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Innovation Awards finalists

The 30 JEC World Innovation Awards finalists


Identify, promote and reward the most innovative composite solutions worldwide. The JEC Innovation Awards pay tribute to Innovation through the cooperation of raw material producers, processors and End-Users. Every presented Innovation should allow the manufacturing of a part of final Product. 30 International collaborative programs, detailed above, will be presented at the show. 10 of these programs will be rewarded for their exceptional impact and performance.

 

Sponsored by

Kordsa

 

Aerospace Application

Infusion technology for an aircraft wing

AeroComposit, JSC (Russia) and partner Solvay (UK).

The use of infusion technology to manufacture primary structural elements for an aircraft wing, making it possible to build integral composite structures with high elongation and a complex aerodynamic form.

Key benefits: lighter aircraft structures; lower cost of equipment; reduced total time and power spending; more flexibility in production; lower porosity, better quality of parts.

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Modular thermoplastic stiffening panels

Fraunhofer ICT (Germany) and partners Airbus Operations GmbH (Germany), Laser Zentrum Hannover e.V. (Germany), TenCate Advanced Composites BV (The Netherlands), ElringKlinger AG (Germany), KMS Automation GmbH (Germany).

Modular thermoplastic stiffening panels for aerospace applications. The panels lead to weight and cost savings, in addition to easy adaptation. They are recyclable and exhibit outstanding flame resistance. 

Key benefits: weight savings; modular design; easy integration by laser transmission welding; integrated functionality via hybrid molding; economical manufacturing for high volumes. 

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Polyurethane-rtm nose cone for jet engines

University of Applied Sciences Rapperswil (Switzerland) and partners FACC (Austria), Rühl Puromer GmbH (Germany), Isotherm AG (Switzerland), WPT, TU Dortmund (Germany)

Using the high-pressure polyurethane-RTM process, jet engine nose cones with optimized properties can be manufactured in a fraction of the time commonly needed today.

Key benefits: better impact and abrasion properties; dramatically reduced production time and costs; optimized and easier processing; prolonged operating time; lower material costs.

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Aerospace Process

Complex structural applications of mai sandwich technology

Airbus (Germany) and partners BMW Group (Germany), Technical University of Munich (TUM) (Germany), Neue Materialien Bayreuth GmbH (Germany), Werkzeugbau Siegfried Hofmann GmbH (Germany), BASF SE (Germany), Foldcore GmbH (Germany), Neenah Filtration (Germany), SGL Carbon GmbH (Germany).

Production of a cost-effective, complex 2.5D thermoplastic composite sandwich structure with a very short cycle time of less than 5’ for aerospace materials and 2.5’ for automotive materials.

Key benefits: high functionality through injection directly on skin; prevention of voids in the outer layer due to the process; very economic due to short cycle times in one device; cross-industry mid- and large-scale production.

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Mould-less monocoque manufacturing process

M. Torres Diseños Industriales SAU (Spain)

New manufacturing process for large monocoque composite structures with fully integrated reinforcements and without the need for complete molds.

Key benefits: dramatic tooling reduction, up to 70%; global manufacturing cost reduction, up to 40%; weight reduction due to the elimination of fasteners; topological optimization of the reinforcements; process flexibility breakthrough.

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Full-ooa tp welded primary airframe

Stelia Aerospace (France) and partners Porcher Industries (France), Sintex NP (France), Compose Tool (France), CETIM (France), Aviacomp SA (France), Institut de Soudure / Composite Integrity (France). 

Full-OoA thermoplastic airframe with industrial dynamic induction welding demonstration using carbon tape for future fuselage applications and multi-functional parts produced by an overmolding process. 

Key benefits: induction welding demonstration for fuselage panels; 100% OoA thermoplastic structure; new design opportunity; fully automated, cost-effective process; 100% recyclable airframe (TP). 

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Automotive Application

Composite lightweight automotive suspension system

Ford-Werke GmbH (Germany) and partners Gestamp (UK), GRM Consulting (UK), University of Warwick (UK).

A structural composite suspension component producing significant weight savings using an industry-first patented prepreg/SMC/steel overmolded manufacturing process, designed applying newly developed computer-aided engineering (CAE) technology.

Key benefits: weight reduction with an associated reduction of CO2 emissions; complex composite part manufactured in one shot; reduced engineering/development time to market; CAE tools for the optimization of multi-material parts.

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Lightweight seat back frame for suv second row

Hanwha Advanced Materials (South Korea)

Development of the world’s first SUV second-row seat back frame using composite materials.

Key benefits: low weight; Sshort cycle time and reduced number of parts; recyclable.

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Development and manufacturing of a full-cfrp car body

Kangde Composites Co., Ltd (China) and partners KDX Roding Europe Automobile (Germany), Faststar New Energy Automobile (China). 

Lightweight CFRP hypercar body.

Key benefits: using the mechanical advantages of carbon fiber; reduced part number and processing difficulty; improved endurance, lower emissions and high noise & vibration characteristics; technical reserve for future mass production. 

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Automotive Process

Mass production of cfrp stabilizers and drop links

Action Composites (China) and partner Dr. Ing. H.c. F. Porsche AG (Germany).

For the first time in a series production car, the stabilizers on the front and rear axles are made of carbon, as are their coupling rods, for outstanding performance.

Key benefits: 55% weight saving; short cycle time: less than 6 minutes; reduced CO2 emissions; CFRP capability for suspension parts; opening a new market for CFRP. 

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High-volume cfrp production: carbon rear wall module

Audi AG (Germany) and partners Voith Composites GmbH & Co. KG (Germany), Dow Automotive (Switzerland), Zoltek Corp. (USA).

For the first time, the full potential of CFRP can be used in high-volume production thanks to a newly developed rear wall module and cost-efficient production technologies.

Key benefits: cost-efficient, high-performance composite solution; functional system integration in a body part module; new manufacturing technology for high-volumes ; pre-assembly parallel to the assembly line; maximum design freedom of CFRP in high-volume production.

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Combining cfrp and injection moulding for series production

Dr. Ing. H.c.F. Porsche AG (Germany) and partner Plan B GmbH (Germany).

Innovative manufacturing method for a vehicle substructure combining CFRP and injection molding to create a flexible clip as an overmolded fastener onto a rigid component.

Key benefits: using the advantages of thermosets and thermoplastics; quick and robust manufacturing of the components; easy substitution of pure thermoplastic parts; less expansive than complex-geometry CFRP parts.

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Construction & Infrastructure

Below the line: concrete pipe repair with carbon fibre

Grupo Navec (Spain) and partners Saertex GmbH (Germany), Henkel (Germany).

In-situ manufacturing of a carbon fiber pipeline by means of an epoxy resin infusion process and subsequent vacuum consolidation, using the existing reinforced concrete pipe as a lost mold.

Key benefits: calculated, tested, and proven reliability in real-life use case; durability with estimated lifetime of 40 years; safe construction and installation phases; execution in half the time; much lower cost than traditional solutions.

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Cabkoma CFRTP strand rod

Komatsu Seiren Co., Ltd (Japan) and partners Kanazawa Institute of Technology (Japan), Nagase ChemteX Corporation (Japan).

Komatsu Seiren developed a CFRTP strand rod capable of ultra-high speed molding at low cost by in-situ polymerizing of a thermoplastic epoxy resin.

Key benefits: high productivity at low cost; high durability and high strength; non-ferrous, rustproof material; lightweight and windable; good processability, can be applied on-site.

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Innovative pultruded deck for station platforms

Solutions Composites (France) and partner Top Glass (Italy). 

Innovative pultruded deck for station platforms to improve and provide safer accessibility to trains.

Key benefits: lightweight material, ease of use; high mechanical performance, robustness; material savings, resulting in cost savings; great fire properties; long-lasting solution. 

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Marine

New process for manufacturing hydrofoils

Multiplast Groupe Carboman (France) and partner Groupe Bénéteau (France). 

Multiplast transferred wind-blade building knowledge from one of its branches to create a mass production process for the manufacture of foils (one set a week).

Key benefits: reduced production cost; improved ergonomics for better work performance; waste reduction. 

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From steel to composites in a 110m-long river cruise ship

Saertex GmbH (Germany) and partner Meyer Werft (Neptun) (Germany).

From steel to composites: Neptun and Saertex created a composite deck for a 110m-long river ship certified by the CCNR European authorities.

Key benefits: CCNR approval; 5cm less draft: longer season; passenger safety in case of a fire on board; 45% weight savings; design freedom for the ship engineers.

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Composite cargo decks for a 7000-car car carrier vessel

Uljanik JSC (Croatia).

SIEM Cicero car carrier vessel using a large number of GRP composite structures for cargo decks, saving considerable weight, reducing fuel consumption and CO2 emissions.

Key benefits: reduced fuel consumption: 4.5% or 2.1 t/day; increased payload: 800 tons; reduced production lead time; improved crew and cargo safety in case of a fire; same production cost as conventional design.

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Railway

Optimised lightweight carbon fibre bogie frame

ELG Carbon Fiber Ltd (UK) and partners Alstom Transport (UK), Magma Structures (UK), University of Birmingham (UK), University of Huddersfield (UK).

This is the first project to develop a carbon-fiber bogie frame including recycled material that addresses the barriers that have prevented commercial adoption. 

Key benefits: weight reduction of at least 50%; reduced track wear and maintenance; reduced global warming potential; high-volume manufacturing technique; reduced capital cost of the composite solution.

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Composite rail door

Penso (UK).

Penso designed and manufactured a composite rail door-leaf assembly suitable for London Underground, improving the reliability and maintenance of the original aluminum component. 

Key benefits: overall weight saving; new window cassette design; improved durability; closed-cell core to prevent water ingress; compliant with BS 6853 Category 1A.

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Breakthrough in railways: renovating the ice train

Saertex GmbH & Co (Germany) and partners Forster System-Montage-Technik GmbH (Germany), Alan Harper Composites (UK).

Replacing plywood floor panels with Saertex Leo® GFRP panels in 66 of the prestigious ICE3 fast trains of Deutsche Bahn. 

Key benefits: passenger safety: compliance with new EN 45545-2 standard; 50% weight reduction; increased lifetime, high tensile strength; non-toxic solution; ease of use: vacuum infusion. 

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Sports & Leisure

Project cedrus: advanced carbon hydrofoil for kites

Adherend Innovations, LLC (USA) and partner Composites Universal Group (USA).

Using a patent-pending design and manufacturing technique based on optimized composite materials, Project Cedrus is the lightest, safest, most compatible, and environmentally friendly hydrofoil ever introduced. 

Key benefits: reduced environmental impact; safety; low weight; low cost; compatibility.

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Modular construction system for a motorcycle rear swingarm

BMW Group (Germany) and partners EDAG Engineering GmbH (Germany), KraussMaffei Technologies GmbH (Germany), Chr. Karl Siebenwurst GmbH & Co. KG (Germany), TUM-LCC (Germany), Automation W + R GmbH (Germany), FHG-IGCV (Germany).

Modular system for a complex-shaped carbon fiber-reinforced swingarm to individually adjust the mechanical properties at competitive cost and weight compared to metallic solutions.

Key benefits: performance-adapted parts within one mold; adapted load path, carbon UD tape reinforcement; economic large-scale production possible; high design flexibility by injection molding; good coherence with simulation and testing results.

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First-ever carbon/pei hockey stick

Schappe Techniques (France) and partners Visceral Performance Inc. (Canada), Groupe CTT (Canada), Compsult (Canada), Mat-Comp (Canada). 

An advanced hockey stick (made of continuous carbon-fiber-reinforced thermoplastic materials) that delivers superior toughness/durability and on-ice performance, while being fully recyclable. 

Key benefits: superior toughness/durability of the composite; short consolidation cycle; fully recyclable (hollow part).

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Smart Cities

5g smart led lighting pole

Exel Composites Oyj (Finland) and partners Nokia Bell Labs (Finland), Vaisala Oyj (Finland), Teleste Oy (Finland), Indagon Oy (Finland).

Smart LED lighting pole with integrated functions. A real-world use-case product that enables the development of a smart city.

Key benefits: integrated functions – enables new business models; ease of assembly, lightweight pole; longer lifetime compared to steel and wood; aesthetically camouflaged antennas.

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Wet Core Pod composite housing module

MC Materiales Compuestos (Argentina) and partners Plaquimet (Argentina), Purcom (Brazil), IS Groupe - Composite Integrity (France) - G12 Innovation (Brazil). 

The Wet Core Pod is a composite housing module that, through industrialization, facilitates the most complex, expensive and time-consuming stage of a construction project.

Key benefits: reduce construction time, increase productivity; total quality control; energy save and environment friendly. 

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Infugreen 810 bio-resin for the seabubble water taxi

Sicomin (France) and partner Decision SA (Switzerland). 

The InfuGreen 810 bio-based infusion resin offers the highest level of sustainable content on the market, the same performance as conventional epoxies and high-volume manufacturing capability. 

Key benefits: highest level of sustainable content on the market; same performance as conventional epoxies; enables high-volume manufacturing; DNV/GL certification; first industrial-volume bio-epoxy infusion resin.

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Sustainability

Innovative thermoplastic-matrix wind turbine blade

Arkema Inc. (USA) and partners IACMI - The Composites Institute (USA), Johns Manville (USA), Huntsman Polyurethanes (USA), Sika Axson (USA), TPI Composites (USA). 

The nine-meter demonstrator blade highlights new technologies to drive down the LCOE. Technologies are available for use in current wind blade manufacturing plants.

Key benefits: more environmentally friendly materials/processing; recyclable thermoplastic blade shell and shear web; First use of textile PAN carbon fiber in wind applications; overall lower cost of blade manufacture; 100% post-consumer PET foam usage. 

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3-in-1 line for recycled composites manufacturing

CETIM-CERMAT (France) and partner CETIM (France).

Modular line using an innovative thermomechanical process to manufacture large-scale panels from composite or plastic waste and for hotstamping parts from these panels.

Key benefits: modular, flexible production line; production of high-performance recycled composites; cost effectiveness; technologies adapted to SMEs.

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Loop 650: a sustainable cradle-to-cradle composite sailing boat

GS4C srl (Italy) and partners Entropy Resins (Spain), Isomatex (Belgium), Diab (Sweden), GIVIDI Fabrics (Italy), Cormatex (Italy). 

Sustainable, zero-landfill cradle-to-cradle industrial composite manufacturing technology demonstrator.

Key benefits: industrial ready; cradle-to-cradle recycling; zero-landfill manufacturing; low embodied energy.

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