22
Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected] PRESS RELEASE Paris, January 18, 2017 JEC GROUP CELEBRATES COMPOSITE INNOVATION AT JEC WORLD 2017 AND HANDS OUT JEC INNOVATION AWARDS TO 13 “COMPOSITE CHAMPIONS” While this year’s show will take place from Tuesday March 14 to Thursday March 16, 2017 at the Paris Nord Villepinte Exhibition Centre, France, JEC Group is proud to unveil the names of the 13 winners of the JEC Innovation Awards. The JEC Innovation Awards reward the best composite breakthroughs based on their technical interest, market potential, partnerships, financial & environmental impact and originality. Composite innovations in the spotlight at JEC World This year, the submissions for the Innovation Awards programme were impressive, both in quantity and diversity, and more importantly in quality. Manufacturing processes for large series are growing in importance this year. This movement is expected to trigger a more massive use of composites. Therefore, we could see a change of scale in our industry, particularly in certain mass production sectors such as the automotive sector, for example, where the supply chain is reconfiguring through mergers and acquisitions, the upstream integration of automotive suppliers and the downstream integration of raw materials producers.” says Mrs Frédérique Mutel, JEC Group President & CEO. Just as last year, a high number of submissions came from the automotive industry, thus perfectly illustrating the current market trends. Process improvement was also one of the most represented themes, highlighting the importance of cycle time reduction. With 13 categories ranging from raw materials to process, to applications in various fields such as Aeronautics, Automotive, Construction, Marine and Better Living, the winning projects offer a complete overview of the composite value chain, and the many future opportunities that are still to be taken in the field of composites. The JEC Innovation Awards ceremony will highlight 13 innovators on stage and will take place on Wednesday March 15 at 5 p.m. at JEC WORLD (Paris Nord Villepinte - France). All exhibitors and visitors are welcome to attend the ceremony. The JEC Innovation Awards Program is sponsored by JEC Composites Magazine, Luxinnovation, Luxembourg and the National Composite Centre – Luxembourg (NCC-L). www.jeccomposites.com With a network of 250,000 professionals, JEC Group is the largest composite organization in the world. It represents, promotes and helps develop composite markets by providing global and local networking and information services. For the past 20 years, JEC has achieved continuous growth and acquired an international reputation. It has opened offices in North America and Asia. The Company is entirely owned by the non-profit Center for the Promotion of Composites. JEC Group’s policy is to systematically invest its profits in the creation of new services to benefit the industry. After successfully winning over the composites industry, JEC Group is now enlarging its scope to the next segment of the value chain, i.e. manufacturers and end-users. Through Knowledge and Networking, JEC's experts offer a comprehensive service package: the JEC publications - including strategic studies, technical books and the JEC Composites Magazine - the weekly international e-letter World Market News and the French e-letter JEC Info Composites. JEC also organizes the JEC World Show in Paris – the world’s largest composites show, five times bigger than any other composites exhibition, JEC Asia in Singapore and JEC Americas in Atlanta; the Web Hub www.jeccomposites.com; the JEC Composites Conferences, Forums and Workshops in Paris, Singapore and Atlanta and the JEC Innovation Awards program (Europe, Asia, America, India and China). The composite industry employs 550,000 professionals worldwide, generating 69 billion USD worth of business in 2015.

PRESS RELEASE Paris, January í ô, î ì í ó - · PDF fileAND HANDS OUT JEC INNOVATION ... “Plug-and-play” composite ship door ... The thermoplastic SGV are manufactured by

  • Upload
    vandan

  • View
    220

  • Download
    3

Embed Size (px)

Citation preview

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PRESS RELEASE Paris, January 18, 2017

JEC GROUP CELEBRATES COMPOSITE INNOVATION AT JEC WORLD 2017 AND HANDS OUT JEC INNOVATION AWARDS TO 13 “COMPOSITE CHAMPIONS”

While this year’s show will take place from Tuesday March 14 to Thursday March 16, 2017 at the Paris Nord Villepinte Exhibition Centre, France, JEC Group is proud to unveil the names of the 13 winners of the JEC Innovation Awards. The JEC Innovation Awards reward the best composite breakthroughs based on their technical interest, market potential, partnerships, financial & environmental impact and originality.

Composite innovations in the spotlight at JEC World

This year, the submissions for the Innovation Awards programme were impressive, both in quantity and diversity, and more importantly in quality. “Manufacturing processes for large series are growing in importance this year. This movement is expected to trigger a more massive use of composites. Therefore, we could see a change of scale in our industry, particularly in certain mass production sectors such as the automotive sector, for example, where the supply chain is reconfiguring through mergers and acquisitions, the upstream integration of automotive suppliers and the downstream integration of raw materials producers.” says Mrs Frédérique Mutel, JEC Group President & CEO.

Just as last year, a high number of submissions came from the automotive industry, thus perfectly illustrating the current market trends. Process improvement was also one of the most represented themes, highlighting the importance of cycle time reduction.

With 13 categories ranging from raw materials to process, to applications in various fields such as Aeronautics, Automotive, Construction, Marine and Better Living, the winning projects offer a complete overview of the composite value chain, and the many future opportunities that are still to be taken in the field of composites.

The JEC Innovation Awards ceremony will highlight 13 innovators on stage and will take place on Wednesday March 15 at 5 p.m.

at JEC WORLD (Paris Nord Villepinte - France).

All exhibitors and visitors are welcome to attend the ceremony.

The JEC Innovation Awards Program is sponsored by JEC Composites Magazine, Luxinnovation, Luxembourg and the National Composite Centre – Luxembourg (NCC-L).

www.jeccomposites.com With a network of 250,000 professionals, JEC Group is the largest composite organization in the world. It represents, promotes and helps develop composite markets by providing global and local networking and information services. For the past 20 years, JEC has achieved continuous growth and acquired an international reputation. It has opened offices in North America and Asia. The Company is entirely owned by the non-profit Center for the Promotion of Composites. JEC Group’s policy is to systematically invest its profits in the creation of new services to benefit the industry. After successfully winning over the composites industry, JEC Group is now enlarging its scope to the next segment of the value chain, i.e. manufacturers and end-users. Through Knowledge and Networking, JEC's experts offer a comprehensive service package: the JEC publications - including strategic studies, technical books and the JEC Composites Magazine - the weekly international e-letter World Market News and the French e-letter JEC Info Composites. JEC also organizes the JEC World Show in Paris – the world’s largest composites show, five times bigger than any other composites exhibition, JEC Asia in Singapore and JEC Americas in Atlanta; the Web Hub www.jeccomposites.com; the JEC Composites Conferences, Forums and Workshops in Paris, Singapore and Atlanta and the JEC Innovation Awards program (Europe, Asia, America, India and China). The composite industry employs 550,000 professionals worldwide, generating 69 billion USD worth of business in 2015.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

THE 13 “COMPOSITE CHAMPIONS” WINNERS OF THE JEC INNOVATION AWARDS

AERONAUTICS – IHI Corporation (Japan) Innovative composite fan system for aero-engines

AUTOMOTIVE, STRUCTURAL – Forward Engineering GmbH (Germany) T-RTM

AUTOMOTIVE, EXTERIOR – LG Hausys (South Korea) One-piece roof rack

CONSTRUCTION – ACCIONA Construcción SA (Spain) Innovative composite panels, an alternative to steel and concrete for high-speed railway tunnel construction

PROCESS – IRT M2P (France) Fast RTM

MANUFACTURING – Voith Composites GmbH & Co. KG (Germany) Voith Roving Applicator

SUSTAINABILITY – Faurecia (France) NAFILite™ microcellular foamed material

MARINE – VABO Composites (the Netherlands)

“Plug-and-play” composite ship door

3D PRINTING – +LAB - Politecnico di Milano University (Italy) Smart manufacturing of continuous-fibre composites: Atropos

SOFTWARE – e-Xstream (Luxembourg) Digimat AM

SPORTS – Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) (Germany) Recurve bow riser

RAW MATERIALS – Covestro Deutschland AG (Germany) Desmocomp® – a novel solution for composites

BETTER LIVING – Brødrene AA (Norway) Vision of the Fjords, Ship of the Year 2016 in Norway

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category : AERONAUTICS

Winner: IHI Corporation (Japan)

Partners: IHI Aerospace (Japan), Industrial Technology Center of Fukui Prefecture (Japan), Mitsuya Co., Ltd. (Japan), SHINDO Co. (Japan), Mitsubishi Rayon Co., Ltd. (Japan), Toray Industries, Inc. (Japan)

Name of Product or Process: Innovative composite fan system for aero-engines

Description: IHI Corp., together with its partners, developed an innovative lightweight composite system for fan cases and the first thermoplastic composite structural guide vane (SGV).

To increase fuel efficiency in aircraft engines, the bypass ratio (ratio between the mass flow rate at the entrance of the engine to the mass flow rate entering the core) has to be increased. But this requires a larger fan case, which, if it was made with traditional materials, would greatly increase the weight of the engine and negate some of the gain efficiency.

Using composites for the primary structural fan case and SGV was the route IHI chose to achieve the required bypass ratio. Using its own developed materials, a thermoset for the fan case and a thermoplastic for the SGV, along with carbon fibres in both cases, IHI managed over 20% weight savings over previous-generation aircraft engines, thus contributing to further fuel consumption reductions.

With this project, it is the first time that thermoplastic composites are selected for primary structure parts in aircraft engines. The thermoplastic SGV are manufactured by prepreg cutting and layup at IHI’s Soma factory, and the main advantage is that they show low delamination after high-velocity impact. The thermoset used for the fan case was also developed to show superior impact energy absorption against high-velocity impact, which is one of the main criteria for both these engine parts.

This innovation was successfully applied to the Airbus A320neo, powered by the PW1100G-JM engine. This engine was certified by FAA in December 2004 while the Airbus A320neo was certified in December 2015.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: AUTOMOTIVE, STRUCTURAL

Winner: Forward Engineering GmbH (Germany)

Partners: KraussMaffei (Germany), ALPEX Technologies GmbH (Austria), Dieffenbacher

(Germany), Saertex (Germany), Henkel (Germany), Handtmann (Germany), TUM/LCC

(Germany)

Name of Product or Process: T-RTM

Description:

The aim of this project is to develop the near-net-shape T-RTM (thermoplastic resin transfer moulding) process for high-volume production. This innovative process combines the advantages of thermoplastic resin and the design freedom offered by HP-RTM technology for complex parts.

To demonstrate the process potential, a roof frame for the Roding roadster was re-designed, having in mind that the roof frame is a structural element for the car. The roof structure is made of a complex multi-preform part with hybrid textiles and integrated metal inserts, impregnated with a low-viscosity polyamide 6 (PA6) by HP-RTM. This low viscosity allows better impregnation of the fibres, a higher fibre-volume-fraction, and thus improved mechanical properties and an overall reduced wall thickness, which reduces material cost.

To further reduce cost, the expensive carbon fibre was partly replaced with glass fibre, thanks to in-ply hybridisation within a non-crimp fabric (NCF). As such, a low amount of carbon fibres is enough to add stiffness to the glass fibre layers. All these optimisations lead to a 16% material saving for the roof frame compared to epoxy resin RTM.

To ensure a cost as low as possible, Forward Engineering also focused on the integration of metal inserts in order to ensure optimised load transfer and to minimise roof assembly costs in mass production. Two types of inserts are used in the demonstrator: Al-casted inserts treated for ideal matrix adhesion applied directly on the dry preforms, and steel-threaded inserts applied by river nuts. During the RTM process, an additional form locking due to overmoulding with pure resin occurs, and the resin also prevents galvanic corrosion.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: AUTOMOTIVE, EXTERIOR

Winner: LG Hausys (South Korea)

Partner: Hyundai-Kia Motor Company (South Korea)

Name of Product or Process: One-piece roof rack

Description:

With increasing pressure on

automobile manufacturers to

reduce the carbon footprint of

their vehicles, weight reduction

is becoming a major

prerequisite.

The goal of this project is to

reduce the weight and cost of a

part that is traditionally made

of aluminium and largely

unnoticed in the composite

industry.

This innovation aims to reduce the weight and cost of a roof rack through the use of a continuous-fibre thermoplastic (CFT) composite. To achieve this goal, LG Hausys developed a manufacturing process where the CFT, made of polypropylene and glass fibres, is first pre-formed to the desired shape and then overmoulded to form the ribs that will add rigidity to the rack. In the final step, the formed roof rack is painted using a new surface treatment technology.

The advantage of this project is that the technology was developed for high design freedom, enabling better adaptation of the rack on the roof, which will help reduce the part cost for mass production across a broad range of vehicles. This innovation reduced the part’s weight from 3.8 kg to 2.76 kg, which represents a 28% reduction, while maintaining the required performance. This CFT roof rack is also beneficial from an assembly point of view as the number of parts is reduced to 1 from 5 in existing aluminium roof racks.

Overall, compared to an aluminium roof rack, the cost is reduced by €5.2/part.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: CONSTRUCTION

Winner: ACCIONA Construcción SA (Spain)

Partners: Owens Corning (Spain), Scott Bader (UK), CELO - APOLO Construction Systems

(Spain), LUM-Industry (France), BYK-Chemie GmbH (Germany), Nanjing Loyalty Composite

Equipment Manufacture Co. Ltd. (China)

Name of Product or Process: Innovative composite panels, an alternative to steel

and concrete for high-speed railway tunnel construction

Description:

When the two 24km-long Pajares high-

speed railway tunnels met the problem of

continuous water infiltration on around

30% of the total tunnel length, few of the

available solutions in the market were

able to solve the issue.

The innovative composite panels

developed by Acciona proved to be the

best solution in this demanding

construction work because they

managed to meet all the technical

challenges while complying with the

flame-retardant requirements associated

with this type of application.

The challenges of this innovation were diverse because of the many criteria that had to be met. From a mechanical point of view, the use of composites made it possible to meet the structural requirements while being thin enough not to change the tunnel’s diameter and being compatible with catenary systems. The design flexibility offered by composites also enabled Acciona to develop a system with leak-proof joints and an anchorage system. The 9.2-metre-long panels were also flexible enough to adapt to the shape of the tunnel and its irregularities.

Another concern in this project was the need to produce as many as 15,000 panels within the delivery schedule and to keep the cost of the composite panels as low as possible. To achieve this, Acciona opted for a pultrusion process and developed a low-cost resin injection system and fibre impregnation chamber that were adapted to the viscosity of the flame-retardant resin formulated for the project. This new system made it possible to produce one composite panel in 34 minutes on a continuous basis.

The other advantages of composites in this application were their low maintenance and high corrosion resistance compared to traditional construction materials. Finally, the handling and installation of the panels in the tunnel were easy and fast thanks to the lightweight nature of the composite panels.

To sum up and illustrate the size of the project: more than 15,000 panels were produced, covering about 200,000 square metres of tunnel for a total of 1,700 tonnes of composites.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: PROCESS

Winner: IRT M2P (France) Partners: Arkema (France), Compose (France), Faurecia (France), Chomarat (France), Hexion (France), Hutchinson (France), Composite Integrity (France), SISE (France), PINETTE P.E.I. (France), Renault (France)

Name of Product or Process: Fast RTM

Description:

This innovation is the result of a series of

innovations developed by the partners of the Fast

RTM collaborative project.

Pinette P.E.I. (compact press and loading &

unloading device), Compose (innovative tooling for

net-shape parts), SISE (cost-effective

thermoregulation system), Chomarat (optimised

reinforcement materials), Hexion & Arkema

(reactive resins), Composite Integrity (closed-mould

process), and Renault, Faurecia & Hutchinson

(integration and design) worked together to provide

the solutions that would make the project a success.

All these individual developments resulted in the creation of an industrial-scale platform to demonstrate the feasibility of mass-produced structural composite automotive parts using reactive RTM processes. This fully- automated platform is based on C-RTM (compression resin transfer moulding) and is compatible with reactive thermoplastic and thermoset resins, which impregnate the part faster and better than RTM and make the process flexible and adaptable to the needs of car manufacturers.

Thanks to an automated environment (loading and unloading) and cutting-edge equipment especially developed for the project, the Fast RTM platform can produce large (up to 3 m²), fully net-shape, functionalised and structural composite parts in a cycle time of 120 seconds. To ensure the traceability and quality of the resulting parts, the platform is also fully instrumented with automatic data acquisition, process parameter traceability, energy consumption measurement systems and on-line non-destructive control systems.

The initial target of this innovation being mass-market cars, the Fast RTM project focused on a technically and economically optimised solution, integrating functionalisation, net-shape and a fully-automated process to keep the costs and cycle times as low as possible. Thanks to this focus, the process was easily adopted by other industries in need of higher production rates, such as aeronautics, railways and the entire transportation sector.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: MANUFACTURING

Winner: Voith Composites GmbH & Co. KG (Germany)

Name of Product or Process: Voith Roving Applicator

Description:

This innovation is a fully-automated

direct fibre placement machine, called

the Voith Roving Applicator (VRA).

The VRA uses untreated roving and

binder powder to generate a net-shape

dry stack. The stack is produced in four

different steps: first, the roving is spread

and assembled in a 50mm-wide tape, a

binder is applied on the tapes on-line,

then the tape width is checked by on-line

quality control and finally, the bindered

tapes are placed on a rotatable/movable

table by several pairs of grippers.

This results in the assembly of a near-net-shape preform stack step by step, with local reinforcements or layers that can be placed at any angle in any area.

The main advantage of this manufacturing process is that the resulting preform is fully adapted to the mechanical requirements and loads of the final part, with great flexibility and fast adaptation. The VRA being linked with an automated production line already used for an automotive high-volume series CFRP material, it provides increased efficiency and better integration.

Moreover, even though the individual grippers are quite standard, the VRA is scalable: the lay-up rate can be increased by a factor of two by doubling the number of grippers. And several units can be placed in parallel upstream tape manufacturing lines, which presents a strong advantage compared to standard dry fibre placement machines.

In addition to this increased production rate, this innovation has a strong goal of reducing production costs. Untreated roving and binder are used due to their cost effectiveness, but also because, thanks to the VRA, these raw materials can be processed into a useable preform directly from the fibre in one step – without having to use costly intermediate steps or semi-finished products, and with almost no waste.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: SUSTAINABILITY

Winner: Faurecia (France)

Partner: Automotive Performance Materials (APM) (France)

Name of Product or Process: NAFILite™ microcellular foamed material

Description:

To meet environmental concerns in

the automotive industry, this

innovation focuses on reducing

environmental impacts throughout

the material’s life cycle.

Whereas traditional composites

make it possible to reduce the CO2

emissions of vehicles during their in-

service life, bio-sourced composites

can help reduce this impact during

both the manufacturing process and end-of-life disposal.

The goal of the NAFILite™ microcellular foamed material developed by Faurecia is to further reduce the environmental impact of composite materials.

NAFILite™ combines a microcellular foaming process based on injection (with a mould-opening technology) with the existing NAFILean™ material grade: an injectable and recyclable material made of 20% hemp fibres and polypropylene. The NAFILean™ compound with 20% renewable content is injected with additives in a closed mould. The mould is then slightly opened to accommodate the material’s expansion (due to CO2

release).

The resulting foam is 30% lighter than the current market reference for injected structural parts used in automotive interiors. The combination of weight savings, renewable natural fibres and a recyclable thermoplastic material reduces its environmental impact by up to 30%.

Furthermore, to reach the quality standards of automotive OEMs, the microcellular structure of the final material provides improved perceived quality in terms of robustness and fit and finish, and also presents good thermo-mechanical properties versus standard materials.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: MARINE

Winner: VABO Composites (the Netherlands)

Partners: ICO BV (the Netherlands), Spil Composites (the Netherlands)

Name of Product or Process: “Plug-and-play” composite ship door

Description:

Traditionally, ship doors are made of steel or aluminium,

which is detrimental to weight but also to corrosion

resistance. Corrosion being a threat and involving huge

costs, it was only natural that some alternative would

eventually make it to production.

This innovation offers such an alternative, as VABO

Composites developed a “plug-and-play” composite ship

door and hatches designed to replace the existing metal

solution.

The door and hatches are produced by RTM in a modular moulding system, which allows the production of several door dimensions at a lower cost. The core and post-production processing is done by CNC milling and all the other parts are assembled and checked in VABO’s workshop to ensure that the products can be used directly in yachts, cruise ships, commercial ships, etc.

The advantages of this innovative ship door are obviously the fact that composite materials have great corrosion resistance and are lighter than metal – a fully-equipped door with dimensions 1800 x 800 mm weighs less than 45 kg, i.e. approximately 60% weight saved versus the steel version – thus improving the balance and fuel efficiency of ships. But composite doors also require low maintenance as no lubrication is needed and they include some additional functions.

The doors successfully passed fire resistance tests and have excellent acoustic damping and insulation properties, meaning there is no need to add insulation as it is the case for aluminium and steel doors.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: 3D PRINTING

Winner: +LAB - Politecnico di Milano University (Italy)

Partner: Owens Corning (France), KUKA Robotics (Germany)

Name of Product or Process: Smart manufacturing of continuous-fibre

composites: Atropos

Description:

Atropos is the name of the first 6-axis robotic

arm able to 3D print continuous- fibre

composites using thermosetting resins.

In the process supporting Atropos, the fibres are

impregnated and drawn to the head of a

numerically-controlled machine that can place

them in a precise and repeatable manner. Once

extruded by the printing head, the material is

irradiated by a dedicated UV lamp to quickly cure

the resin.

The choice of focusing on thermosetting resins with curing times shorter than one second makes it possible to place continuous fibres at speeds of about 50 mm/s for now, thereby rapidly generating products characterised by significantly higher working temperatures compared to conventional thermoplastic resins.

To optimise the internal and external shape of the object, +LAB developed a slicing algorithm that can predictively plan the machine movements to place the reinforcing material where the maximum stresses appear in the final object. Furthermore, the algorithm can also vary the fibre/matrix ratio up to 60% in volume. With both these characteristics, it is possible to obtain a lightweight and customisable part with optimised performance according to its use.

The main strength of this project is the ability to control the fibre direction as the part is produced to get the best of the fibres’ anisotropic nature, thanks to the algorithm developed by +LAB. Thus, different parts with the same shapes can be produced and customised according to their in-service loads.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: SOFTWARE

Winner: e-Xstream (Luxembourg)

Co-Winner: Solvay (France)

Name of Product or Process: Digimat AM

Description:

With the impressive growth

rate of additive manufacturing

(AM) over the past years, e-

Xstream set-up a solution to

help the AM industry

transitioning from prototyping

to actual manufacturing of

composite parts.

This innovation combines different software programs to offer solutions for materials development, process simulation and printed part performance.

From the materials point of view, e-Xstream will provide the tools (Digimat-MF and Digimat-FE) to engineer advanced composite materials specifically for AM.

Regarding process simulation, Digimat-AM is an innovative software program fully dedicated to modelling the Fused Deposition Modelling (FDM) and Selective Laser Sintering (SLS) printing processes for reinforced materials. The goal of Digimat-AM is to be able to “print right the first time” by optimising the manufacturing process quality (minimising part deformation, for example) and by predicting the as-printed part performance.

The Digimat platform will also be able to simulate the printed part’s performance as a function of the material and the printing process parameters such as tool or sintering laser path. This unique tool is a major step forward for the development and design of composite parts by AM, bringing the performance and efficiency of 3D-printed parts to the level required for the industry.

Digimat is the only software on the market that will enable end-users and printer OEMs to bring reliability to printed parts, thanks to warpage prediction, evaluation of many process parameters by simulation, eliminating the cost of the trial & error previously needed to optimise these parameters. Moreover, as the impact of the printing direction can be assessed, the numerical simulation reduces the need for many mechanical tests down to a few validations.

Fig. 1: Predicting the failure indicator distribution due to burst pressure of a printer polimotor plenum using the Sinterline® material. Courtesy of Solvay Engineering Plastics.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: SPORTS

Winner: Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) (Germany)

Partners: Hochschule für Technik und Wirtschaft (Germany), Faculty of Design (Germany)

Name of Product or Process: Recurve bow riser

Description:

This innovation is a new generation of bow risers made of carbon fibre composite materials.

Whereas the use of composites in bow risers is now quite common, this riser was made utilising an unconventional but stress-adapted design, making it up to 40% lighter than current solutions (carbon or aluminium)

while also improving the mass-specific stiffness by about 43% compared to a reference riser made of aluminium. To be able to manufacture an actual part, IPF used the Tailored Fibre Placement (TFP) technology, a process invented at IPF Dresden, to produce four preforms with a truss-like structure. With this highly versatile technology, IPF managed to demonstrate the capability of a variable-axis composite design. Because state-of-the-art composite manufacturing is mainly based on multi-axial design, the realisation of a stress-adapted design may be quite hard, if not feasible at all.

The application of composite materials according to precalculated variable-axis directions can therefore lead to superior part performance, using the anisotropic nature of fibres in the best possible way, and can help to use far less resources, thus allowing for cost savings.

Another important phase of the project was the development of the manufacturing process. Due to the part’s complex shape, with various holes and inserts, the development of a closed pressurised RTM mould was not possible. Instead, a quasi-closed tool was manufactured with special inserts for resin inlet and areas for air pressure evacuation. The final consolidation process is basically a closed-mould infusion process, which helps to reduce the manufacturing costs as no RTM pressurisation device is required, without affecting the part quality.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: RAW MATERIALS

Winner: Covestro Deutschland AG (Germany)

Name of Product or Process: Desmocomp®, a novel solution for composites

Description:

One of the main concerns of building and infrastructure manufacturers regarding composite materials is their ability to withstand environmental degradation, and in particular UV light. To face this issue, Covestro developed the Desmocomp® matrix material.

This polymer is based on aliphatic polyurethane (PU) and presents good weathering and UV resistance to protect the composite from environmental influences, thus making the use of UV stabilisers, UV

veils and protective coatings unnecessary.

To provide a complete solution for exterior applications, Desmocomp® can also rely on the good mechanical properties of PU, such as dimensional stability (low thermal expansion coefficient), thermal insulation, and good chemical and fire resistance, as well as anti-graffiti properties.

First developed for the pultrusion process, one of the main processes used for composites in infrastructure, Desmocomp® can be used in open and closed moulds, and thanks to an innovative single-component system, it is easy to process and cost effective as no injection boxes, meter-mix pumps or additional investments are needed.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

Category: BETTER LIVING

Winner: Brødrene AA (Norway)

Co-Winners: Saertex GmbH & Co KG (Germany), DIAB group (Norway), Reichhold (Norway)

Name of Product or Process: Vision of the Fjords, Ship of the Year 2016 in Norway

Description:

When Brødrene AA was commissioned to develop a ship for use on tourist excursions in the UNESCO World Heritage-listed fjord of Nærøyfjord, it faced the challenge of combining mass tourism and the need to preserve the environment with an impact as low as possible. The solution Brødrene AA came up with was a ship with lots of external open spaces for sightseeing as well as vast window areas and an efficient catamaran design to reduce waves and wash on the shores of the fjord.

The only solution that provided the required stiffness to realise the designers’ intention was carbon fibre reinforced polymers and carbon sandwich materials. All of the ship’s structural elements are made out of carbon sandwich laminates (decks, walls, stairs, ceilings…), including the 42-metre-long and 5-metre-high hulls of the catamaran structure, which are produced in a one-shot vacuum infusion process, thus making the Vision of the Fjord the largest commercial passenger boat to be built in carbon fibre. Saertex provided the fabrics, Diab the low-weight core for the sandwich composite and Reichhold the rubber modified vinylester.

The low weight of the sandwich laminates also enabled the ship to be propelled by electric motors with lower power, making it clean and silent. In this project, the use of composite materials was mandatory to be able to provide the required design while making the ship environmentally friendly in the process as well.

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE

AERONAUTICS – IHI Corporation (Japan) Innovative composite fan system for aero-engines Copyright: © JEC Group/IHI Corporation

AUTOMOTIVE, STRUCTURAL – Forward Engineering GmbH (Germany) T-RTM Copyright: © JEC Group/Forward Engineering GmbH

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE

AUTOMOTIVE, EXTERIOR – LG Hausys (South Korea) One-piece roof rack Copyright: © JEC Group/LG Hausys

CONSTRUCTION – ACCIONA Construcción SA (Spain) Innovative composite panels, an alternative to steel and concrete for high-speed railway tunnel construction Copyright: © JEC Group/ ACCIONA Construcción SA

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE

PROCESS – IRT M2P (France)

Fast RTM Copyright: © JEC Group/IRT M2P

MANUFACTURING – Voith Composites GmbH & Co. KG (Germany) Voith Roving Applicator Copyright: © JEC Group/Voith Composites GmbH & Co. KG

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE

SUSTAINABILITY – Faurecia (France) NAFILite™ microcellular foamed material Copyright: © JEC Group/Faurecia

MARINE – VABO Composites (the Netherlands) “Plug-and-play” composite ship door Copyright: © JEC Group/VABO Composites

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE

3D PRINTING – +LAB - Politecnico di Milano University (Italy) Smart manufacturing of continuous-fibre composites: Atropos Copyright: © JEC Group/+LAB - Politecnico di Milano University

SOFTWARE – e-Xstream (Luxembourg) Digimat AM Copyright: © JEC Group/e-Xstream

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE SPORTS – Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) (Germany) Recurve bow riser Copyright: © JEC Group/ Leibniz-Institut für Polymerforschung Dresden e.V.

RAW MATERIALS – Covestro Deutschland AG (Germany)

Desmocomp® - a novel solution for composites Copyright: © JEC Group/ Covestro Deutschland AG

Press contacts : JEC Group – Thierry-Alain TRUONG – [email protected] APOCOPE – Dorothée DAVID – Marion RISCH +33 (0)1 45 78 87 37 / mail: [email protected]

PICTURES AVAILABLE

BETTER LIVING – Brødrene AA (Norway) Vision of the Fjords, Ship of the Year 2016 in Norway Copyright: © JEC Group/Brødrene AA