#Composites

2024-03-14

First thermoplastic composite structure demonstrator

Hexcel and Arkema achieve a groundbreaking milestone in the field of aeronautical structures with the realization of a first thermoplastic composite structure demonstrator at JEC 2024. This achievement stems from the strategic partnership between Hexcel and Arkema.

The high-performance thermoplastic composite structure was designed and manufactured using HexPly® thermoplastic tapes. These aerospace-grade materials are developed from Arkema’s Kepstan® PEKK resin and Hexcel HexTow® AS7 and IM7 carbon fibers.

The demonstrator project was carried out as part of the collaborative project known as HAICoPAS. The primary goal of HAICoPAS is to optimize the design and production process for unidirectional composite tapes made from high-performance thermoplastic resins and continuous carbon fibers. Additionally, the project aims to develop a more efficient tape placement technology and a novel continuous and dynamic in-situ welding (ISW) assembly system with real-time quality control. Ultimately, the objective is to produce composite parts that can replace metallic materials (such as steel, aluminum, and titanium) in aircraft structures, achieving both cost competitiveness and high production rates.

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

1. The development, implementation, and characterization of carbon/thermoplastic (C/PEKK) tapes.

2. The creation of an automated deposition process for consolidation outside of autoclaves.

3. The establishment of the ISW welding technology for assembly.

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

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

Presentation of the demonstrator project at JEC © 2024 Hexcel

Novel flame-retardant and recyclable fiber-reinforced composite

Airplanes and passenger trains must meet strict safety requirements, including fire safety standards. This calls for materials that are flame-retardant, lightweight, robust, and scalable. Empa researchers, in collaboration with their industry partner Elantas, have now succeeded for the first time in making such a material – a composite – fully recyclable.

WHILL selects Teijin’s tough, lightweight Carbon Fiber Composite for new last-mile mobility

Teijin Limited announced today that WHILL Inc., a global leader in inclusive mobility technology, has selected Sereebo® P CFP series, a carbon fiber-reinforced thermoplastic (CFRTP) material, for key structural components of the upcoming WHILL Model C Lite. Sereebo® P CFP series provides high strength, light weight, design flexibility and system cost advantages to the Model C Lite, which is a battery powered, single-seat, last-mile device. This new model combines maneuverability with light weight and one-handed folding to ensure ease of handling and operation.

Fewer pores, greater impact tolerance: Peter Dornier Foundation Prize 2026 honours material research on fibre-reinforced composite components for aerospace industry

Microscopically small pores that form during manufacture, or barely visible impact damage, can severely impair the load-bearing capacity and service life of fibre-reinforced composite components. Two young researchers have presented groundbreaking work in this field and will both be awarded the 2026 Peter Dornier Foundation Prize: Dr.-Ing. Benedikt Neitzel from the Technical University of Ilmenau for his doctoral thesis on pore minimisation in the RTM process, and Johanna Buschmann, M.Sc., for her master’s thesis, completed at the German Aerospace Centre, on the improved impact tolerance of 3D fabrics compared to 2D laminates.

KARL MAYER invites the Global Textile Industry to celebrate its 90th anniversary at its German Headquarters in 2027

KARL MAYER is turning its anniversary year 2027 into a milestone for the textile sector. To mark its 90th anniversary, the industry leader is inviting customers, partners, and experts from around the world to a unique event series in September aimed at pushing boundaries, unlocking new opportunities, and jointly setting the course for a new era in textiles – just as KARL MAYER has done throughout its history. The company’s headquarters in Obertshausen, near Frankfurt, is the place to be.

ITMF names three winners of the Sustainability & Innovation Award 2026

Three projects from the UK, Korea and China have been selected as winners of the ITMF Sustainability & Innovation Award 2026. The projects address textile-to-textile recycling, chemical recycling for automotive textiles and a regenerative approach combining silk production with ecological restoration.

Durak Maxibalance thread supports users’ movement and balance comfort

Durak Tekstil, a leading brand in its industry, has developed Durak Maxibalance, a new product engineered with bio-ceramic and FAR IR technology. Ushering in a new era for sportswear, activewear, and medical textiles, this technology offers features designed to support balance and movement comfort by reflecting the energy absorbed from the body back into it.