The 2022 finalists of JEC Composites Innovation Awards unveiled

A fuel for the composites industry

Innovation is the essence of this industry – each year it opens new doors and builds the path towards our future. More than just an award ceremony, the JEC Composites Innovation Awards are an opportunity to foster inspiration and cooperation between actors of the whole value chain: to showcase some excellent but possibly undisclosed projects on a global stage and to boost the enthusiasm of an expert audience always eager to uncover new horizons and create business opportunities

After pre-selection of the finalists by an international jury representing the entire composites value chain, one winner will be selected during the awards ceremony which will be held on the 26th of April in Paris, a week before JEC World 2022, and available in live streaming.

Discover here the finalists in each category:

Category Aerospace – Application

1. Lightweight multi-material passenger aircraft seat

Company: Queen’s University – Structural and Multidisciplinary Systems Design Lab, (Canada)
Partner(s): Korea Carbon Industry Promotion Agency (KCARBON) – South Korea
Description: A lightweight aircraft seat assembly combining long fiber prepreg sheet material and innovative multi-material topology optimization. Designed for 16G certification and mass minimization. This aircraft seat assembly was designed and produced using KCARBON’s novel long fiber prepreg sheet (LFPS) material. This composite innovation consists of a reinforcement layer composed of randomly oriented and positioned chopped carbon fiber tow, each pre-impregnated with an epoxy resin matrix.

Key benefits:

1. Significant structural weight reduction
2. Improved aircraft fuel efficiency
3. Considerable operational cost savings
4. Extended flight range
5. Reliable 16G crash safety certification

More information: http://ilyongkim.ca/

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2. 100% thermoplastic panel for cabin interiors 

Company: Diab (Sweden)
Partner(s): Rescoll, France – AkzoNobel, Netherlands – Roctool SA, France
Description: Diab has developed a 100% thermoplastic and recyclable sandwich panel for Aerospace cabin interior able to answer the current challenges (sustainability, REACH compliance, production rate increase…). The 100% thermoplastic (TP) sandwich panel developed is made of TP skins and a Diab Divinycell TP foam core. The TP skins can be directly welded on the foam core without the use of an adhesive film. All the materials used in this development are already qualified at various Aerospace OEMs and used in serial production today. Thus, this development is a concrete short-term solution for Aerospace cabin interiors.

Key benefits:

1. Recyclable panel
2. Significant production time savings
3. Weight and global costs savings
4. REACH regulatory compliance (no phenolic)
5. One step process

More information: www.diabgroup.com

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3. HX50 Helicopter

Company: Composite Integration Ltd (UK)
Partner(s): Hill Helicopters, UK
Description: Composite Integration developed multiple tooling and process techniques to manufacture a highly complex 5 seat single turbine helicopter fuselage as a single moulding without bonded joints. The innovation in this project revolved around the requirement to make a highly complex state of the art 5-seater civil helicopter fuselage as a single piece moulding removing the requirement for bonded joints. Analysis of the structural loads by the Hill Helicopters team had demonstrated that by achieving this aim, weight and material could be saved, stiffness could be increased, and service life could be improved.

Key benefits:

1. Creation of a major new aircraft manufacturing company
2. Development of lightweight single part highly complex structures
3. Reduction in bonded joints leading to stronger, safer. lighter structures
4. Evolution of liquid resin moulding techniques for very high-quality structures
5. Reduction in capex and opex for manufacturing process

More information: www.composite-integration.co.uk

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Category Aerospace – Process

1. IRIS Lower Wing Cover

Company: Spirit AeroSystems (UK)
Partner(s): Advanced Forming Research Centre, UK – Broetje-Automation GmbH, Germany
Description: Fabrication process for composite aerostructures combining self-heated tooling, resin infusion, and advanced automation to reduce equipment and materials cost and improve rate and design integration. The IRIS™ demonstrator combines a self-heated tool and Spirit’s patented resin infusion technology to produce the world’s first 17 metre Lower Wing Cover (LWC) demonstrator with no autoclave or oven. Spirit produced a 7 metre Lower Wing Cover (LWC) demonstrator the previous year to mitigate risk, leading to the successful production of the 17 metre LWC in 2021. Utilizing its design for manufacturing and infusion expertise, Spirit achieved complete integration of the LWC skin and stringers into a single component while improving damage tolerance as well as enabling weight and material savings.

Key benefits:

1. Self-heated tooling enables up to 20% cycle time reduction utilizing conduction
2. Up to 30% operating cost savings: reduced capital, floor space, & energy usage
3. Integrated part design leads to lower assembly cycle time and cost
4. Combined inspection and metrology cell reduces validation time up to 50%
5. Automated stringer consolidation/forming/trimming cell improves rate

More information: www.spiritaero.com

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2. Aerospace grade fibre-steered cylinder

Company: iCOMAT LIMITED (UK)
Partner(s): Bristol University, UK – ESA, Netherlands
Description: iCOMAT has manufactured the world’s first high-performance, space grade fibre-steered cylinder, outperforming the conventional straight-fibre baseline in a structural test. Two representative scale launcher cylinders (diameter of 600 mm and a length of 1100 mm) were designed and manufactured, a traditional Quasi-Isotropic (QI) straight-fibre baseline and an optimised fibre-steered version. A finite element analysis (FEA) based structural analysis model was developed and implemented for design optimisation. Eight layers of IM7/8552 Aerospace grade prepreg were deposited with iCOMAT’s Rapid Tow Shearing (RTS) machine to manufacture both configurations. The material was slit to 100mm wide tapes, which is a lower-cost format compared to traditional Automated Fibre Placement (AFP) and is also a key enabler for higher deposition rates (up to 100 kg/ hour). Both cylinders were manufactured by roll-wrapping the steered plies over aluminium mandrel, allowing accurate control of joint position through the stack. Both components were autoclave cured, followed by end potting and precision machining. After detailed CMM metrology and ultrasonic inspection, both quasi-isotropic (QI) and RTS cylinders were fully instrumented with strain gauges and Digital Image Correlation at the University of Bristol.

Key benefits:

1. 24% increase in buckling load, 8% improvement in stiffness
2. Higher production rates; wider and thicker tapes
3. Low costs; more affordable materials and lower slitting costs
4. Lighter more robust designs
5. No steering defects; no gaps/overlaps, no wrinkles, inline width control

More information: www.icomat.co.uk

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3. Innovative Infusion Airframe Manufacturing System

Company: MTorres Disenos Industriales S.A.U. (Spain)
Partner(s): Airbus Defense and Space, Spain
Description: Automated OOA portable manufacturing system for an integrated torsion box of a wing (including skin, stringers, spars and stiffeners in a one-shot part), thus avoiding assembly processes and fasteners. MTorres has implemented and tested an innovative airframe manufacturing system for Airbus. The main objective of the IIAMS project (Innovative Infusion Airframe Manufacturing System) Cleansky 2, is the development of an innovative pilot system to manufacture an integrated composite wing box structure. Airbus has designed the component. MTorres has been responsible for the design and manufacturing of the equipment and the demonstration parts. Wing box is manufactured by OOA infusion. Structural elements use MTORRES AFP for narrow dry fiber. 3D layup was used for the skin, and 2D layup plus hotforming for the rest of elements.

Key benefits:

1. OOA, one-shot infusion
2. Automated process
3. Parts integration, no fasteners
4. Portable, low-cost
5. Energy-saver, lightweight

More information: www.mtorres.com

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Category Automotive & Road Transportation – Structural

1. First competitive structural application – CFRTP

Company: BMW-AG (Germany)
Partner(s): BMW AG, Germany – BMW AG, Germany
Description: New design approach using endless carbon fiber only for the load pathes, connecting the load pathes with injection moulding, no waste production in just 3 process steps, best composite economics ever. The innovation is based on a new design approach, production technology and integration into the body shop. The design philosophy is changed from surface-based design to rod based design leading to a minimal usage of endless carbon fiber along the load pathes. The fibers are perfectly loaded by pressure and tensile and can be optimised by size. Shear forces are transmitted by the short fiber reinforced injection moulding material. The injection moulding process offers greater freedom of design and depth of integration e.g. inserts, control units, wiring harness, etc. The production process just needs three process steps: Impregnation of the fibers, forming the unidirectional rods, injection moulding, which are all fully automated. trimming process are not needed any more. We could realize a zero-waste composite production for the first time.

Key benefits:

1. Cost Efficiency
2. Lightweight
3. Use of recycled carbon fibers, recyclability of the component
4. Simplified automated Production process chain with just 3 steps
5. No waste, net shape process

More information: www.bmwgroup.com

2. TUCANA

Company: Jaguar Land Rover Limited (UK)
Partners(s): Broetje Automation UK Ltd, UK- CCP Gransden ltd, UK – Expert Tooling & Automation Limited, UK – Toray International U.K. Limited, UK – University of Warwick, UK – CFMS Lilited, UK
Description: TUCANA is an enabler for future Battery Electric Vehicles (BEVs) demonstrated by redesign of the whole rear body structure of a Jaguar I-Pace. Unlike traditional fabric-based manufacture using RTM or Autoclave technology which are not viable for a high volume (40,000+ unit per annum) cycle time nor a business case point of view, TUCANA focused on optimizing the use of material and maximizing the MPa/kg. To achieve this, the topology optimization helped define the major load-path hence creating the skeleton of the structure where fast-cure continuous carbon or glass fibre UD (Uni Directional) were laid. To put flesh around this skeleton and connect the UD together CF-SMC (Carbon Fibre Sheet Moulding Compound) and GF-SMC (Glass Fibre Sheet Moulding Compound) were used for the low cost, fast cycle time and high design freedom capable of achieving complex 3D shapes and convoluted design features not (easily) achievable with traditional fabric. Tailored materials, specific moulding parameter and proprietary modelling method were key to success.

Key benefits:

1. Lighter body structure
2. Reduced CO2 emission as an enabler of Battery Electric Vehicle adoption
3. Stiffer body structure coping with BEV structural requirements
4. Reduced part count – lower energy, floorspace, logistics (ie. fewer trucks)
5. Ease of adoption, comply with automotive manufacturing process & infrastructure

More information: www.jaguarlandrover.com

3. 2021 Grand Cherokee composite tunnel reinforcement

Company: BASF Corporation (USA)
Partner(s): L&L Products, USA – Stellantis, USA
Description: Replacement of a high strength steel concept in a safety critical application using a pultrusion over molded with thermoplastic to reduce weight, part count, tooling cost, and meet performance. L&L Products Continuous Composite Systems (CCS™) utilized BASF Elastocoat® 74850 Polyurethane System for the continuous glass fiber pultrusion and BASF Ultramid® 8350 HS Impact Modified Polyamide for injection molding over the pultruded insert creating a new type of hybrid. The process is highly automated requiring no human contact from the time the continuous fiber insert is pultruded until the part is complete with the over molding and compression limiters.

Key benefits:

1. New High Volume Automotive Application First for Pultrusion
2. A New Polyurethane Resin System
3. New Design Capability for High Strength Applications
4. New Computer Simulation Method for Continuous Fiber Constructs – Post Failure
5. Industry First Pultrusion Processing Speeds

More information: https://plastics-rubber.basf.com/

Category Automotive & Road Transportation – Surfaces

1. Innovation: Lightweight multi-material door

Company: Hyundai Motor Europe Technical Center GmbH (Germany)
Partner(s): Teijin Automotive Technologies, France
Description: Innovative new hybrid material door structure using newly developed low VOC SMC and hybrid glass/carbon SMC. The door is both on and offline paintable and meets all HMG door requirements. Two innovative SMC composite materials, specifically optimized for the application in this hybrid door concept were developed within this joint development project. The outer panel utilizes a modified TCA Ultra Lite® low density SMC material. The inner panel features a newly developed hybrid glass and carbon fiber SMC material. To achieve the required structural performance, an innovative internal “reinforcement ring” was developed to ensure optimal load paths both for static stiffness and crash resistance.

Key benefits:

1. 2.7 kg lighter than steel design (the total per vehicle is 9.2kg)
2. Excellent denting performance and robustness (lower repair costs)
3. Distinctive styling with sharp character lines (more attractive designs)
4. Cost applicable to mass production
5. Online & offline paintability (fully validated with tests for both options)

More information: www.hmetc.com

2. Seamless Integration of Flexible Solar Film in FRP

Company: AUDI AG (Germany)
Partner(s): Mubea Carbo Tech GmbH, Austria – Apollo Power Ltd., Israel
Description: Seamless integration of flexible solar film in automotive fiber-reinforced plastic components (roof top, hood, etc.) for high-volume application, using a high-pressure resin transfer molding process. With the infusion of self-extinguishing polyester resin and biaxial fiberglass fabrics, 3,000 m² of composites frames were manufactured, the largest of which is 4 meters high, 6 meters long and only 250 kg. The innovation comprises integration of non-encapsulated flexible solar films from Apollo Power (Israel) in fiber-reinforced plastic parts by using HP-RTM process at Mubea Carbo Tech (Austria). The final product shows superior results including best solar efficiency (>200Wp), lightweight design (min. 50% lighter than standard solar glass roof), and compliance with automotive quality standards. Ultimately, parts made with sustainable materials like natural fibers (e.g., flax), bio-resins and solar film can reduce CO2 footprint enormously. Furthermore, complex 3D-shapes with higher degree of drapery can be realized too and thus the technology can be transferred to other components and industries (e.g., railway or aerospace).

Key benefits:

1. Lightweight design (more than 50% weight saving vs. solar glass roof)
2. Class A surface with high aesthetics and design freedom
3. Range extends through applied solar film
4. High cycle production with fast cure resin < 20 min per part
5. Possibility to combine flexible solar film with natural fibers and bio-resins

More information: www.audi.de

3. Light flax fibers reinforced automotive headliners

Company: Howa-Tramico (France)
Partner(s): Eco-Technilin, France – University of South Brittany (UBS), France – INRAe, France
Description: The objective is to develop and produce a new automotive headliner with an improved environmental assessment thanks to the use of plant fibre reinforcement instead of petro-based ones. The petro-based version of the composite integrates 7 different layers of raw materials, the main ones being the assembly of PU foam with glass fibers. To manufacture the final part, a thermoforming process is used and then some specific finishing operations such as cuttings.

Key benefits:

1. Improved environmental impacts
2. Recyclability impact: re-using waste
3. Using nonaggressive raw material
4. Using of an existing manufacturing process
5. Good compatibility between flax and resin

More information: www.howa-tramico.com

Category Building & Civil Engineering

1. Structural re-use of thermoset composites

Company: Windesheim (Netherlands)
Description: The innovative methodology of structural re-use of thermoset composites enables End-of-Life thermoset composites to be re-used in new products. It is a circular solution for these materials. In the methodology of structural re-use of thermoset composites the End-of-Life products are machined into smaller parts like strips or flakes. These smaller parts serve as reinforcing elements for new products. Some virgin resin and reinforcement have to be added but the new product is entirely made of thermoset composite components and can be re-used with the same method again when it is End-of-Life or End-of-Use. Therefore, the methodology is a circular solution for the thermoset composite products like windmill rotor blades or composite boat hulls.

Key benefits:

1. Circular solution for End-of-Life thermoset composites.
2. Solution for End-of-Life windmill rotor blades and composite boat hulls.
3. Alternative for tropical hard wood used in infrastructural applications.
4. Makes thermoset composites circular.
5. Gives a good business case for the industry

More information: www.windesheim.nl

2. SOF.Radlink – Composite Radial coupling

Company: OPTIMAS (France)
Partner(s): Arkema, France – Somocap, France
Description: The SOF Radlink System enables to connect easily and quickly each tunnel segments for underground infrastructure. It combines Composite and thermoplastic process for durable solutions. The composite innovation of this project is based on the replacement of a conventional steel material solution by an innovative composite material and design to make a high strength and lightweight solution. The thermoplastic resin Elium made possible to make the main composite part by pultrusion and to thermoform the final part at the final design. From a generic flat pultruded composite part made with glass fiber a final part is formed by using compression and heat. Pultrusion gives the possibility to produce high quality and performance part with a great production output compatible with the objectives of quantities and cost of the project and thermoforming gives the flexibility to produce any design for the coupling from generic, flat composite part.

Key benefits:

1. More durable, avoid corrosion risk
2. Increase installation speed in precast factory
3. Reduce the global system weight
4. Usable in a seismic area
5. Useable in automized installation

More information: www.optimas.com/services/tunnels

3. Eco Facade – Building facade biocomposite panel 

Company: EFW – Elbe Flugzeugwerke GmbH (Germany)
Partner(s) : Faserinstitut Bremen, Germany – Hightex Verstärkungsstrukturen GmbH, Germany – BioMat Department – Institute of Building Structures and Structural Design (University of Stuttgart), Germany – Fraunhofer IFAM, Germany
Description: Sustainable, eco-friendly facade panel based on renewable materials with load-path-compatible and variable design meeting class A fire requirements. Shading and insulation ensure energy efficiency. This newly developed biocomposite is primarily intended for application in architecture and building industry. The innovation behind this biocomposite project involves several aspects. The invention is based on a holistic development approach aimed at sustainable product design and the goal of finding new technical solutions.

Key benefits:

1. Shading and insulation of buildings
2. Fully environmentally friendly design
3. Fulfillment of fire prevention class A
4. Functional integration (lighting, heating structures)
5. Cross-industry technology applicability

More information: www.elbeflugzeugwerke.com

Category Design, Furniture & Home

1. Kairlin®: a new recyclable & compostable material

Company: KAIROS (France)
Partners(s): Ecotechnilin, France – University of South Brittany, France – University Of Portsmouth, UK
Description: Kairlin® is a recyclable and compostable biomaterial, allowing point-of-sale and signage displays to be produced and recycled with low environmental impact, in line with the circular economy approach. The Kairlin® is a Flax Poly-(lactid)(PLA) reinforced composite panel, developed in monolithic and sandwich structures. These bio-panels present a light weight, easy machining, controlled thickness and surface finish. At each stage of its life cycle, from the flax cultivation which compose it to its end of life, the Kairlin® has been designed and validated at an industrial scale to have a high degree of sustainability in its composition and process. Kairlin® is produced within a very short supply chain, from the flax cultivated and transformed in Normandy (France).The Kairlin® is processed in one shot compression molding step with a very short processing time allowing a high product performance at low cost.

Key benefits:

1. Mirror surface finish for printing
2. Low environmental impact
3. Lightweight & high mechanical properties
4. Recyclability & composting end-of-life
5. Local & circular economy

More information: www.kairos-jourdain.com

2. Te Ahi Tupua – Composites & Artistic Design

Company: Gurit UK Ltd (UK)
Partner(s): Kilwell Fibretube, New Zealand
Description: The use of advanced composite materials, engineering analysis, and manufacturing techniques allowed for the creation of the impressive 12m x 6m carbon fibre sculpture, Te Ahi Tupua in Rotorua, NZ. Planned in steel, the sculpture was initially thought unfeasible due to high costs, lack of local capability and corrosive geothermal environments. A collaboration and creative thinking from Gurit and Kilwell made it feasible. Non-corrosive, lightweight and easily formable into complex shapes, composite materials were an ideal fit. Kilwell decided to use 3D printing to produce a PLA former which would then be wrapped with layers of carbon fibre for structural integrity. 3D printing was a significant enabler for this project, providing a low cost, low waste solution to the problem of forming the complex shape of each individual tube.

Key benefits:

1. Enabling technology for design, allowing for complex shapes.
2. Local employment: Novel production technology allows for local manufacturing.
3. Reducing emissions from production and transport by avoiding imported steel.
4. Environmentally friendly construction with fully recyclable materials.
5. Able to withstand harsh environmental conditions.

More information: www.gurit.com

3. Gravity-free space table and floating chair

Company: Toray Carbon Magic Co., Ltd. (Japan)
Description: Extremely thin and long tabletop dining table and Floating chairs. Hinoki Kogei realized tables and chairs using composites, as it had been impossible to make it real using woodworks.
• Extremely thin long table (4,000 mm × 1,200 mm- thickness 3 mm)
To fabricate an extremely thin long table that cannot be prepared using wood and metallic materials, a comprehensive optimization of the materials, design, and manufacturing methods is performed. The self-weight deflection is minimized, and the strength and rigidity required to withstand loads during usage are maintained.
• Floating chair
The design requirement was to display the seat shell as if it is floating in the air; the seat shell and foot part exhibit a thin structure with unnoticeable and delicate connections between them, and the screws and fasteners are unobservable.

Key benefits:

1. Materialized a gravity-free furniture design using carbon composites.
2. Realized the achievements and possibilities of the use of composites in daily.
3. Utilized various facets of composites in furniture designing.
4. Combining the composite technology and craftsmen skills.
5. Achieved high value–added products that can be sold in markets.

More information: www.carbonmagic.com

Category: Equipment & Machinery

1. Automatic workbench for inline hydrostatic testing

Company: Aumatech srl (Italy)
Partners(s): ECS GmbH &Co. KG, Germany
Description: Automatic workbench for in-line hydrostatic testing of composite pressure vessels from low to high service pressures. Matching line’s cadency, it adds safety and sustainability to the testing phase. Aumatech showcases its innovative equipment called Hydrocontest, an exclusive prototype (international patent filed at UIBM) for Composite Pressure Vessels in-line hydrostatic testing, directly on existing production line. Thanks to the patented design and improved materials of the junction valve, it can operate testing at the regulation-required pressure levels, performing tank’s elastic and residual strain measurements simultaneously with Water Jacket and Direct Expansion methods. All above using just pressurized water, which is depurated and stored at the end of each single test for future usage. Finally, it overcomes limitations of existing equipment, reducing testing cycle time down to 40 sec. and increasing safety standard, as it requires little-to-none handling by operator.

Key benefits:

1. Sustainable process: no destructive testing, reusage of water
2. 100% of production tested automatically
3. Reduced manufacturing cycle time
4. Increased safety level (no operator required)
5. Two simultaneous testing methodologies

More information: www.aumatech.it

2. TorresPrint3D – New large scale composites printer

Company: MTorres Disenos Industriales S.A.U. (Spain)
Partners(s): SABIC SHPP Marketing Plastics SLU, Netherland
Description: TorresPrint3D® is an additive manufacturing process for large components with no need for heated chamber, with variable material deposition capabilities for a more flexible, cost-efficient production. MTorres has developed TorresPrint3D®, a new manufacturing process for large composite structures that allows the manufacturing of any length of component. With an integrated heating system in the AM head that avoids the need of a heated chamber, and supported by a horizontal material application configuration, the innovation facilitates the generation of “unlimited” or “infinite” large geometries.

Key benefits:

1. Fast, cost-efficient lead times
2. No heated chamber needed
3. “Infinite” parts manufacturing feasibility
4. Customizable material width
5. Multi-material selection and use optimization

More information: www.mtorres.com

3. Winding the future – Fibraforce technology

Company: Fibraworks GmbH (Germany)
Partners(s): Hille Engineering GmbH & Co. KG, Germany – SEM GmbH, Germany – Quality Automation GmbH, Germany – Fibraforce AG, Switzerland
Description: Fibraforce technology – revolutionizing the high-volume production of genuine customized multiaxial thermoplastic cross-ply laminates with our continuous and ultra-fast winding process. Lightweight design is a key technology for conserving resources and composites are the cornerstone. They are becoming more common, but often involve complex processes and high costs. Our patented technology enables an efficient, high-volume process for reinforcements with multiaxial fiber orientation, whether they are based on dry fibers or thermoplastic composites. It provides ideal lightweight solutions by delivering customizable reinforcements with fiber orientations and lay-ups required by the market, combined with the benefits of an ultra-fast, continuous, and cost-effective production technology.

Key benefits:

1. Ultra-fast production of customized thermoplastic laminates at up to 675 kg/h
2. Individual material combinations can be processed flexibly and fast
3. Making thermoplastic composites more affordable in cost-driven applications
4. Tailored to customers’ needs to streamline production and reduce waste
5. Increasing sustainability and efficiency in composite based lightweight design

More information: www.fibraworks.com

Category Maritime Transportation & Shipbuilding

1. InfraCore helideck for 85-meter patrol vessel

Company: InfraCore Company (Netherlands)
Description: The project partners tried to design a helideck out of “classical” sandwich and did not succeed. We managed this with our patented InfraCore technology. We demonstrated our capability in the maritime industry for the first time, based on our patented technology and extensive track record in the infrastructural industry (1400 bridges and lock gates installed).

Key benefits:

1. Robust
2. Impact resistant
3. Hydrocarbon fire resistant
4. Lightweight
5. Easily installed

More information: www.infracore-company.com

2. Marine rotor blades made of Voith ‘Carbon4Stack’

Company: Voith Composites SE & Co. KG (Germany)
Partners(s): J.M. Voith SE & Co.KG | VTA, Germany – Gurit, UK – Cotesa GmbH, Germany
Description: Voith Inline Thruster CFRP rotor blades are made using Voith’s groundbreaking prepreg stacks (Carbon4Stack) laminate to provide ultimate vessel maneuverability to the marine industry. The innovative CFRP rotor blade design of the Voith Inline Thruster (VIT) is the result of a close R&D corporation between Voith Composites, Voith Turbo, Gurit and Cotesa. The blades are made using precisely laminated stacks (Carbon4Stack) laid on Voith’s automated machinery (VRA NextGen). The advantages of carbon fiber rotor blades over conventional materials are clear: the material is lighter, stiffer and more resistant to corrosion.

Key benefits:

1. Higher quality standard through precisely automated lamination
2. Higher productivity from faster/fewer manufacturing processes
3. Lower production cost from reduction of processes
4. Reduced waste and reduced manufacturing hazard
5. Higher consistency in the mass manufacturing of parts

More information: www.voith.com

3. Composites enable zero emission high speed ferry

Company: Gurit UK Ltd (UK)
Partners(s): Wellington Electric Boat Building Company, New Zealand
Wellington Electric Boat Building and its team of partners, including Gurit for lightweighting & composites, has delivered the first fully electric, high-speed ferry in this landmark project.

Key benefits:

1. Passenger ferry with zero emissions
2. Commercially viable for operator
3. Reduced operational costs (energy and maintenance)
4. Improved passenger experience through fumeless transport and increased speed
5. Lowered corrosion and fatigue

More information: www.gurit.com

Category Renewable Energy

1. Enabling longer turbines life and operational time

Company: Huntsman Advanced Materials (Switzerland)
Partners(s): Blade Solutions AB, Sweden
Description: A structural adhesive designed for repair of composite wind blades in extreme conditions, able to cure at -20°C , enabling reduction of downtime for improved productivity and CO2 emissions savings. Approved for specialized bonding on wind turbine blades, Araldite® 2050 adhesive is a unique acrylic-type adhesive developed for composites bonding in extreme conditions for the Wind (and Marine) market. Thanks to its innovative catalyst package the adhesive can cure fast, developing high bond strength curing at temperatures down to -20°C as well as in wet environment or even under salt water.

Key benefits:

1. Turbines Downtime Reduction: 25% reduction, up to 50%
2. Operational costs benefits: Increased productivity thanks to reduced downtime
3. Positive impact on climate change: limited downtime compensation by other energy
4. Fast Curing at subzero temperatures: curing possible down to -20°C
5. No water sensitivity: curing possible even under saltwater immersion

More information: www.huntsman.com

2. Spabond 800 Series – Innovation in adhesives

Company: Gurit UK Ltd (UK)
Description: Gurit’s Spabond 840 is an adhesive for bonding large structures like wind turbine blades. Its innovative properties allow for shorter cycle times, ultimately reducing the cost of renewable energy. Spabond is an epoxy-based high strength, rubber toughened, rapid curing long open time adhesive for wind turbine blade bonding. Gurit completely redesigned epoxy adhesives, ensuring that we kept the high performance and reliability for which they are renowned. This innovation solves a traditional paradox as whilst fast curing adhesives exist, they have very short pot-life and working times preventing them being applied to increasingly large bond areas.

Key benefits:

1. Reduces blade production cost
2. Fast reaction, saving 3 hours
3. Application at 40°C, shortens cycle time
4. Safer and more sustainable chemistry
5. Lower energy consumption

More information: www.gurit.com

3. Recyclable blade

Company: Siemens Gamesa Renewable Energy (Denmark)
Partners(s): Aditya Birla Advanced Materials, India
Description: Siemens Gamesa, in partnership with Aditya Birla Advanced Materials has designed, manufactured, and are ready to install the first offshore wind turbine blades that can be easily dissolved & recycled. Lightweight structures are key for designing competitive wind blades and turbines. Composites are the best compromise between weight and strength and are the leading technology within wind industry. The composites are built with resins that are strong and durable, but difficult to degrade and recycle. The majority of decommissioned blades go to landfill. The RecyclableBlade offers the same high quality and lifetime Siemens Gamesa is known for. After decommissioning, the blade can be recycled by dissolving the matrix under mild acidic conditions, thus preventing unnecessary landfill. The reinforcements, core materials, plastics and metal parts can be easily recovered in good quality and value. The matrix is recovered as thermoplastic material with an interesting profile of properties. The recovered matrix and reinforcement can then be reused in appropriate applications.

Key benefits:

1. Low-energy demanding recycling process
2. Reduces life cycle impacts
3. Lowers end-of-life costs
4. Leaves no waste, only resources
5. Easy to adopt, designed for long blades

More information: www.siemensgamesa.com

Category Sports, Leisure & Recreation

1. Race ready bond between thermoset and thermoplastic bio composites

Company: Bcomp Ltd. (Switzerland)
Partners(s): KTM Technologies GmbH, Austria – Mitsubishi Chemical Advanced Materials GmbH, Germany – ALBA Tooling & Engineering GmbH, Austria – Altendorfer Kunststofftechnik GmbH, Germany
Description: 1st ready to market product which unites motorsport proven natural fibre composite materials and road focused bio-based thermoplastics with a reversible and recycling-ready connection technology. The innovation is based on KTM’s CONEXUS technology, which allows to combine thermoset and thermoplastic materials via direct chemical bonding. Sustainability is becoming one of the main drivers behind all new developments and technologies from sports & leisure to mobility. Following this ideal, the consortium created Bcomp’s ampliTex™ flax fabric to replace the carbon- and glass fibres and a bio-based thermoplastic PA6 substitutes conventional PA6. Most importantly, the coupling layer bonds those different material types, and makes it possible to separate them by heating the product to the thermoplast’s softening temperature. This allows the best suited end-of-life option for both technologies.

Key benefits:

1. Scalability: Bonding thermoset and thermoplastic materials
2. Sustainability: High-performance sustainable raw materials
3. End-of-Life: Viable EoL-scenario for composites
4. Design: Showcasing sustainable performance looks
5. Functionalisation: Best material for each requirement

More information: www.bcomp.ch

2. Carbon Composite flame wheelchairs for badminton 

Company: Toray Carbon Magic Co., Ltd. (Japan)
Partners(s): Matsunaga Manufactory Co., Ltd., Japan
Description: A composite wheelchair with novel design concepts, providing light, smooth, and fast mobility due to weight reduction and high stiffness of the monocoque structure. In badminton, the initial speed of the batted shuttlecock is over 400 km/h and is the fastest in ball games. However, by the time it reaches the opponent, the speed is reduced to about 60 km/h: this speed fluctuation is what makes badminton interesting – and requiring a very specific wheelchair for players to express their full potential. This wheelchair made of CFRP with high rigidity and light weight allows the player to show the true nature of their high technical ability.

Key benefits:

1. Development of the world first carbon composite flame wheelchair for badminton
2. Weight reduction by 30% from the conventional model aiming for a 9 kg mark
3. Improved agility and rolling resistance with a highly rigid frame
4. Introduction of monocoque structure and hollow molding to accomplish #2 above
5. Design covering a wide range of physical statures, body shapes, and degrees

More information: www.carbonmagic.com

3. A Hypetex Kromaskin field hockey stick for adidas

Company: Hypetex (UK)
Partners(s): Adidas, Germany – Marque Makers, Hong Kong – Textreme – Oxeon AB, Sweden
Description: The Hypetex Kromaskin field hockey stick for adidas combines a unique coloured carbon spread tow outer finish with an advanced composite construction for exceptional power and consistency on the pitch. The innovation presented uses the patented Hypetex technology to colour a lightweight spread tow plain weave carbon fibre fabric that forms the outer visual and structural surface ply of the Hypetex Kromaskin field hockey stick. In addition to providing the pigmented outer layer, Hypetex Special Projects division also developed the novel construction method for this new hockey stick. The innovative carbon fibre colouring technology and construction technique is applicable to a broad range of composite sporting goods produced with closed moulding techniques including sticks, racquets, and bats, as well as to other bladder or compression moulded composite parts. In the wider composite sector, Hypetex coloured carbon fibre technology can be applied in thermoset and thermoplastic composite components, providing a coloured part solution fully integrated into the moulding process and removing the need for a traditional paint system.

Key benefits:

1. Durable in-mould coloured carbon fibre
2. Exceptional hitting power and consistency on the hockey pitch
3. Maximised carbon fibre packing in mould
4. Preformed core increases fibre consolidation
5. Unique visual appearance without paint

More information: www.hypetex.com

One winner in each category will be selected during the awards ceremony which will be held on the 26th of April in Paris, a week before JEC World 2022, and available in live streaming.

JEC World 2022 • Paris Nord Villepinte
3-5 May 2022
www.jec-world.events