameters. Northern Utah is a hub for defense & aerospace manufacturing with a long heritage. The Juggerbot 3D printing system can produce parts that sustain both high temperature and high strength for applications in composite tooling and final part components. 
“We are proud to be working with an institution like Weber State University’s MARS Center, and the expertise their team has in both the aerospace and defense industries. Our first machine in Utah could have not found a better home as it will be used in applied research supporting the modern warfighter and pushes the advanced manufacturing needle forward.” says JuggerBot 3D Vice President Daniel Fernback.

Les travaux des partenaires du projet ont permis de lever les verrous technologiques identifiés au début du projet via notamment :

• Le développement, la mise en œuvre et la caractérisation de tapes carbone / thermoplastique (C/PEKK).
• Le développement du procédé de dépose automatique pour consolidation hors autoclave
• Le développement du procédé d’assemblage par la technologie de soudure ISW

La définition des pièces élémentaires destinées à constituer les pièces assemblées du démonstrateur HAICoPAS (design et cahier des charges) a été réalisée en étroite collaboration avec un comité industriel consultatif composé d’Airbus, Safran, Daher, Hutchinson et ATC. La version finale du démonstrateur aéronautique HAICoPAS réalisée en bande composite et assemblée par la technologie ISW est présentée dans l’espace d’exposition des JEC World Innovation Planets dans la section Mobility

Ce démonstrateur innovant a pu être réalisé dans le cadre du projet collaboratif « HAICoPAS » (Highly Automatized Integrated Composites for Performing Adaptable Structures) Le projet HAICoPAS est un projet collaboratif porté par Hexcel, Arkema, leurs partenaires industriels (Ingecal, Coriolis Composites, Pinette Emidecau Industries (PEI) et l’Institut de Soudure), ainsi qu’un consortium de laboratoires universitaires porté par le CNRS composé du PIMM (CNRS – Arts et Métiers ParisTech – le Cnam, LTEN (CNRS – Université de Nantes). Ce Projet R&D Structurant Pour la Compétitivité (PSPC) a été soutenu par Bpifrance dans le cadre du Programme d’investissements d’avenir et labélisé par le pôle de compétitivité Polymeris.

Une enveloppe de plus de 56 millions d’euros d’aides pour ces nouveaux projets innovants

Au-delà de très nombreux projets liés au bois et aux activités forestières, ou encore au secteur médical, on constate aussi que les acteurs du marché des composites n’ont pas été oubliés. Apparaissent ainsi dans la liste de la préfecture de Nouvelle-Aquitaine Ariane Group SAS, Diab, Rescoll, Safran Additive Manufacturing Campus, Thales AVS France Gironde et Vienne, Safran Electrical & Power (Deux-Sèvres), Akzo Nobel, le GIP Chemparc, etc.

Ce nouveau lot de projets, bénéficiant du soutien de l’État, représente une enveloppe budgétaire de 56,83 millions d’euros, visant à stimuler la recherche, l’innovation et la souveraineté industrielle. Depuis le déploiement du plan France 2030, ce sont 441 projets qui ont été soutenus en Nouvelle-Aquitaine pour un montant total de 824,6 millions d’euros d’aides.

Réindustrialisation et décarbonation à l’agenda

« Cette nouvelle vague de lauréats démontre les capacités de mobilisation de ces établissements et entreprises issus de l’ensemble du territoire de la Nouvelle-Aquitaine, dont certains dans des domaines déjà reconnus comme l’exploitation du bois ou l’aéronautique. Ces entreprises souhaitent résolument innover et investir dans des outils de production plus performants et résilients. Elles participeront donc aux efforts de décarbonation, une des priorités de France 2030 pour atteindre les objectifs de la stratégie nationale bas carbone qui vise une diminution de 35 % des émissions de gaz à effet de serre de l’industrie en 2030 », commente Étienne Guyot, préfet de Gironde et de Nouvelle-Aquitaine.

Photo: Depuis le lancement du plan France 2030, 441 projets ont été soutenus en Nouvelle-Aquitaine pour un montant de 824,6 millions d’euros d’aides.

The four products certified by HRC this time are recycled short carbon fibre, recycled carbon fibre composite felt, recycled carbon fibre scattered moulding plate and recycled carbon fibre building moulding plate. No additional chemicals are added during the production and manufacturing process. Both recycled carbon fibre materials use advanced recycling technology. The performance retention rate of the 100% recycled carbon fibre produced is greater than 90%, with excellent mechanical properties. They have been used in the construction engineering industry. Automobile manufacturing, rail transportation, aerospace and other fields also have broad application prospects.

In recent years, as public awareness of environmental protection continues to awaken, how to establish a sustainable and recyclable development model has become an important proposition for the strategic organization of enterprises. As the first composite material company in China to open the closed loop of carbon fiber application and one of the first composite materials companies to obtain GRS certification, HRC has actively promoted the research and development and promotion of carbon-neutral products such as natural fibers, recyclable fibers, hydrogen tanks, and thermoplastics since its establishment. The successful certification of this series of carbon neutral products is also one of the important results of a series of green development initiatives launched after HRC officially joined the “Carbon Neutral Action Alliance” as a council member in 2023.

In 2020, the European market experienced a sudden down­turn due to the COVID-19 pandemic. However, we wit­nessed a swift recovery in the sector after the European Union member countries re­opened their borders. This rebound surpassed the ex­pectations of market analysts, proving to be more dynamic than similar recoveries in Asia and North America.

In 2022-2023, like many other companies, we had to con­tend with a number of geopo­litical events which resulted in escalating costs of raw materi­als and energy. Despite all this, demand remained buoyant and was fuelled by the ongoing stream of projects within the European composites industry.

JEC Composites Magazine: The COVID-19 pandemic highlighted vulnerabilities in the supply chain. What is Toray doing to secure its supply chain for European customers?
Jean-Marc Guilhempey:Toray Industries op­erates in Asia, Europe and the United States. This means that we can produce locally as much as possible. All of our sites are capable of supplying another site on another continent. Toray Industries includes not only carbon fibre producers but also weavers and prepreg manufacturers in Europe. This means we can offer a response that is perfectly tailored to the needs of our European cus­tomers, allowing us to deliver fully-integrated solutions.

JEC Composites Magazine: At a time when China is gradually asserting itself in carbon fibre production, what is Toray Europe doing to help maintain the group’s leading position in the sector?
Jean-Marc Guilhempey: Toray Industries de­livers premium quality across its product range, featuring some unparalleled offerings in performance within the composites market, such as the T1100S/G carbon fi­bre. As a market leader, Toray Industries is constantly de­veloping new products to en­sure it remains at the forefront of innovation. CFE Europe is able to manufacture in France and distribute the most com­prehensive array of carbon fibre products throughout Europe. Our production facil­ities and technical sales teams are strategically located, al­lowing us to promptly address customer needs, maintain high ethical standards, and remain compliant.

JEC Composites Magazine: How important is the Abidos site in the group’s industrial network?
Jean-Marc Guilhempey: Our Abidos site (Pyrénées-Atlantiques, France) is the sole producer of stand­ard carbon fibre tow with­in the group in Europe, and the oldest overseas site with­in Toray group. It is a key play­er on our strategic chessboard. The construction of a 6th pro­duction line is a perfect ex­ample of this. This expansion is geared towards meeting the growing demand for carbon fibre in Europe (Figure 1).

The place of Europe in Toray’s galaxy
Toray Industries, Inc. confirms the expansion of its subsidiary Toray Carbon Fibers Europe S.A. On December 6, 2023, Toray-CFE laid the foundation stone for its 6th production unit, in the presence of 2 top Japanese managers, Minoru Yoshinaga and Hiroshi Enomoto. Jean-Marc Guilhempey, Chairman of the Board of Directors of Toray-Carbon Fibers Europe, recalled the site’s industrial epic while highlighting the work of its teams. This plant expansion will also create jobs. Annual production capacity at the Abidos plant will rise from 5,000 tonnes to 6,000 tonnes, enabling it to meet growing demand in several markets (civil aerospace, defense, civil nuclear, satellites and automotive).
“Soficar’s first production line started up in 1985. At that time, production capacity was just 300 tonnes a year, less than a 10th of today’s capacity. By 2025, when construction of the new line is complete, CFE will be in a position to meet the growing demand from European markets”, points out Minoru Yoshinaga, noting that the group posted sales of €7.44 bn (¥1,199.4 bn) in the first half (April to September), a contraction of 4.9% compared with the same reference period of 2022. The carbon fibre and composite materials business grew by 0.8%, driven in particular by the aerospace sector.
Environmental ambitions quantified
Toray’s choice underscores the significance of Europe, and France in particular, in the group’s global network. The group is present in the Czech Republic, France, Germany, Italy, the Netherlands, Spain, Sweden, Switzerland, Hungary and the United Kingdom. The European development has involved numerous external growth operations, such as in Sweden in 2019 when Toray took control of Sweden AB, which also has subsidiaries in Portugal and Tunisia. The Japanese giant is also expanding its presence in North African markets.
Toray’s development is accompanied by a very precise environmental vision. Before the 2050 carbon neutrality goal, Toray has set ambitious interim milestones for 2030. The activity of innovative products that promote sustainable development will be multiplied by 4.5 by 2030 (with the base set in 2013), while greenhouse gas emissions will be reduced by at least 50%. Water consumption for production will also be reduced by 50% by 2030.

JEC Composites Magazine: What is your vision for France’s reindustrialisation and competitiveness in the current global climate?
Jean-Marc Guilhempey: There’s no doubt that the French government is actively engaged in revital­ising our country’s industri­al sector and the France 2030 programme is a good exam­ple. Our competitiveness hinges on our capacity to innovate, reduce our carbon footprint, manage energy costs effective­ly, and skilfully train our work­force to align with the current industrial requirements.

Sustainable development is now a major concern, particularly in the composites industry and in the production of raw materials. How do you approach this issue, particularly in production, a critical phase?
J.M.G.: We have been anticipating the environmen­tal impact of each of our in­vestments for a number of years. In the long term, we want all our industrial sites to be carbon neutral. Our latest production line will integrate state-of-the-art technologies to tackle these challenges. Additionally, we are able to manufacture biobased carbon fibre, in compliance with the ISCC+ standard which we ob­tained in autumn 2023.

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“After a successful launch and deployment, we are very excited to report that during the launch and early operations (LEOP) stage, we received signals from LizzieSat™,” said Carol Craig, CEO at Sidus Space. “This milestone marks the beginning of Sidus’ new era as a satellite manufacturer and operator and demonstrates our ability to deliver cutting-edge space hardware while pushing the frontiers of space technology and data collection. We have methodically executed on our strategy of building a leading Space and Defense as a Service company with an experienced team, innovative and advanced technologies, a vertically integrated manufacturing facility, and a robust spacecraft supply chain. It’s exciting to show proof of this capability for government and commercial customers alike.”

Two more LizzieSat™ satellites are expected to launch from Cape Canaveral Space Force Station later this year and will provide tailored intelligence solutions for industries such as defense, agriculture, maritime, and oil and gas.

The solar panels of LizzieSat™ satellite are built with aluminum honeycomb with composite skin.

Dietmar Wennemer, President & CEO of Virtek Vision, said, “Our IRIS 3D Process Monitoring Software, working in tandem with our Ai-based Camera System, enables users to supplement their static manufacturing data with high-resolution, colour images captured during ply layup and assembly processes to address the increasingly stringent demands of modern manufacturing. In essence, our system enables manufacturers to collect and manage data visually throughout their entire manufacturing process.”

A standout feature at the show has been IRIS Ai for Universal Inspections, slated for launch in mid-2024, which enables users to create and deploy customized AI inspection models based on their chosen parameters. Darian Butt, Virtek’s Senior Director of Products, explained, “The user’s custom-built AI inspection model will run within the Virtek IRIS platform and is fully integrated with IRIS’s laser-guided build process. When the system detects an anomaly, it prompts the operator to either correct and re-inspect it, or defer to a supervisor to accept it before moving on to the next step in the assembly process.”  

Wennemer added, “With the imminent launch of our new Ai-driven software, we demonstrate how we have successfully harnessed the power of Industry 4.0. Ever-increasing amounts of data and machine learning require smart algorithms to detect anomalies and highlight them in real-time. Our focus was to make the implementation and use of smart technologies easy and operator friendly. Humans will make the decisions and information is provided intuitively to make our customers’ factories even more efficient and more productive.”

“We are thrilled to announce our commitment to Dovetail Electric Aviation,” said Alvaro Fernandez Baragaño, CEO of Aciturri Aeroengines and Chief Diversification Officer of the Aciturri group. “This partnership represents a significant opportunity to drive innovation in the aviation industry and broaden our contribution to a more sustainable future. We look forward to working closely with Dovetail Electric Aviation to bring their groundbreaking technology to market.“

Aciturri’s investment in Dovetail Electric Aviation underscores the company’s commitment to sustainability and innovation in aerospace manufacturing. By supporting the development of electric aircraft, Aciturri is playing a key role in shaping the future of air travel, making it more sustainable and environmentally friendly.

David Doral, CEO of Dovetail Electric Aviation, commented on the partnership, stating, “Aciturri’s involvement brings not only financial support but also significant capabilities that will greatly enhance our technology roadmap and accelerate our path to market. Their track record and expertise in high technology aerostructures and engine parts will add immense value to our operations, helping us bring our innovative solutions to market faster and more efficiently.“

Dovetail is initially targeting certification of its first battery-electric powered aircraft in 2026, as a first step to bring a product in the market. Later on, Dovetail will focus on the certification of electric-hydrogen aircraft conversions, with preliminary work currently underway with the integration of Dovetail’s first hydrogen-electric powertrain. The purpose behind an electric-hydrogen aircraft conversion for Dovetail is to extend the range of the battery-powered aircraft.

With this agreement Aciturri becomes the lead investor in the second tranche of Dovetail’s seed investment round. With a total target of USD 7 million, Dovetail split its seed round in two tranches or parts, with the first one closed last year, with the airlines Rex in Australia, and Volotea and Air Nostrum in Europe, as the most relevant investors. In this second tranche Aciturri is leading the round, to be closed shortly with the addition of at least one institutional venture capital fund.

Dovetail’s hybrid electric aircraft will be using composite components.

Nord Composites brings to this alliance its recognized know-how in the design and manufacture of composite materials. Thanks to its expertise and experience, the French company has set itself apart through the quality of its products and its ability to meet the specific needs of its customers.
“Composites Essential Materials is recognized for its excellence in the value-added distribution and manufacturing of composite materials in the United States, as well as for its in-depth knowledge of the local market”, said Nick DAN, cofounder of CEM in Port St. Lucie, Florida. “We are excited about how this new, expanded relationship with Nord Composites will help us accelerate our growth, taking our company to the next level”. Added Maritsa DAN President and co-founder.

The creation of Nord Composites U.S. represents a major opportunity for both companies, who will now be able to pool resources and skills to offer tailor-made solutions to a diversified customer base.
“This joint venture also strengthens our presence in the U.S. market, enabling us to be closer to our customers and better understand their expectations and requirements”, continued Aurélie.

As the company born of this fruitful collaboration, Nord Composites U.S. is committed to pursuing the values that have made its two founding companies so successful: innovation, quality, and customer service. The alliance will allow the companies to work together to meet the challenges of the global composite materials market while opening up new prospects for growth and development for all employees.    

Reconciling sustainability and competitiveness

“We are proud to join CSR Europe which has been one of the driving forces behind the Green Deal in Europe, to which Syensqo fully subscribes. Within this network, we must explore new ways to implement sustainability principles in European organisations and make it more effective. And this decisive transformation must also allow us to enhance our competitiveness”, explains Ilham Kadri, CEO of Syensqo.

“Our scientific and technological foundation serves greater efficiency for sustainable development and growth. It’s a comprehensive approach that involves the group and its employees, as well as our entire value chain”, adds Titta Rosvall-Puplett, responsible for sustainability development within the group.

Objective carbon neutrality by 2040

To ensure that words are translated into actions, Syensqo’s leaders confirm the group’s commitments in three main areas: climate and nature; sustainable growth; and ‘a better quality of life’. In the first area, Syensqo aims for a 23% reduction in its scope 3 greenhouse gas emissions by 2030, compared to a 2021 baseline. A 40% reduction is aimed for scopes 1 and 2 for which carbon neutrality objective is set for 2040. In terms of business development, Syensqo aims for sales from the circular economy to represent 18% of its total revenue by 2030. For the quality of life aspect, the group commits to achieving gender parity in its middle and senior management by 2033, while also working on the remuneration of all employees.

Concilier durabilité et compétitivité

« Nous sommes fiers de rejoindre CSR Europe qui a fait partie des éléments moteurs du Green Deal en Europe auquel Syensqo adhère pleinement. Au sein de ce réseau, nous devons explorer de nouvelles voies pour mettre en œuvre le principe de durabilité dans les organisations européennes et le rendre plus efficace. Cette transformation décisive doit aussi nous permettre d’améliorer notre compétitivité », expose Ilham Kadri, présidente directrice générale de Syensqo.

« Notre ancrage scientifique et technologique est au service d’une plus grande efficacité pour le développement durable et la croissance. C’est une démarche globale qui comprend le groupe et ses collaborateurs, mais aussi toute notre chaine de valeur », renchérit Titta Rosvall-Puplett, en charge du développement durable au sein du groupe.

Objectif neutralité carbone en 2040

Pour garantir que les discours sont relayés d’actions, les dirigeants de Syensqo confirment les engagements du groupe dans trois grands domaines : climat et nature ; croissance durable ; et ‘un meilleur cadre de vie’. Dans le premier périmètre, Syensqo vise une réduction de 23 % de ses émissions de gaz à effet de serre du scope 3 d’ici 2030, par rapport à une base de 2021. Une réduction de 40 % est visée pour les scopes 1 et 2. Cet objectif de neutralité carbone est fixé à 2040. Sous l’angle du développement de ses activités, Syensqo veut que les ventes issues de l’économie circulaire représentent 18 % de son chiffre d’affaires global à l’horizon 2030. Pour le cadre de vie, le groupe s’engage à viser la parité pour son middle et son senior management à l’horizon 2033, tout en travaillant sur la rémunération de tous les collaborateurs.

As a company with upcycling as the main product concept, BioPowder promotes circular principles. Reduce-reuse-recycle: operating along these lines requires a holistic approach from the raw material up to the final applications of the natural particles. 

BioPowder is part of an ecosystem of olive and fruit processing value chains. Besides transforming the by-products (fruit pits, seeds and shells) and giving them a second life, the company creates innovative markets for compostable micro-particles, always with the goal of supporting composite makers on their journey towards more sustainability. Sustainability, a word that appears over-used these days, should be filled with meaning and a clear action plan. Otherwise, it will remain a label with little impact.

Current sustainability initiatives in the materials industry focus mainly on recycling: there is consensus about manufacturers’ responsibility to provide valid end-of-life solutions, and recycled content has become a number one strategy to reduce a product’s environmental impact. The team behind BioPowder believes that holistic sustainability should start at the material design stage. Tackling climate change and the ever-growing amounts of waste should involve conscious resource consumption, re-use/re-purposing and extended product lifespans.

BioPowder partners with composite makers to reach a two-fold goal:
1. Reduced carbon and environmental footprints
2. Functional benefits of end products for diverse industrial applications.

In other words, the company offer well-rounded support for manufacturers’ journey to making greenwashing-free products that work.

The BioPowder reduced footprint strategy

Commonly used tools to perform a product’s lifecycle analysis (LCA) often focus on emission-based data, such as the carbon footprint, which is deemed crucial in the context of greenhouse gas emissions and their role in climate change. However, to fully quantify a product’s environmental impact, it is crucial to look at it as part of a wider context. This is what the ecological footprint measures. In other words, it reflects the amount of natural resources an organisation uses in relation to the availability of such resources. Hence, its impact on the depletion of natural ecosystems.

BioPowder’s waste-to-value processes are free from chemicals, resource efficient and local. As a result, carbon emissions values are kept to a minimum. Considering the origin of olive stones, it becomes clear that they are in fact a source of bio-carbon. Research by the International Olive Council suggests that olive trees absorb around 10kg of CO2 per kg of harvested olives. With these facts in mind, the olive-processing ecosystem including oil and by-products is a carbon-negative one.

Consequently, the incorporation of olive stone powders into composites can dramatically improve a material’s environmental footprint. Besides supplying compostable particles, BioPowder is expanding its R&D capabilities to support end-product development, i.e. testing in various binder systems, particle surface functionalisation and colouring.

Unique properties and functional benefits of olive stone particles

a. Reinforcing properties: Olive stone particles, with a hardness of approx. 3.5 (Mohs), enhance the impact and abrasion resistance of a polymeric compound, leading to a longer lifespan of performance materials. Examples include reinforced natural and synthetic rubber, PVC sheets, pipes and cables, engineered wood and ceramic composites.
b. Weight-reduction: Particularly beneficial for lightweight components in industries such as automotive, medical or aerospace. Polymers, both bio-based and conventional, are often filled with mineral powders to achieve hardness and stability. Replacing these heavyweight fillers with olive stone particles can lead to a lower material requirement and an overall weight reduction of the final compound.
c. Decorative and anti-skid effects: Customisable particle sizes that are easy to apply in various compounding systems. Masterbatches, based on PE, PP, PVC, polystyrene, PLA/PHA, can be created with new decorative effects and an elevated bio-content.
d. Hydrophobicity and barrier properties: In addition to fully natural powders, BioPowder offers a range of surface-treated particles that enhance compatibility with different polymer chemistries. This functionalisation improves hydrophobicity, reduces oil absorption, and adds to the overall longevity of bio-based performance composites.

Driving circularity

BioPowder’s approach represents a noteworthy shift in the materials industry towards sustainability. The company’s use of olive stone particles derived from food industry by-products showcases a commitment to upcycling and circular principles. By addressing the environmental impact at the material design stage, BioPowder advocates for a holistic sustainability perspective, going beyond the current focus on recycling. Collaborating with composite makers, its efforts aim to genuinely reduce carbon footprints while offering functional benefits to end products. In a landscape where the term “sustainability” is often overused, BioPowder’s endeavours stand out as a practical contribution towards minimising waste and creating environmentally conscious materials with real-world applications.

About BioPowder:
BioPowder is a specialist supplier of micronized fruit stone powders as bio-based ingredients, additives and abrasives. Derived from food processing side streams, the company’s products support a circular economy and enable manufacturers to reduce their environmental impact. Founded in 2017 and headquartered in Malta, the company sources from the Mediterranean region and manages production in Southern Spain. BioPowder is part of a sustainable supply chain that focuses on upcycling agricultural by-products (not crops), taking a local approach that reduces waste and does not disrupt the food chain.

How to reduce satellites’ mass

« Eutelsat 36D is the latest milestone in our long-standing partnership with Eutelsat, which has lasted for over 30 years. This is the 22nd geostationary satellite we have built for them. It will provide expanded capacity over Africa and Eurasia », commented Philippe Pham, Director of Telecommunications and Navigation Systems at Airbus.

The Eurostar Neo range of telecommunications satellites from Airbus was developed with the support of the European Space Agency (ESA) and other partners, including the Centre national d’études spatiales (CNES) and the UK Space Agency(UKSA). These satellites combine an electrical power of 18 kW with a reduced mass, around 5 tonnes, thanks to Airbus’s electric orbit raising (EOR) technique. Mass control has been optimised through the development of new materials, such as the contribution from Bercella on several critical parts of the Eurostar Neo platform.

Contenir la masse des satellites

« Eutelsat 36D est le dernier jalon de notre partenariat de longue date avec Eutelsat, qui dure depuis plus de 30 ans. Il s’agit du 22e satellite géolocalisé que nous construisons pour eux. Il offrira une capacité étendue sur l’Afrique et l’Eurasie », commente Philippe Pham, directeur des télécommunications et des systèmes de navigation chez Airbus.

La gamme des satellites de télécommunications Eurostar Neo d’Airbus a été développée avec le soutien de l’European Space Agency (ESA) et d’autres partenaires dont le Centre national d’études spatiales (CNES) et l’UK Space Agency (l’UKSA). Ces satellites associent une puissance électrique de 18 kW à une masse réduite, de l’ordre de 5 tonnes, grâce à la technique EOR (pour electric orbit raising) d’Airbus. La maîtrise de la masse a notamment été optimisée par le développement de nouveaux matériaux, à l’image de l’apport de Bercella sur plusieurs pièces névralgiques de la plateforme Eurostar Neo.

One challenge to date has been that these components can hardly be manufactured in large-scale production processes. The use of thermoplastic fibre composite sandwich semi-finished products can be the solution here. These can be produced efficiently in continuous processes and turned into components in automated manufacturing processes. The participants in the joint “HyWaSand” project, which has now been successfully completed, have shown what is possible with this.

A flap for a storage compartment in a truck cabin was produced as a demonstrator. “We wanted to prove that the sandwich construction method with continuously produced thermoplastic sandwich semi-finished products is possible for such applications. Together with our partners, we succeeded,” says Dr. Ralf Schlimper, who led the project at the Fraunhofer IMWS.

The thermoplastic sandwich molding technology developed at the institute proved to be particularly valuable in achieving this goal. This is based on a new type of thermoforming process and was developed specifically for the fully automated production of continuous fiber-reinforced sandwich components with a thermoplastic matrix in large series. Thermoplastic sandwich semi-finished products, consisting of a thermoplastic honeycomb core and cover layers of fibre-reinforced thermoplastic UD tape laminates, are heated in an infrared oven and, after automated transfer to the molding tool, 3D thermoformed and functionalized by means of injection molding.

“The TS molding technology proved to be very efficient in our project. We were able to show that it enables the efficient production of 3D-molded and functionalized lightweight components in sandwich construction in the injection molding cycle, i.e. with cycle times of around one minute. This shows the potential for further fields of application, such as the car body sector,” says Schlimper.

In the project, ThermHex Waben GmbH focused primarily on the development of hybrid sandwich semi-finished products with a small cell width and functional polymer and metal foils to improve the surface quality. In addition, the new development of continuously manufactured semi-finished sandwich products with even lower material usage was driven forward. In conjunction with the necessary adaptation of the manufacturing process to make it suitable for series production, it was possible to achieve a further reduction in costs and weight compared to the previous standard configurations and non-recyclable material alternatives from reaction injection molding (RIM) processes. At the semi-finished product level, 30 to 45 percent of the weight can be saved with the same material thickness or up to 22 percent of the weight with comparable mechanical performance and greater material thickness. This improved resource efficiency in the use of materials also has a proportionally positive effect on material costs and CO₂ emissions.

In test structures, the project was able to demonstrate that components with Class A surfaces, which are particularly important for the automotive industry, can also be manufactured from thermoplastic semi-finished products in sandwich construction. Progress was also made for metal-plastic hybrid sandwich materials as part of the “HyWaSand” project, for example the lamination of test structures with metallic cover layers within the TS molding process.

“There are still open research questions here that we want to continue working on. This makes it all the more valuable that we have made great progress in the project in providing virtual engineering methods for process and component development and have also developed feasible test tools for various common component design features. The new possibilities for inline inspection and for suitable non-destructive testing methods to ensure component quality also enable us to rapidly bring the technology even closer to application in various cost- and weight-sensitive areas,” says Schlimper.

“We are currently investigating the transferability of the results to customer development projects in order to facilitate entry into new market segments,” says Matthias Biegerl, who led the project at ElringKlinger. “The potential is huge. By manufacturing the components in large series, cost-efficient lightweight structures for interior and body components can be produced.”

The demonstration at JEC World 2024 has already generated a lot of interest. The project partners will also present the component and the technology at the Composite Sandwich Conference on April 24-25, 2024 in Halle (Saale).

With a legacy of excellence stemming from the acquisition of Vacuum Furnace Engineering (VFE), and VFE’s prior acquisition of Autoclave & Industrial Controls (AIC Service), Busch has evolved into a one-stop-shop for customers’ specific autoclave requirements.

At JEC World, attendees had the opportunity to engage with Busch experts and discover firsthand how Busch’s autoclave solutions can enhance manufacturing processes. Visitors to the Busch booth learned about the company’s dependable services, which encompass tailored support packages to ensure maximum equipment uptime, irrespective of brand. Additionally, Busch showcased its range of new equipment and upgrades, including custom vacuum systems.

The Autoclave Management and Control System (AMCS) demonstrations were of particular interest to attendees, owning to its ability to be customized to meet unique customer requirements, with remote monitoring capabilities enabling worldwide support.

Furthermore, attendees discovered the value of Busch’s calibration service, which helps customers understand the performance of their production equipment, leading to reduced product failures, increased reliability, less downtime, and decreased production running costs.

The total project investment is approximately 120 million euros. After completion, the annual revenue of the project is expected to exceed 1 billion euros, providing strong support for Voith Group’s leading position in the field of global hydrogen storage technology

To enhance collaboration and UK industry advancement, the NCC will offer access to the hardware in 2024, as part of its Hydrogen programme. A game changing innovation it will drive transformational change, reducing the time, cost and complexity of cryogenic testing.

A key feature is the cryostat’s optical access allowing material specimens to be viewed during the test process. An enabling element of the test, it looks at the cracks that are developing in the composite material, focusing on the known composite challenge of ‘microcracking’. The test has a cycle time of approximately 30 minutes to cool and test allowing a high throughput of test specimens. This is achieved by using cryogenically cooled nitrogen gas, utilising a design with a low thermal mass and volume.

NCC are working with the National Physics Laboratory (NPL) to validate the cryostat design and quantify data repeatability, to ensure it meets industry standards.

Announcing the cryostat innovation, Matt Kay, Principal Engineer at the National Composites Centre said, “The cryostat concept will be transformational by quickly and cost effectively screening materials that are candidates for conventional cryogenic testing. It will reduce barriers to entry and increase the rate of cryogenic materials testing, helping engineers and researchers to develop new products for the emerging liquid hydrogen industry. It forms part of the NCC’s journey in developing specialist expertise to support the UK’s transition to the hydrogen economy.”

CERN is the world’s leading laboratory for particle physics located near Geneva, Switzerland. The carbon fibre tube supports the heart of the upgraded CMS detector, a “camera” with more than a billion pixels to record proton-proton collisions at the highest ever-made energies and unprecedented resolution. In a few years, once fully commissioned, the upgraded CMS detector is expected to collect 10 times the data recorded so far in the hunt for new particles and aims to understand the origins of the Universe.

The BTL Tracker Support Tube had to be manufactured from materials with extremely low radiation resistance, have a precise circular cylinder structure, be very strong and stiff, and meet an accelerated delivery schedule. Because the final tube had such challenging requirements, traditional tooling or manufacturing approaches would have been unaffordable. Innovative techniques were used, starting with the manufacture of curved, solid laminate arc segments rather than a full cylinder. Precision machined arc segment stiffeners help hold the arcs to strict dimensions once assembled. Low coefficients of thermal expansion are maintained in all 3 directions: radially, circumferentially, and along the length of the tube.

Prior to making the full-scale tube, RWC built a full diameter but much shorter version of the part as a technology demonstrator. RWC was presented with an Industry Gold Award from CERN in 2022 for this effort, and ultimately won the program from Purdue for the full-size hardware due to the success of the demonstration model and its affordability.

The delivered hardware is 5.3-meters long by 2.4-meters in diameter. It is constructed of ultra-high-modulus prepreg and Nomex honeycomb core made with PMT-F6 cyanate ester resin. There are 1680 metallic inserts made of solid carbon epoxy, titanium and stainless steel; and it includes two 110 MSI carbon fibre (K13916/ F6) rails to support scientific instruments. Surface accuracy requirements were tested to 2.4mm cylindricity inhouse before shipment.

John Marks, VP of Product Development, said, “We were excited to take on this challenging program and to know that we will be contributing to the advancement of humanity’s understanding the fundamental construct of matter. Our work on the demonstration model and final hardware pushed our team’s technical skills to the limit, and we couldn’t be prouder of their performance on this program.”

The Mine refines granulated nickel matte from their smelter into premium-grade nickel powder and briquettes containing 99.8% nickel. Nickel powder is further processed into nickel sulphate at a Refinery in Australia. Nickel sulphate is an essential ingredient in the lithium-ion batteries that drive electric vehicles (EVs). It could be argued that the increase in sales of EVs is one of the biggest climate wins of 2023. Indeed, according to the 2023 Report from Climate Action Tracker, of the 42 sectors which need to achieve net zero status by 2050, the only sector which is on track is the share of EVs in light-duty vehicle sales. Considering how road transport currently accounts for 11% of global greenhouse gas emissions, EVs play a vital role in reducing these emissions.

As such, the polymeric technology required to repair and improve assets within the EV industry equally plays a vital role in supporting the transition to net zero. By repairing damaged assets instead of decommissioning and sending them to landfill, this significantly reduces the climate impact that would otherwise be incurred in this process.

Case study: Feed tank suffering from corrosion

Under Insulation & SCC The Customer’s stainless steel feed tank was suffering from corrosion under insulation and chloride induced stress corrosion cracking. They required a solution that would not only restore the integrity on the substrate, but also protect the asset against future corrosion damage. Not only this, but as the tank operates at elevated temperatures of approximately 70°C (158°F) and processes highly corrosive medium, the repair solution would need to be able to withstand these harsh conditions.

Rezitech specifies Belzona composite wrap solution

Having worked with Rezitech over the course of five years, the Customer had complete confidence in the range of Belzona metal epoxy repair composites and industrial repair coatings the Distributorship offers. As such, they decided to contact them again for their advice and system recommendation.

Following an inspection by Heath Westell, Sales Engineer at Rezitech, the composite wrap system, Belzona SuperWrap II, was specified.

Commenting on this specification, Heath said: “This composite wrap system is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application. The system is specially formulated to restore the strength of holed, weakened and corroded pipe and tank walls, making it the ideal solution for protecting the asset against corrosion under insulation for the long term. In addition, thanks to the cold-curing properties of the composite wrap system, this mitigates the need for hot work, making it a reliable alternative to welding.”

Application procedure:

Firstly, all traces of oil and grease contamination were removed using a suitable Rezitech Degreaser. Following this, the surfaces were grit-blasted to provide a surface cleanliness compliant with ISO 8501-1 SA 2½ (ASNZ 1627.4 class 2.5) with a minimum 75 μm (3 mil) rough angular profile.

Once the surface was prepared, the Belzona 9381 reinforcement sheet was measured out and then wetted out with the Belzona resin system. The resin was then systematically applied to the areas to be repaired. Following this, the Belzona reinforcement sheets were then applied to the tank in three layers. The compression film was then added to the top of the application area. Next, using a roller, the Belzona SuperWrap II composite wrap system was then spread, rolled and compressed to the surface of the tank. The system was then left to cure for approximately eight hours.

Bypass the need for replacement with polymeric technology

By investing in the Belzona composite wrap solution, this enabled the Customer to successfully bypass the need to replace the corroded asset, and instead prolong the lifespan of the asset for years to come. Thus, this enabled the Customer to make significant savings in both time and money. In addition, given the important role EVs play in reducing global carbon emissions, it could be argued that polymeric technology also plays a fundamental role in supporting this transition by safeguarding the integrity of key assets within this industry.

The funding will enable Cellexcel to engage with industry partners to further develop and commercialise Cellexcellent™ in real-world applications, while building its capabilities to enhance biomaterial water resistance.

“Achieving a successful first funding round demonstrates both the strength of our approach and the enormous, pressing opportunity that exists to reduce emissions by enabling the wider usage of biomaterials,” said Tim Pryce, Executive Chair, Cellexcel. “Since I joined Cellexcel in July 2022, we’ve focused on strengthening the team and putting in place the structure to effectively commercialise our technology. Our new funding enables us to move to the next step, engaging industry partners in areas such as automotive, packaging and construction to match our technology to pressing market needs for more sustainable materials that deliver the highest levels of performance.”

College green ventures

College Green Ventures is an early stage venture firm which supports innovative companies with a mission to improve the health of our planet. It is investing in Cellexcel through The Innovation Fund in partnership with QUBIS and Sapphire Capital Partners LLP.

“Cellexcel’s technology solves a pressing, real-world need around decarbonisation,” said Oisin Lappin, Managing Director at College Green Ventures. “As well as its technology and scientific strengths, it has assembled a strong management team that has a proven track record in commercialising innovation. We are excited by the potential market applications for the technology and the impact this can make.”

Low carbon innovation fund 2/Turquoise

The Low Carbon Innovation Fund 2 (LCIF2) is managed by Turquoise, the UK merchant bank specialising in energy, environment and efficiency.  LCIF2 is a venture capital fund investing in eligible small to medium sized businesses based in England, particularly the areas covered by its local government backers, developing products and services which will have a beneficial environmental impact. LCIF2 is funded by the European Regional Development Fund (ERDF), following a successful bid by Norfolk County Council and the University of East Anglia. ERDF is an investment programme part financed by the European Union. LCIF2 is part of the UK government’s portfolio of business support products.  Both LCIF2 and Turquoise participated in the round.

“We are delighted to have invested in Cellexcel. Lowering the carbon footprint of vehicle and building exteriors is a major challenge and Cellexcel has a unique solution to offer,” said Kevin Murphy, director of Turquoise, the fund manager of Low Carbon Innovation Fund 2. “This innovative solution increases the water resistance of biocomposite materials and enables this natural product to replace more carbon intensive products made from plastics, fibreglass or carbon fibre.”

Anglia Capital Group/New Anglia Capital

Anglia Capital Group (ACG) is an Angel Investment network which invests in start-ups and early growth stage businesses who are providing innovative and potentially disruptive solutions to their industry.

New Anglia Capital provides match funding for start-ups who receive angel investment from within Norfolk and Suffolk. This co-investment fund is backed by £4m from New Anglia Local Enterprise Partnership, in partnership with Anglia Capital Group, and aims to stimulate entrepreneurship and economic growth across Suffolk and Norfolk.

After securing investment from angel investors within the ACG network, Cellexcel received match funding from the New Anglia Capital Fund.

“Cellexcel came to Anglia Capital Group with a strong pitch and a compelling solution which is truly innovative in its approach,” said Hannah Smith, Managing Director, Anglia Capital Group (ACG). “The scientific credentials of the team speak for themselves and this, combined with the strong management team meant that Anglia Capital Group’s members – and New Anglia Capital – could see a real opportunity for Cellexcel to succeed. They have strong growth plans for the future and ACG is excited to be a part of their journey.”

As a former BAE Systems employee, Clint will also work alongside junior engineers to enable the growth of new talent within the sector and within the specialism of weights engineering.

To add to the stress team capability, Macsen Taker has been appointed as a graduate engineer following his graduation in aerospace engineering at the University of Manchester.

Also joining Airframe Designs, Hayley Berry has been appointed as quality and security controller. She formerly worked in the medical manufacturing industry within quality control as a product testing specialist for nine years.

Bryony Goodall has also been appointed business and executive support officer with a successful track record of providing administration support across diverse types of organisations.

Jerrod Hartley, CEO of Airframe Designs, said: “We’re excited to find such talent to strengthen our business as we grow to meet the demands of the industry. We strive for business excellence in all of our dealings and our people are at the heart of that. The teams working on our specialist components span an age range of five decades with skills in design, analysis, certification and additive manufacturing.”

Recent projects undertaken by Airframe Designs include the integration of new systems into heavy lift drone platforms, conceptual design at a platform level for new uncrewed air-systems, test rig and tooling for electric vehicle propulsion systems and most recently the design and analysis of operator consoles for a special mission aircraft.

Airframe Designs provides expertise and solutions for the aviation, defence and space industries worldwide with its specialist skills in engineering, design, analysis, certification and additive manufacturing.

MITO’s Executive Vice President, Caio Lo Sardo, spearheaded the application for the Manufacturing Readiness grant as well as expenditure choices. Lo Sardo focused on three main areas for improvement: technology, process improvement, and employee safety.

MITO implemented an ERP that will provide MITO with operational efficiency and accuracy, managing inventory, production, warehousing, customer orders, and  purchasing process, and shipping. This technology solution will minimize errors, save unnecessary costs, and streamline operations procedures in a single place.

MITO installed an automated milling/screen system that will be used towards MITO’s flagship formulation, E-GOTM, and speed up the manufacturing at the post-processing level. The high output post-processing equipment will enable MITO to achieve large-scale volume processing and fulfill orders with efficiency, quality, and consistent batch-to-batch post-processing.

MITO invested in an automated ventilation system that reduces air interior pollution. The Downdraft tables and Non-Sparking Walk-in clean air stations enable MITO to maintain a safe working environment and air quality in the Indianapolis warehouse space. While collecting hazardous dust from particles during manufacturing (post-processing) and packaging as well as during the research activities to characterize MITO’s formulations in different polymers and troubleshoot customer issues, the system keeps hazardous and controlled particulates from reaching the environment, contributing to a key MITO value – a sustainable operation.

 “The new equipment and technology purchases are directly related to better manufacturing output, increasing capacity, and developing both more efficient and safer processes. Using the Manufacturing Readiness grant for critical large expense purchases also allowed MITO to focus on small but meaningful areas of manufacturing improvement,” states Lo Sardo. “Our E-GO additive is sold by the gram. Additional development is ongoing to make this process more robust and cost-effective. The material is engineered to deliver large value at low loading levels – users need 0.1% of E-GO by weight of the material. Our product could quickly make a significant market impact with a large volume or high-impact use case. And we now have the capacity to scale our production, through the support of the Conexus grant.“

A case study on how MITO has deepened their manufacturing ability through the Manufacturing Readiness grant can be found here.

What are the examples of qualifying smart manufacturing investments?
Projects should directly affect manufacturing processes and focus on investments in commercial-ready equipment through established vendors. The equipment should be beyond ‘advanced’ in nature, i.e. more technologically intensive and broadly innovative than mere upgrades via standard automation, increased capacity, tighter tolerances, improved fabrication techniques, or other incremental improvements that are common for the applicant’s sector. Strong applications offer a detailed description for how the applicant is undertaking an initiative that will be transformative beyond the status quo for themselves and competitors. The equipment should credibly leverage technologies such as industrial internet of things (IIoT), sensor technology, COBOTS, additive manufacturing (3D printing), big data and analytics, cybersecurity, machine learning, artificial intelligence (AI), digital twin, advanced modeling, blockchain, autonomous robotics or vehicles, augmented, virtual, or mixed reality, cloud computing, and advanced communications (5G, etc).

Cure Marine CEO Carl Bird said the launch marked the beginning of a new era for the company. “The ‘Cure Custom 70’ is the largest sailing vessel ever launched by Cure Marine and indeed the first all-carbon sailing catamaran to be launched in Australia in the last five years”, Carl Bird said. “The launch not only reinforces Cure Marine’s commitment to innovation but also solidifies our position as a major player in the industry.”

Founded in 2005 by Sunshine Coast locals Dave Biggar and Ian McMahon, Cure Marine began as an ambitious project to create a leading composites facility and deliver high-end sailing vessels for the recreational market. Alongside sister companies Zone RV and One Composites, Cure Marine is dedicated to elevating the Australian Marine Industry with continuous innovation and quality craftsmanship.

Owens Corning’s vertically integrated glass nonwovens business that supports the Roofing segment and other building products customers, along with the recently acquired WearDeck business, remain core activities of the company and are out of the scope of this evaluation.

Brian Chambers, Board Chair and Chief Executive Officer of Owens Corning, said, “Our Board and management team regularly review strategic opportunities with a goal to maximize shareholder value. Through this disciplined approach to capital allocation, we have taken actions over the past several years to optimize our performance and have concluded it is the right time to explore options for our glass reinforcements business as we continue to focus on strengthening our position in building and construction materials.”

“We’re proud of our 85-year pioneering legacy in glass reinforcements products and technology,” said Chambers. “Our talented glass reinforcements team has consistently produced differentiated, high-quality products based on our material science expertise, deep technical knowledge, and broad application experience. We have built market-leading positions in key regions and applications, including renewable energy, which creates the opportunity to operate as a core business within another company or as a stand-alone entity focused more on industrial end markets. Throughout our review, we are committed to maintaining our strong customer relationships with the same high standards and close collaboration.”

The company has retained Morgan Stanley & Co. LLC as financial advisor to assist in the review of strategic alternatives.

A range of options are under consideration, including a potential sale, spinoff, or other strategic option. There can be no assurance that the strategic review will result in any transaction or other outcome. The company has not set a timetable for completion of the review and does not intend to disclose developments or provide updates on the progress or status of the review unless and until it deems further disclosure is appropriate or required.

The first experiment assesses the performance of a sample coupon part made with Stratasys’ Antero^® 800NA FDM^® filament filled with tungsten. Antero 800NA is a high-performance PEKK-based thermoplastic with excellent mechanical properties, chemical resistance, and low outgassing characteristics. Adding tungsten is intended to provide shielding against harmful radiation such as gamma rays or x-rays.

The second passive experiment is designed to see how 3D-printed materials perform in space. It will include Antero 840CN03 FDM filament, which features ESD properties for use with electronics and was used on the Orion spacecraft. The experiment will also include a new ESD photopolymer manufactured by Stratasys partner Henkel for use with Stratasys’ Origin^® One 3D printers and designed for high-heat environments. This experiment will subject coupon samples of the 3D-printed materials to moon dust, low pressure that can lead to outgassing, and the rapid temperature swings that result from virtually no atmosphere on the moon.

“Additive manufacturing is an important technology for space missions where every ounce of weight matters and high performance is essential,” said Chief Industrial Business Officer Rich Garrity. “This set of experiments will help us understand how to fully leverage 3D printing to keep people and equipment safe as we travel to the moon and beyond.”

Parts will be brought to the lunar surface by an unmanned lander in a Stratasys 3D printed carrier structure made from ULTEM™ 9085 thermoplastic, which is a material also commonly used in commercial aircraft interiors.

Advancing Tooling and Mold Production

The additive manufacturing process excels in tooling and draping mold production, offering reduced lead times, increased production flexibility, and efficient cost and inventory control. However, effective utilization has traditionally demanded expertise and methodological intricacies.

This collaboration shifts the focus towards user experience, providing simple, robust, and accessible workflows. Operators of any level can now easily program and oversee mold printing from a basic CAD file.

“Partnering with ADAXIS enables us to offer our customers an integrated turnkey solution, comprising seamlessly integrated equipment and software, making our technology and expertise instantly accessible to a broader audience.”

AdaOne introduces a range of unique features tailored for tooling production:

1. Automatic Internal Support: Reduces design time and material usage by the automatic generation of internal stiffeners inside the tooling geometry.

2. Localized Double Bead on Main Surfaces: Generation of machining margin and local reinforcement to facilitate machining of the tooling surfaces.

3. Selective Corner Compensation: Adds extra material at corners to ensure correct final geometry after machining.

4. Continuous Printing Path: Minimizes starts and stops through automatic seam positioning and tool path optimization.

AdaOne also generates machining trajectories, providing operators with a comprehensive turnkey solution.

The AdaOne integration with BEAD technology, supported by Belotti’s expertise, simplifies path programming, reduces material usage, and shortens print time. A collaboration with Airtech ensures that operators receive pre-configured settings tailored to their materials, seamlessly meeting industry standards.

“Collaborating with Belotti’s expert team while applying our expertise in user experience and software development allows us to integrate numerous and unique features into a robust, stable, and industrial-grade solution,” says Emil Johansson, CPO of ADAXIS.

ecoRacer30

As a member of the Alliance for European Flax-Linen and Hemp, Bcomp, headquartered in Fribourg, Switzerland, has this year been working with Northern Light Composites (nlcomp), based in Monfalcone, northern Italy, on the creation of what is billed as the first fully recyclable nine-metre-long sailing boat – the ecoRacer30.
The boat is based on nlcomp’s proprietary rComposite technology – a combination of thermoplastic resins and BComp’s ampliTex high-performance natural fibre reinforcement fabrics and patented powerRibs technology.

It was built in a collaborative effort with the help of Barcelona-based Magnani Yachts, which took care of the composite manufacturing, and Sangiorgio Marine, which provided technical assistance as the boat was being assembled at its shipyard in Genova, Italy.
Magnani Yachts has subsequently become the first shipyard to hold an rComposite license and others are now being encouraged to adopt the technology.
“As the most commonly used material in boat building, fibreglass is not easily recyclable,” says Fabio Bignolini, CEO of nlcomp. “Consequently, many fibreglass boats end up being burned, sunk or abandoned. In the European Union, there are an estimated 80,000 abandoned boats with only one in twenty disposed of in an environmentally responsible manner.”

The second ecoracer30 is currently under construction and has already been sold and nlcomp is planning to build a fleet of eight of these boats in time to enter a series of regattas in the summer of 2025.

Flax 27

Greenboats, based in Bremen, Germany, is another specialist in building boats from natural fibre composites and has this year launched the Flax 27 daysailer

The lower hull of this vessel is also made from Bcomp’s ampliTex technical fabrics in combination with a sandwich core of recycled PET bottles. Using a vacuum infusion process, the fibres were integrated with a plant-based epoxy resin in order to further reduce the CO2 footprint of the vessel.The light structure and modern shapes of the lower hull of the boat result in very fast, sharp and agile handling on the water. Greenboats has also recently announced significant new backing from alliance member Groupe Depestele, which manages 13,000 hectares of flax land in Normandy, France.

“We’re at a pivotal juncture in the evolution of natural fibre composites as a new product category,” says Jan Paul Schirmer, managing director of Greenboats. “Our clients believe in our technology but demand a more reliable and scalable supply chain. Our partnership with Groupe Depestele will go a good way to establishing this.”

Expectations

Different expectations for the performance of parts must be guaranteed, such as impact resistance, rigidity, surface appearance and resistance to hydrolysis, which is simpler with an established supply chain.
The Beneteau Group, based in Croix de Vie, France, for example, manufactures more than 30,000 composite parts per year to equip its boat decks and is looking to incorporate more natural fibres into them.
This year Beneteau Group has collaborated with Chomarat on the development of hybrid composites of glassfibre and hemp. The resulting TER²A mat was a finalist in 2023 JEC Innovation Awards.

Blue Nomad

A project in Switzerland has meanwhile proposed the use of flax fibre composites in solar-powered habitats designed for comfortable living on the oceans – as the world grapples with the frightening implications of climate change and rising sea levels.
As envisaged by students from Institut auf dem Rosenberg in St Gallen, Switzerland working with Denmark-based SAGA Space Architects,
Blue Nomad structures would form modular blocks to establish large communities and oceanic farms.
It’s a striking vision of a future where the lines between land and water blur, and sustainability and community building lie at the heart of new human settlements.
The vision is not just theoretical however – plans are now being made for a maiden voyage of a Blue Nomad home across Europe to promote ocean sustainability and climatology.
The project’s scale models for the London exhibition, as well as the first Blue Nomad structure, are based on natural fibre composites again employing BComp’s ampliTex flax fibres in gradient designs, along with a natural bio-resin.

Monitoring the marine market as pioneers in new composite development, Alliance for European Flax-Linen and Hemp continues to be amazed at the innovation and pace of development.

Whatever the future holds, it appears flax fibres and natural fibre composites will have an important role to play.

“This is a major milestone for us. Aircraft design and production are strongly regulated for a good reason: to produce safe mobility products. I am pleased that Volocopter’s production facility has the trust of and stamp of approval from LBA to manufacture commercial aircraft that can be delivered to customers once the VoloCity receives type certification. Our team has proven that we can produce safe and high-quality test aircraft, and we now look forward to shortening our production lead time for scaling,” says Andreas Fehring, Chief Operating Officer of Volocopter.

Under EASA’s SC-VTOL (Special Condition VTOL) Enhanced certification category, the VoloCity will become the first commercial eVTOL with the highest global safety standards in aviation. Achieving this safety standard allows VoloCity to fly above congested urban areas quietly and efficiently, adding an extra layer of alternative mobility to the transportation mix in cities.

ecoRacer30

En tant que membre de l’Alliance, Bcomp, dont le siège est à Fribourg (Suisse), a travaillé cette année avec Northern Light Composites (nlcomp®), basé à Monfalcone, dans le nord de l’Italie, sur la création de ce qui est présenté comme le premier voilier de neuf mètres de long entièrement recyclable – l’ecoRacer30.
Le bateau est basé sur la technologie propriétaire rComposite de nlcomp® – une combinaison de résines thermoplastiques et de tissus de renforcement en fibres naturelles haute performance ampliTex™ de Bcomp, ainsi que sur la technologie brevetée powerRibs™.

Le bateau a été construit en collaboration avec Magnani Yachts, basé à Barcelone, qui s’est chargé de la fabrication des composites, et Sangiorgio Marine, qui a fourni une assistance technique lors de l’assemblage du bateau dans son chantier naval de Gênes, en Italie.
Magnani Yachts est ainsi devenu le premier chantier naval à détenir une licence rComposite et d’autres sont maintenant incités à adopter cette technologie.
“La fibre de verre, qui est le matériau le plus couramment utilisé dans la construction navale, n’est pas facilement recyclable”, explique Fabio Bignolini, PDG de nlcomp®. “Par conséquent, de nombreux bateaux en fibre de verre finissent par être brûlés, coulés ou abandonnés. Dans l’Union européenne, on estime à 80 000 le nombre de bateaux abandonnés, dont seulement un sur vingt est recyclé de manière responsable.”

Le deuxième ecoracer30 est actuellement en construction et a déjà été vendu. nlcomp® prévoit de construire une flotte de huit de ces bateaux à temps afin de participer à une série de régates durant l’été 2025.

Flax 27

Greenboats, basé à Brême, en Allemagne, est un autre spécialiste de la construction de bateaux en fibres naturelles composites et a lancé cette année le voilier de jour Flax 27. La coque inférieure de ce bateau est également fabriquée à partir de tissus techniques ampliTex™ de Bcomp, combinés à un noyau sandwich de bouteilles PET recyclées.

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Grâce à un processus d’injection sous vide, les fibres ont été intégrées à une résine époxy à base de plantes afin de réduire davantage l’empreinte CO₂ du navire.
La structure légère et les formes modernes de la coque inférieure du bateau se traduisent en un comportement très rapide, vif et agile sur l’eau.
Greenboats a également annoncé récemment un nouveau soutien important de la part du Groupe Depestele, membre de l’Alliance, qui gère 13 000 hectares de lin en Normandie.
“Nous sommes à un moment charnière de l’évolution des composites à base de fibres naturelles en tant que nouvelle catégorie de produits”, déclare Jan Paul Schirmer, directeur général de Greenboats. “Nos clients croient en notre technologie mais exigent une chaîne d’approvisionnement plus fiable et plus évolutive. Notre partenariat avec le Groupe Depestele y contribuera largement”.

“Nous sommes à un moment charnière de l’évolution des composites à base de fibres naturelles en tant que nouvelle catégorie de produits”, déclare Jan Paul Schirmer, directeur général de Greenboats. “Nos clients croient en notre technologie mais exigent une chaîne d’approvisionnement plus fiable et plus évolutive. Notre partenariat avec le Groupe Depestele y contribuera largement”.

Les attentes

Différentes attentes concernant les performances des pièces doivent être garanties, telles que la résistance aux chocs, la rigidité, l’aspect de surface et la résistance à l’hydrolyse, ce qui est plus simple avec une chaîne d’approvisionnement bien établie.
Le groupe Beneteau, basé à Croix de Vie, en France, par exemple, fabrique plus de 30 000 pièces composites par an pour équiper les ponts de ses bateaux et cherche à y incorporer davantage de fibres naturelles.
Cette année, le groupe Beneteau a collaboré avec Chomarat pour développer des composites hybrides de fibre de verre et de chanvre. Le produit qui en résulte, le TER²A mat, a été finaliste des JEC Innovation Awards 2023.

Blue Nomad

Un projet suisse propose d’utiliser des composites à base de fibres de lin dans des habitats alimentés par l’énergie solaire et conçus pour vivre confortablement sur les océans, à l’heure où le monde est confronté aux conséquences effrayantes des aléas climatiques et de la montée du niveau des mers.
Comme l’envisagent les étudiants de l’Institut auf dem Rosenberg de Saint-Gall, en Suisse, en collaboration avec l’agence danoise SAGA Space Architects, les structures Blue Nomad formeraient des blocs modulaires permettant d’établir de grandes communautés et des fermes océaniques.
Il s’agit d’une vision saisissante d’un avenir où les frontières entre la terre et l’eau s’estompent et où la durabilité et la construction de communautés sont au cœur des nouveaux établissements humains.
Cette vision n’est pas seulement théorique : des plans sont en cours d’élaboration pour le voyage inaugural d’une maison Blue Nomad à travers l’Europe afin de promouvoir la durabilité des océans et la climatologie.
Les modèles réduits du projet pour l’exposition de Londres, ainsi que la première structure Blue Nomad, sont basés sur des composites à base de fibres naturelles, employant à nouveau les fibres de lin ampliTex™ de Bcomp dans des motifs dégradés, ainsi qu’une bio-résine naturelle.

Alliance for European Flax-Linen and Hemp, qui suit le marché nautique en tant que pionnière dans le développement de nouveaux composites, continue d’être étonnée par l’innovation et le rythme de développement.

Quel que soit l’avenir, il semble que les fibres de lin et les composites à base de fibres naturelles auront un rôle important à jouer.

This revolutionary fireproof material, unlike any FRP composite material on the market, offers remarkable protection for FRP products against heat and fire events. This fireproofing capability paves the way for a significantly safer and more sustainable future across diverse FRP applications and industries.

A game-changer for FRP products and applications

ALEC² PyroWall™ fundamentally transforms fire protection for FRP products by providing a fireproof barrier. This is particularly crucial for sectors like:

Infrastructure construction
ALEC² PyroWall™ enhances the fire safety of new infrastructure components like building panels and cladding.

Infrastructure repair
Professionals can use ALEC² PyroWall™ to provide fireproof protection for FRP used to retrofit existing infrastructures and augment long-term safety.

Unlike traditional fire-resistant FRP, ALEC² PyroWall™ boasts:
• Zero Burn Rate – Eliminates the risk of ignition or fire propagation even in extreme heat.
• Unmatched Safety – Safeguards people and assets from impacts of fire events.
• Enhanced Structural Integrity – Maintains its form and characteristics during extreme heat and fire events, preventing catastrophic failures of the FRP being protected.
• Stops Fire Damage – properly protected FRP structures and/or products will not experience any significant impact.

Composite circularity and sustainability redefined

Beyond its exceptional fireproof capabilities, ALEC² PyroWall™ also achieves a remarkable 100% circular lifecycle:
• Closed-Loop System – Enables infinite recycling and reuse, eliminating reliance on virgin materials and landfill waste.
• Recycled Content – Composed of ~85% recycled industrial waste, it maximizes waste recovery and reuse and minimizes environmental impact.
• 100% Reusable – At end of use PyroWall™ can be easily recycled and processed into new products.

A safer and circular option for manufactured FRP composites used in diverse industries

The unique combination of fire proof safety and sustainability offered by the ALEC² PyroWall™ material empowers various industries to enhance their circular and sustainable composite materials goals:

Construction
From fireproofing building components and cladding to safer FRP infrastructure products, ALEC² PyroWall™ elevates fire safety to a new achievable standard in the built environment.

Manufacturing
Fireproofing FRP enclosures can significantly enhance people and asset safety in facilities.

Renewable energy infrastructure
Fireproofing critical components in wind turbines and battery storage systems ensures reliable and sustainable energy generation.

“The significance of ALEC² PyroWall™’s fireproof, circular and sustainable benefits extends across numerous industries using FRP products, such as construction, maritime, mobile and transportation revolutionizing fireproofing protection and environmental responsibility. As a fireproof barrier, ALEC² PyroWall™ empowers infrastructure construction and repair projects to achieve exceptional fire safety standards, safeguarding lives and assets. Take, for instance, its application in the marine industry. ALEC² PyroWall™ ensures exceptional fire safety within yacht and cruise ship interiors, critical components, and structures. This enhances passenger safety and underscores our commitment to composites circularity and sustainability. Similarly, ALEC² PyroWall™ offers a transformative solution that safeguards cargo ships, offshore platforms and marine infrastructure. By utilizing a material that is both fireproof and 100% recyclable, we’re helping safeguarding lives while contributing to a composite circularity and more eco-conscious future,” said Bill Hayward at WT&C.

« Thales est une société qui revêt un intérêt certain pour les filières propres à Phelma comme les filières Ingénierie Physique pour la photonique et la microélectronique (IPHY), Signal, image, communication, multimédia (SICOM), Systèmes Embarqués et Objets Connectés (SEOC), Science et ingénierie des matériaux (SIM), Biomedical engineering (BIOMED) ou le parcours de master Photonique et Semiconducteurs (PhSem) », évoque Pablo RUBIOLO, directeur adjoint en charge des relations entreprises de l’école.

Accompagnement des étudiants Grenoble INP – Phelma dans la construction de leur projet professionnel

Grâce à cet accord, Thales participera à l’intégration des étudiants et diplômés de Phelma en offrant des opportunités de stages et d’alternance, d’emplois et de Volontariat International en Entreprise (VIE), entre autres initiatives.

« La signature de cette convention officialise un partenariat de longue date entre Phelma et Thales, comme en atteste le nombre d’étudiants que nous accueillons chaque année en stage et alternance, mais aussi la diversité des collaborateurs diplômés de l’école répartis dans nos différents sites géographiques, nos secteurs d’activité et nos métiers-clés. Ce partenariat sur 3 ans nous permettra d’explorer davantage les synergies d’ordre académique et dans la recherche. », évoque Marion FELIX, Responsable Relations écoles & Attractivité chez Thales.

Partage d’expertises

Thales impliquera également ses experts dans le programme d’études des élèves-ingénieurs de Phelma et prendra part à des conférences métiers via des séances en amphis carrière, destinées aux étudiants de première année, ainsi qu’à des conférences plus générales portant sur des enjeux sociétaux spécifiques et ouvertes à un public plus large.

Thales accueillera également sur certains de ses sites industriels, des étudiants de Phelma pour leur faire découvrir leur entreprise de manière générale, mais également leurs ateliers de fabrication, leurs showrooms… Ce temps sera également un moment d’échange où les questions d’évolution des métiers et des compétences pourront être abordées.

Qualité des enseignements et participation à la vie de l’école

En outre, sa participation à des conférences, sa présence lors des simulations d’entretiens des étudiants de troisième année, ainsi que sa participation à la Journée des partenaires de l’école témoignent de son fort engagement envers notre institution.

Photo : Grenoble INP – De gauche à droite : Pablo RUBIOLO, directeur adjoint en charge des relations entreprises de l’école, Marion FELIX, Responsable Relations Ecoles et Attractivité Sud-Est chez Thales et Aurélie DI NOLA, responsable administrative du service des Relations entreprises de l’école.

Sustainability roadmap well on its way – 345 certified sustainable products

Last January, BASF’s Monomers division committed itself to developing a circular option in every major product line by 2025. Now, only one year later, the division continues to deliver on that promise. As of February 2024, approximately 70 percent of the large portfolio of isocyanates, polyamides, glues and resins, precursors and inorganics products are available in chemically recycled (Ccycled®) or biomass-balanced variants2 (BMB), as LowPCF products3 or even ZERO variants (Zero Emissions, Renewable Origin). In total, the division now offers 345 certified sustainable product alternatives to its various customer industries, which range from food packaging, textiles, automotive or construction to wood binders and many others.

New technologies to boost the sustainable transformation

Besides offering more sustainable product variants, BASF’s Monomers division continues to invent completely new solutions like its polyol recycling. Further, the division develops new proprietary technologies that drive the sustainable transformation of the various industries it serves. With the newest addition to its portfolio, loopamid®, the Monomers division has developed an innovative solution to improve circularity in the fashion industry and recycle polyamide 6-based textile waste. With this cutting-edge technology, used fibers and materials can be recycled into new yarn over multiple cycles while retaining the material characteristics of conventional virgin polyamide. More information about this breakthrough technology is available here.

Various operational excellence measures cut tons of CO2 emissions

Besides the significant additions to its product portfolio, BASF’s Monomers division has also successfully implemented many measures for its production sites in all regions that further reduce carbon emissions. With these CO2 mitigation measures Monomers contributes significantly to BASF’s ambitious sustainability target of reaching net-zero carbon emissions by the year 2050. Utilizing the benefits of BASF’s global Verbund network, several high-impact measures resulted in substantial CO2 reductions. A prime example are improved heat recovery measures at the site of Shanghai BASF Polyurethane Co. Ltd. (SBPC), which are expected to reduce CO2 emissions by up to 34,000 tons every year.

Shanghai is a pioneer in the development of the hydrogen energy industry and actively promotes the sustainable development of fuel cell vehicles. The goal is to build a world-class hydrogen energy technology innovation highland, industrial development highland, and diversified demonstration application highland by 2035. As the “City of Automobiles”, Jiading District has become the area with the largest automobile industry, the most complete industrial chain, and the most significant industrial agglomeration among individual cities in China, according to Forvia.

Based on the favorable policy environment and the solid business foundation established by Forvia in Shanghai and Jiading District, the group decided to locate its new hydrogen energy business entity in Shanghai and establish Faurecia (Shanghai) Hydrogen Solutions Holding Co., Ltd. The new entity has approximately 35 employees and has established a hydrogen storage system assembly line with an annual output of 1,000 units to continue to provide the market with hydrogen energy products with better performance and cost.

Key players in hydrogen energy

Reducing emissions and improving air quality have been at the heart of Forvia group innovation for more than 20 years. As one of the recognized clean energy sources, hydrogen energy has become the centerpiece of the group’s carbon neutrality strategy. Since 2018, the Group has invested more than 400 million euros in the research and development of hydrogen energy technology. Through its Symbio joint venture with Stellantis and Michelin, Forvia develops and manufactures hydrogen storage systems and fuel cells, covering 75% of the hydrogen transportation value chain.

Forvia is actively deploying the hydrogen energy industry and will develop hydrogen storage solutions suitable for different application scenarios such as passenger cars, commercial vehicles, logistics, and industry in the next ten years. Forvia group’s goal is to become a global leader in hydrogen transportation and plans to achieve sales of 3.5 billion euros by 2030 combined with the Symbio business.

Drawing up a blueprint for the hydrogen energy industry in China

As the world’s largest hydrogen producer, China has elevated hydrogen energy to a national energy strategic status and is a strategic emerging industry and a key development direction for future industries.

Forvia is working in the same direction as China’s strategy and has planned ahead of schedule. It acquired Shenyang Silinda Anke New Technology Co., Ltd. in 2021 and officially launched its hydrogen energy business in China. The newly established Faurecia Silinda Safety Technology (Shenyang) Co., Ltd. factory has supplied a total of more than 15,000 Type III ctylinders for vehicles, and took the lead in obtaining the country’s first Type IV hydrogen storage bottle production qualification and product type certification.

In addition, Forvia continues to increase investment in hydrogen energy business, has established R&D centers in Shanghai and Shenyang, and controls 2 hydrogen cylinders production and manufacturing bases. At present, Forvia has achieved an annual output of more than 1,000 hydrogen storage systems, and large-capacity IV hydrogen storage bottles are in the testing phase. Forvia has established cooperative relationships with many relevant parties in the hydrogen energy field to jointly promote the development of China’s hydrogen energy industry.

Ma Chuan, member of Forvia’s global executive committee and president of Forvia China, said: “Hydrogen energy is an important energy source for the future and a key driver of the decarbonization of mobility. Forvia is committed to using leading technologies and solutions. The plan will promote the development of China’s hydrogen energy industrialization and help China’s automobile industry and society as a whole achieve the 30-60 dual-carbon goal.”

The work of the project partners has successfully overcome the technological barriers identified at the beginning of the project, including:

1. The development, implementation, and characterization of carbon/thermoplastic (C/PEKK) tapes.
   
2. The creation of an automated deposition process for consolidation outside of autoclaves.
   
3. The establishment of the ISW welding technology for assembly.

The definition of elementary parts intended to form the assembled components of the HAICoPAS demonstrator was carried out in close collaboration with an industrial advisory committee comprising Airbus, Safran, Daher, Hutchinson, and ATC. The final version of the aeronautical demonstrator, made from composite tapes and assembled using ISW technology, is currently on display at the JEC World Innovation Planets exhibition in the Mobility section.

This innovative demonstrator was successfully developed within the framework of the collaborative project “HAICoPAS” (Highly Automatized Integrated Composites for Performing Adaptable Structures). The HAICoPAS project is a collaborative initiative led by Hexcel and Arkema, along with their industrial partners (Ingecal, Coriolis Composites, Pinette Emidecau Industries (PEI), and Institut de Soudure). Additionally, a consortium of university laboratories, spearheaded by CNRS and comprising the PIMM (CNRS – Arts et Métiers ParisTech – Cnam) and LTEN (CNRS – Université de Nantes), played a crucial role in this endeavor. The Structuring R&D Project for Competitiveness (PSPC) received support from Bpifrance as part of the Investment for the Future Program and was endorsed by the Polymeris competitiveness cluster.

The MODALIS Group, an intermodal logistics solution provider (manufacture-lease-maintenance of containers, swap-bodies and intermodal wagons, management of intermodal and combined transport terminals, engineering in intermodal solutions and energy savings) and the engineering firm AGESIA, an expert in thermoplastic composites, are unveiling their brand new prototype swapbody with a lightened floor, which they have just previewed in the Planet Mobility exhibition area at JEC World 2024, the world’s leading trade fair for composite materials and their applications.

A ground-breaking innovation, the result of four years’ research and development, this new 45 ft intermodal transport unit codified C45 (L=13,710 m x W= 2,550 x H= 2,900 mm), the most common model in Europe, dedicated to all European road-rail freight professionals, can easily circulate on all rail and road networks, a considerable asset for European hauliers.

A resistant composite that has economic and ecological benefits

Designed using a composite material, with a thermoplastic ‘structural sandwich’ panel, this new swap-body aims to save almost a tonne, in particular due to the composite panel replacing both the steel crossmembers and the wooden plywood initially used in the floors of this type of transport unit. Its assembly is joined to the special steel stringers by means of a chemical bond, a technology developed and patented by AGESIA called CIB (Covalent Intermediate Bonding).

Also not that thick, the steel/composite floor offers the largest interior volume on the market, while being extremely strong.

These are decisive advantages, particularly from an economic perspective, for intermodal transport professionals, who will be able to transport more goods with the same body. “There are already lightweight bodies, but they provide less interior volume because the floor is too thick. It’s possible to have units with greater interior volume, but they are heavier. With this new flat rack, we’ll provide a unique product that combines both aspects,” explain Pierre-Nicolas Chilles, MODALIS Technical and Innovation Manager, and Jan Verhaeghe, Managing Director of the engineering firm AGESIA.

There are also ecological advantages in the context of decarbonising transport, because this composite material is 100% recyclable and the quantity of carbon dioxide (CO2) emitted per tonne of goods transported intermodally is reduced.

A prototype subjected to many technical tests before going into production

prototypes will eventually be manufactured by CCFC, the Italian manufacturer of road-rail semi-trailers, swap-bodies and containers, which was acquired by MODALIS in January 2023. Following official technical and laboratory tests (more than 250,000 body movements simulated to observe changes in the flat rack over a 20-year period), the lightweight swapbodies will be put into circulation on the road and rail networks for further analysis under real operating conditions. At the same time, the engineering firm has developed a ‘digital twin’ prototype based on fibre optics: cutting-edge technology for intermodal transport! This digital twin makes it possible to reproduce the movements undergone by the swap-bodies over time and thus to anticipate any technical problems so as to enhance the lightweight swap-body prototype.

With this innovation, the Modalis group is pursuing its ambition to offer a sturdy range of innovative equipment to European hauliers, shippers and logistics operators to encourage them to move towards low-carbon intermodal logistics.

Photo: From left to right: Pierre-Nicolas Chilles, MODALIS Technical and Innovation Manager, Bernard Meï, MODALIS Group CEO, and Jan Verhaeghe, Managing Director of the engineering firm AGESIA.

Rear Admiral Doull stated,

“In today’s visit, we are reminded of the critical role that innovation and excellence in manufacturing play in supporting the UK’s security. Norco’s dedication to advancing composite solutions not only contributes to our nation’s defence capabilities but also reinforces our position on the global stage as leaders in technological and engineering competence. It’s partnerships like these that ensure our continued security and technological edge.”

Mark Northey, Managing Director of Norco, expressed his gratitude for Rear Admiral Doull’s presence and the strong partnership between Norco and the Royal Navy,

“Reflecting on Norco’s upcoming 40th anniversary and my 30 years leading the charge, the journey has been remarkable. Having Rear Admiral Doull visit our facilities really puts into perspective the vast array of products we’ve developed and our significant contributions to national defence. This visit underscores the dedication and hard work of our team, highlighting our commitment to innovation and excellence in composite manufacturing.”

This visit reinforces the strong relationship between Norco Composites & GRP and the UK’s defence sector, highlighting the company’s role in contributing to national security and technological advancements.

“Rolling out CityAirbus NextGen for the very first time is an important and very real step that we are taking towards advanced air mobility and our future product and market. Thank you to our community, team and partners all over the world for helping us make this a reality,” said Balkiz Sarihan, Head of Urban Air Mobility at Airbus.

At the same time, Airbus is expanding its global network and partnerships to create a unique ecosystem that will foster a successful and viable AAM market. Airbus recently signed a partnership agreement with LCI, a leading aviation company, to focus on the development of partnership scenarios and business models in three core AAM areas: strategy, commercialisation and financing.