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Technical Conferences [clear filter]
Tuesday, June 1
 

10:00 CEST

Composites for sustainable Mobility
  • Nonwoven fabrics
  • T-RTM-process
  • eco-efficiency analysis

The project „Composites for sustainable Mobility“ – short “CC4CosiMo” – was launched by a consortium consisting of renowned industrial partners and important research institutes in the composite base Augsburg, Bavaria. Its aim is to transmit innovative sustainable thermoplastic composite technologies into high volume production in the fields of automotive engineering and aerospace.
The basis of the parts is recycled carbon fiber. They are being processed inside the T-RTM process as nonwoven fabric. Along the production chain the technology readiness level is raised in order to exploit the potential of the material. What is unique is the new material class of web based composites. This recycled material has a lean and at the same time highly individualized manufacturing process. Furthermore innovative methods of industry 4.0 are being used through the utilization of a digital twin which raises the part quality and reduces the rejection rate.
Additionally an eco-efficiency analysis was conducted. Parts based on high performance virgin UD material and recycled nonwoven fabric have been compared. Thereby it was proven that recycled nonwoven fabric is the more sustainable solution concerning economic and ecological aspects.
The use of recycled fibre is only one pillar for sustainable composites. It is important to focus on the matrix at the same time. In this use case bio-based caprolactam has a great potential. An advantage of the thermoplastic matrix PA6 is the possibility of depolymerization. Here, the matrix is not lost during the recycling process (compared to pyrolysis). This shows that there are unutilized potentials.

Speakers, Jury Members & Final...
avatar for Matthias FRONING

Matthias FRONING

Research Fellow, ITA Augsburg GmbH
Matthias Froning earned his degree of bachelor of science in cooperation with the Muhr & Bender KG at the university of Siegen.He completed his bachelor thesis at the company CarboTech, Salzburg.Afterwards he made his specification at the Technical University Munich (TUM) at the Chair... Read More →


Tuesday June 1, 2021 10:00 - 10:25 CEST
Conferences (Hall 6 - Room 611)

10:25 CEST

Approaching Zero – Waste-Free Production of Composite Wheel Structures
  • Spoke wheels
  • Zero waste design
  • Eco efficient production

Due to their complex geometry, wheels and wheel-like structures made of fibre-reinforced plastic (FRP) usually consist of a large number of blanks made of flat semi-finished products. These semi-finished products are cut from webs with cutters, whereby even with careful planning an unavoidable proportion of waste is produced. With "CompoSpoke" a process has been developed which enables the production of spoke wheel structures in wet winding with virtually no waste.
It consist of a multi-stage procedure, which allows full variability with regard to the geometry. In a first step, a ring is wound which already matches the later spokes in width and thickness. This ring is automatically formed into the spoke structure using moulded parts manufactured in 3D-printing. Compressions and strains are compensated precisely so that a constant band tension is maintained. In a further step, an outer ring can optionally be wound, for example as a rim bed. With rigorous use and suitable products, the entire component can be produced from a single continuous roving which makes multiple positioning unnecessary.
The optimized use of raw materials makes the CompoSpoke process competitive to metallic construction methods. This is particularly the case when, due to small batch sizes, casting of metallic components close to the final contour is not an option. For instance, the material input of milled components and the energy required to recycle the chips is significantly higher compared to the production of a FRP-spoke wheel using the CompoSpoke process. In addition, further energy saving potentials can be exploited through the advantages of lightweight construction throughout the life cycle of the component.

Speakers, Jury Members & Final...
avatar for Marcel BÜCKER

Marcel BÜCKER

Project Leader, Institut für Verbundwerkstoffe GmbH
• Born 12.08.1981• 2009: Diplom-Wirtschaftsingenieur (TU Kaiserslautern, Germany)• 2016: Dr.-Ing. (Institute for Composite Materials, TU Kaiserslautern, Germany)• 2016 – 2019: Head of product development at Schäfer MWN GmbH, Renningen, Germany• Since 2019: Project leader... Read More →


Tuesday June 1, 2021 10:25 - 10:50 CEST
Conferences (Hall 6 - Room 611)

10:50 CEST

UPCYCLING for thermoplastic composites : How to recycle with added value using ThermoPRIME® & Thermosaic® technologies
  • Upcycling for thermoplastic composites = added value
  • Market and Industrial opportunities
  • Contribution to global cost reduction of composites

Recycling thermoplastic composite materials with an “upcycling” approach is a way to contribute to the grow of the global thermoplastic composite market. As a lot of waste is generated during the production process of panels and preforms, finding solutions for recycling it with more added value is a real concern.
Contrary to chemical or “downcycling” technologies, the innovative process Thermosaïc® & ThermoPRIME® allows the production, from waste, of large-scale panels having maximized mechanical performances. Based on a thermomechanical and "step by step" process, this line is a concrete cost-effective recycling technology which provides a way to reuse the generated waste or end-of-life components by producing new composite materials with a competitive cost/performance ratio. Two ways of production are possible with the same line :
  • Thermosaïc®: recovery of thermoplastic composite production waste and/or end-of-life products, sorted and crushed beforehand, then shredded. Shreds are bound by thermocompression into the shape of structural panels with a continuous production. The breakdown approach is to keep the intrinsic value of the composite (no separation of the fibre and the matrix) during the recycling process.
  • ThermoPRIME®: recycled plastic materials are associated with continuous or long fiber reinforcements, to produce recycled composite panels with a higher technical and economic value.
Easy to use and cost-effective, the technology is based on usual industrial equipment, with initial investment and operating cost lower than a continuous production line (e.g.: line with a double belt press). Flexibility of the line allows the process of various thermoplastic matrix combined with different kinds or mixed reinforcements.

Speakers, Jury Members & Final...
avatar for Frederic RUCH

Frederic RUCH

Manager of Polymer Composite & Engineering department, CETIM GRAND EST
F. Ruch is the manager of Polymer Composite & Engineering department, at Cetim Grand Est. After a PhD in physico-chemistry, he has been working for 10 years in the field of polymer/composite failure analysis, and more recently as an engineering consultant. In addition, since 2011... Read More →
avatar for Clément CALLENS

Clément CALLENS

BU Manager Industry of the Future, CETIM GRAND EST
Mechanical engineer with a background in automotive industry (10 years) in process optimization and industrialization.After this industrial experience, skills were completed with an innovation expertise as project manager during 5 years in the technical center CETIM (as QSP® project... Read More →


Tuesday June 1, 2021 10:50 - 11:15 CEST
Conferences (Hall 6 - Room 611)

11:15 CEST

From bottle to energy
  • Renewable energy sector to re-think supply chain for raw materials
  • Shift from PVC-based chemistry to PET and bio-based materials
  • When will we have scalable technologies to recycle composites?

Renewable energy is a booming sector. Over the years, wind energy has been able to claim a prominent position in the landscape of sustainable energy, having reached cost parity with fossil fuels in 2019. This rapid development towards a widespread and cost-effective means of energy generation forces the industry to rethink its supply chain for both affordable and sustainable raw materials.
Gurit has been at the forefront of the wind revolution as a material supplier and over the years has continuously developed solutions to support the dynamic and innovative wind industry. Over the last few years we saw a shift from legacy core based on PVC chemistry to a more affordable and sustainable technology centred on thermoplastic and in particular PET. This shift is not only a matter of technologies used, it has put a strong focus on the complete supply chain to be able to deliver solutions that are not only affordable but also are increasingly sustainable, for example thanks to the use of recycled PET.
In addition to the use of recycled materials there is a strong trend towards bio based materials, such as Balsa wood or bio based epoxy for marine and other applications.
Challenges are still ahead of us as the industry looks at opportunities to improve the end of life impact of composite structures. While we become greener in our choice of materials the industry still lacks scalable technologies to fully recycle composite materials and structures.



Speakers, Jury Members & Final...
avatar for Emiliano FRULLONI

Emiliano FRULLONI

Chief Technology Officer, GURIT
Dr. Emiliano Frulloni, Chief Technology Officer; PhD in Materials Science and Technology, University of Perugia; MBA Manchester Business SchoolItalian & British citizen, born 1974.Professional background (main stages) :2005 Development Engineer, Cytec Engineered Materials/2009 R&D... Read More →


Tuesday June 1, 2021 11:15 - 11:40 CEST
Conferences (Hall 6 - Room 611)

11:40 CEST

12:00 CEST

Industrial circular solution for the environmentally safe recycling of wind turbine blades and other GRP products
  • There exists a current lack of viable and environmentally friendly wind blade recycling solutions
  • R&D for current KESCON technology began in 2003 and is possible only due to many years experience in recycling industry
  • Transforming wind blades and other fiberglass products into valuable end products

There are currently 120.000 wind turbines in Europe alone that will eventually need to be disposed of, and more are being built every day. Almost everything from these giant structures can be recycled. The blades, constructed of GRP, however, cannot.
KESCON Engineering has been a leading player in the recycling industry for over 20 years. Since 2003, the company has been focusing on developing viable and environmentally friendly solutions for the recycling of composite materials including fiberglass, polyurethanes and other critical materials. On the back of this research, KESCON has developed a patented, circular recycling process to transform wind blades and fiberglass products into valuable end products, including pellets and high tech IFS panels, on an industrial scale.
Its IFS panel is a product geared towards use in the construction industry. Its properties, including its thickness swell, modulus of rupture (MOR), and modulus of elasticity (MOE), are superior to particle board, OSB and cement board. It can be custom designed to meet specific applications. Lastly, in contrast to waste incineration and co-processing, the process is environmentally friendly, with minimal NOx and CO2 emissions.
In the presentation we will focus on the recycling process, how we achieve the material properties observed in the finished products, and how the technology is being scaled to meet industrial needs.


Speakers, Jury Members & Final...
avatar for Reinhard KESSING

Reinhard KESSING

President, KESCON Engineering
Mr. Reinhard Kessing provides consulting, engineering and equipment supply services for the Composite Panels Industry worldwide. With over 25 years experience in the industry and successful plant commissioning of over 50 projects in more than 18 countries, he has proven to be a reliable... Read More →
avatar for Nicolas DERRIEN

Nicolas DERRIEN

Managing Director, NEOGEN25
Greentech entrepreneur. Co-founder and CEO of NEOGEN25 - innovative solutions for the circular economy and material transformation. Developing platform for the sustainable and efficient recycling of wind blades/fiberglass material. Worked with Global Fiberglass Solutions, the US pioneers... Read More →


Tuesday June 1, 2021 12:00 - 12:25 CEST
Conferences (Hall 6 - Room 611)

12:25 CEST

Holistic View on Recycling and Utilization of CFRP
  • Recycling / Circular Economy
  • Utilization ans Solutions
  • Applications and Performance for recycled Carbon Fibres

During this talk the speaker will present the current status of the global recycling industry. Therefore, he will present a statistical waste model containing data from the past (cut-off rate, fly-buy ratio, production capabilities etc.) and forcast data to present the development of CFRP and CF wastestreams. Those Data will be showing the increasing waste amount divided by sources and products. After that he will present a rough overview of modern recycling technologies like pyrolysis (microwave and conventional) as well as solvolysis, carding and wet laying. He will focus on research questions that are solved and have to be solved to enable the industry for a real circular economy, containing the utilization of CF in steel and cement manufacturing. In the end he will talk about products and their properties made with recycled fibres. Technologies like forming and back moulding of thermoplastic rCF-organisheets or wet compression moulding are actual possible for rCF nonwoven products and will be explained in terms of cycle time, properties and lot size. Fraunhofer have several projects at the moment to evaluate the properties of rCF products and benchmark them to other material like glass textile or virgin carbon fibre. The results of those projects will be shown and an outlook will be given. rCF have a high potential for CO2 neutral material and substitution of virgin materials that can fit to both automotive and aerospace industry.





Speakers, Jury Members & Final...
avatar for Jakob WÖLLING

Jakob WÖLLING

Head of Department, Fraunhofer IGCV
Jakob Wölling was studing Aerospace Technology an Stuttgart at the IFB. After doing his diploma he went to Fraunhofer in Bayreuth to set up a department for ceramic composites. After 7 years he moved to Fraunhofer IGCV to Augsburg in the year 2009. There he became the head of deparment... Read More →


Tuesday June 1, 2021 12:25 - 12:50 CEST
Conferences (Hall 6 - Room 611)

12:50 CEST

Biocomposites and automation for future sustainable industries. Case study: The building industry
  • Biocomposites
  • Digitalization and Automation
  • Building Industry

The lecture will highlight new visions for dealing with alternative bio-based materials in the form of (Biocomposites) in architecture and the building industry. The lecturer will showcase current industrial projects that the speaker (Prof. Dahy) is leading and how this influenced the way of making new vision for future sustainable architecture and accordingly the architectural design scenarios and applications. Examples from both research and teaching will be given and thoroughly analysed. Built up mock-ups in 1:1 scales with new developed materials, including bio-based and smart materials, will be shown and discussed. At the end, a discussion with be opened about how architecture of the near future should be like in academy and in practice. In addition, discussions including how materialisation and digitalisation have both affected this ‘new’ architecture will take place. Furthermore, methods of preparing future architects for those challenges in the future building industry will be highlighted.

Speakers, Jury Members & Final...
avatar for Hanaa DAHY

Hanaa DAHY

Professor, BioMat Department (Bio-based Materials and Materials Cycles in Architecture) at ITKE Institute – University of Stuttgart
Hanaa Dahy, born in Cairo, is a registered architect in Germany and in Egypt. After earning her PHD with excellence at the University of Stuttgart in 2014, Dahy established her (BioMat) department "Biomaterials and Material Cycles in of Architecture" since 2016 at ITKE (Institute... Read More →


Tuesday June 1, 2021 12:50 - 13:15 CEST
Conferences (Hall 6 - Room 611)

14:00 CEST

A responsible approach to design and manufacturing of composite facades
• Realising organic designs through the use of adaptive moulds resulting in less waste during manufacture
• Comparison of carbon footprint of curved facade panels designed in concrete, metal and composites
• Benefits of composite facades from design through to installation



Fibre reinforced plastic materials are a great choice for achieving freedom of design as they can be moulded easily into complicated shapes more easily than other materials. Add to this that the structure can be optimised for any loading given any shape and it is clear why these materials are finding more application in construction.

As environmental regulations become stricter in all industries, it is vitally important to ensure that we are smarter about how we use and manufacture with composites to ensure that architects will choose them, and the construction market will continue using them, in the long term.

This presentation will explain an approach to offering composite solutions for the architect that targets a lower carbon footprint in both the materials and manufacturing process without compromising on design. The adaptive mould will be introduced, a solution that has been used in the past few years by concrete façade manufacturers, and it will be explained how this technology has been adapted for use with composites.
It will be demonstrated that with careful material combinations coupled with the adaptive mould technology, composites the sensible choice to achieve freedom of design. More importantly, it will be shown that there is snowball effect of the benefits of using composites from manufacture right through to installation on the construction site.



Speakers, Jury Members & Final...
avatar for Tahira AHMED

Tahira AHMED

Director, Curve Works
Tahira Ahmed is managing director of Curve Works in The Netherlands. Her background is aeronautical engineering with a specialism in composite materials. Her passion, and the ideology behind Curve Works, is to continuously work on technologies to enable responsible manufacturing without... Read More →


Tuesday June 1, 2021 14:00 - 14:25 CEST
Conferences (Hall 6 - Room 611)

14:25 CEST

CL RESTRAP - Active shear strengthening of concrete
• Most effective shear strengthening method due to the enclosure of tension and compression cord
• Various experimental studies verify the shift from brittle shear failure to ductile flexural failure after the application of CL RESTRAP
• All four contributing factors to the shear capacity of a concrete structure are enhanced using carbon fibre solutions



One promising means of increasing the capacity of existing shear-deficient beams is to strengthen the structure using external prestressed carbon fibre CL RESTRAP’s. In this system, layers of CFRP tape are wrapped around a beam to form a strap which acts like a discrete unbonded vertical prestressing tendon. Various experimental programs have been undertaken to investigate the influence of the strap spacing, stiffness, initial prestress level and/or any pre-existing damage on the strengthened behaviour and mode of failure.
A standard concrete control beam was tested and failed in shear. In contrast, all of the beams strengthened with carbon fibre CL RESTRAP showed a significant increase in their ultimate load capacity with several of the strengthened beams failing in flexure.
Large scale applications have been carried out in 2019 in a commercial project in Switzerland using around 1’200 pretensioned CL RESTRAP’s.

Speakers, Jury Members & Final...
avatar for Andreas WINISTOERFER

Andreas WINISTOERFER

CEO, Carbo-Link AG
Dr Andreas Winistoerfer is the founding partner and CEO of Carbo-Link AG, based just outside of Zurich, Switzerland.He studied MSc. Materials Science at Cranfield University, England before completing his PhD in Engineering at the World-renowned ETH University in Zurich, Switzerland... Read More →


Tuesday June 1, 2021 14:25 - 14:50 CEST
Conferences (Hall 6 - Room 611)

14:50 CEST

Concrete-based composites’ developments in buildings and infrastructure
• Concrete-based composites
• Attractiveness of such composites
• Barriers which need to be overcome



A lot of developments have recently been taking place globally in the use of concrete-based composites in two main sectors, namely buildings and infrastructure projects. This paper presents a range of examples of the use of such concrete-based composites in these two sectors. The paper also reviews the reasons for the attractiveness of such composites as well as the barriers which need to be overcome for further growth.

Speakers, Jury Members & Final...
avatar for Andrew MAFELD

Andrew MAFELD

Founder and Managing Director, Connectra Global
Andrew Mafeld has more than 30 years of experience in the Composites industry. He has a B.Sc in Chemical Engineering from Imperial College, London and an MBA from INSEAD, Fontainebleau. In the first half of his career he worked for Procter & Gamble, Monsanto and Owens Corning. His... Read More →


Tuesday June 1, 2021 14:50 - 15:15 CEST
Conferences (Hall 6 - Room 611)

15:15 CEST

15:35 CEST

The future is here, what are we waiting for?
• Brief history of Glass Fibre innovation in concrete reinforcement and key application overview
• Outlining the biggest opportunities for material conversion
• Call to action, beyond materials, to ensure the future is built to last



Glass Fibre Reinforcements – the newest, oldest technology on Earth. With 70+ years of usage data and nearly 1,000 applications in existence globally, Fiberglass Rebar stands strong in the battle vs traditional reinforcement materials such as steel; however material science is only half the battle and while battling corrosion seems strong enough for us, there’s much more work to be done. We must accept the challenge that outperforming the standard isn’t enough; we must educate end-users, designers and decision makers; we must fight for codes adoption, skill advancement and the development of task forces to ensure change happens. A better way to build has existed, our trades, unions and installers deserve a product that is as equally tough and durable as it is light and easy-to-handle. Together we must stand and unite for change.

Speakers, Jury Members & Final...
avatar for Bryan BARRAGAN

Bryan BARRAGAN

Global Technical Leader, Concrete Reinforcement, Owens Corning
• Dr. Bryan Barragan• Owens Corning• Global Technical Leader, Concrete Reinforcement


Tuesday June 1, 2021 15:35 - 16:00 CEST
Conferences (Hall 6 - Room 611)

16:00 CEST

Epoxy Based composite concrete reinforcement solutions. “Quality, Reliability, Serviceability”
Epoxy is a proven solution for composite applications. “As a Responsible Care® company, our innovations seek to improve product lifespan and reduce waste. In this presentation, We will be highlighting use of Olin Epoxy systems to produce innovative rebar products that improve the lifespan of global transportation & marine infrastructure.
While the concept of basalt-fiber composite rebar is not new, Olin’s LITESTONE™ systems provide unique and superior flexibility during the pultrusion manufacturing process, enabling high-quality output for some of the longest rebar rods in the industry. Inherently non-corrosive, these robust and long-lasting alternatives to steel rebar provide an exceptional alternative for use in marine and infrastructure applications.


• improve product lifespan and reduce waste
• unique and superior flexibility during pultrusion process
• use in marine and infrastructure applications

Speakers, Jury Members & Final...
avatar for Jean Luc GUILLAUME

Jean Luc GUILLAUME

Global Wind and Composite Marketing Director, OLIN
Dr Guillaume began his career within the chemicals industry as a Chemist in the area of emulsion polymerization in 1985.Between then and 2002, he held several management positions in Germany which broadened his knowledge of market development as well as marketing within the chemicals... Read More →


Tuesday June 1, 2021 16:00 - 16:25 CEST
Conferences (Hall 6 - Room 611)

16:25 CEST

New thermoplastic composite rebar concept for concrete reinforcement
• ELIUM® liquid thermoplastic resins
• A new supply chain model
• Recycling solutions



Arkema develops new solution to manufacture composite reinforcement bars (rebars) for concrete using the liquid thermoplastic resin ELIUM® in place of conventional thermosetting solutions.
Composite rebars do not rust or corrode, are relatively insensitive to snow-clearance salts and chemicals used for de-icing, and have an interesting weight to strength ratio. These properties already make them an economically viable and more effective alternative to epoxy-coated steel rebars when life cycle cost is considered. The implications are significant for coastal or cold areas.
Based on the reactive liquid thermoplastic resin technology ELIUM®, a new generation of rebar has been developed that combines the qualities of composites with the new possibilities offered by the use of a thermoplastic matrix. Unlike most thermoplastic resins, ELIUM® can be easily processed through traditional pultrusion using exclusively standard equipment.
ELIUM® -based rebars and cables can be re-heated and easily shaped or bent, reducing the cost of supplying rebars with custom shapes. Moreover, the use of thermoplastic matrix open a way for GFRP recycling of spare part, with a potential strong reduction in environmental impact.
Different solutions are considered to find the most relevant way to recycle rebar wastes. Of course, the mechanical recycling is already well known for thermoplastic materials. Acrylic matrix offer a good miscibility in a wide range of virgin polymers.
Then, the chemical recycling process consists of the polymerization of the matrix to collect the monomers that compose it. After distillation, the purity of the monomers is higher than 99% and comparable with the same monomers from the conventional petrochemical path.

Speakers, Jury Members & Final...
avatar for Guillaume CLEDAT

Guillaume CLEDAT

ELIUM Global Business and Development manager, Arkema
Previously, since 2000, technical consultant in the tech transfer center PPE (now Institut de Soudure) then R&D and technical support manager for EMEA at Cray Valley then CCP Composites, global innovation and marketing leader at CCP Composites and R&D and technical support manager... Read More →


Tuesday June 1, 2021 16:25 - 16:50 CEST
Conferences (Hall 6 - Room 611)

16:50 CEST

CarbonFiberStone: high-performance carbon-negative material to disrupt architecture and keep global warming under 1.5°C
• Construction is responsible for 20% of global CO2 emissions
• TechnoCarbon has patented technologies to fix this problem and disrupt architecture
• TechnoCarbon and our partners are ready to industrialize and scale up CarbonFiberStone



TechnoCarbon disruptive technologies create a path forward towards sustainable architecture, industry and cities while protecting climate, biodiversity and natural resources.
There are currently no economically viable, scalable, high-performance, low-to-no carbon replacements for cement – and its concrete derivatives – or steel in the commercial building, home building and public infrastructure markets. Corrosion-free materials without resource bottlenecks and with faster installation times will own the market. CarbonFiberStone is such a material. Made of stone and carbon fiber, it has the potential to replace and scale up to capture, utilize and store over one billion tons of CO2 per year, while building structures adapted to climate change.





Speakers, Jury Members & Final...
avatar for Stephan SAVARESE

Stephan SAVARESE

CEO, President & Co-Founder, TechnoCarbon Technologies
President at SOP (Saving Our Planet) and TCTF (TechnoCarbon Technologies France), France Country Manager at Climate ScorecardAfter an initial career as an aerospace engineer, science advisor and multiphysics simulation leader, Stephan has become a climate change solution expert (teaching... Read More →


Tuesday June 1, 2021 16:50 - 17:15 CEST
Conferences (Hall 6 - Room 611)

17:20 CEST

Haute Couture meets Biomimetic Design
• Tailored Fibre Placement allowing load optimized structures
• Cost reduction through net-shape manufacturing
• Efficient preforming for high volume production



Tailored Fibre Placement (TFP) is capable of placing carbon fibre where it is necessary and only there. This allows for complex fibre architectures eliminating dead weight and material waste. However, the technology is highly restricted concerning productivity.

Bionic Composite Technologies AG (BIONTEC) was founded in 2009 by representatives of the textile and automation industry in order to industrialise the production of CFRP components.
Based on Tailored Fibre Placement accompanied with Resin Transfer Moulding (RTM) the company has developed its own manufacturing process from fibre to finished component.
Intensive development has resulted in a production process for series of up to 100'000 parts/year. Thus, it lifts the production of complex composite components to a new economic level.
By integrating the entire development and production process in-house, BIONTEC offers complex CFRP components with excellent performance to weight ratio that are ""designed for manufacturing"" and ""designed to costs"".
The process allows to choose the best material combination possible for each specific challenge. According to biomimetic design we aim to achieve the best performance with minimum material usage by placing fibres aligned to the loadpath within the net shape of the component. Subsequent to fabric production we mould ready-to-use components via RTM that can be monolithic, hollow or sandwich structures. Parts are manufactured net-shaped with high quality surface finish minimizing finishing efforts. Both the TFP and RTM process have been highly automated to achieve high and consistent product quality at competitive costs – especially for large volumes.

During our presentation we will give insight in our development and production process from the first idea to serial production an how we levarge the full potential of fibre reinforcements with biomimentic design and tailored fibre placement.



Speakers, Jury Members & Final...
avatar for Benedikt BORCHERT

Benedikt BORCHERT

Sales Manager, Bionic Composite Technologies AG
Benedikt Borchert studied mechanical engineering at Technical University of Munich and Lund University (Sedenb) with a major in fibre reinforced plastics.After his studies he worked in R&D as well as application engineering for textile semi-finished products. 2017 he took over the... Read More →


Tuesday June 1, 2021 17:20 - 17:40 CEST
Conferences (Hall 6 - Room 611)

17:40 CEST

Application of Biomimetic Methodology as a Project Tool for Innovation in Structural Components Using Composite Materials for Road Transport
• high performance composite
• biomimicry
• commercial vehicles



Biomimetics is a systematic research tool related to biological mechanisms, their systems and subsystems, which allows the interaction of design parameters with the natural characteristics of the analyzed elements. Studies related to this subject have show that nature has evolutionary characteristics in solutions analogous to what man finds when designing a product. Thus, we can infer that by employing this tool in product design, we will have a flow of innovation with levels of design disruption.
Faced to the megatrends of innovation, such as electrification, composite materials are gaining more space due to their possibility of complex geometries, structural arrangement conducive to environmental demands and the mixing of raw materials in the formation of a single piece. Such versatility and diversity of production processes allow the composites to reach strength levels higher than those currently available for automotive industry, but with a reduced mass.
Regarding the application of the method in vehicles and implements intended for the transportation of cargo and passengers, it is possible to obtain structural correlations that allow the optimization of components and subsets, making them simpler, lighter and with characteristics that enhance their use. In this context, the present work approaches, through the biomimetic methodology applied to the mobility sector, an optimized structural subset design case, using high performance composite material, subjected to dynamic loading, submitted to real tests on track and bench (seismic base), reproducing random signals from traffic.

Speakers, Jury Members & Final...
avatar for Eduardo TENDE

Eduardo TENDE

Development engineer, STE Parts
With more than 10 years of experience working on product development in the mobility industry, he is a co-founder of STE Parts, a start-up focused on developing innovative solutions using composite materials.
avatar for Joel BOARETTO

Joel BOARETTO

Innovation Manager, Centro Tecnológico Randon
Innovation manager of Randon group acting for 24 years in the automotive industry. Graduated in math and physics, post graduate in process engineer, master degree in mechanical engineer and PhD in materials engineer focusing in composite materials.


Tuesday June 1, 2021 17:40 - 18:00 CEST
Conferences (Hall 6 - Room 611)
 
Wednesday, June 2
 

10:00 CEST

Beyond what we want: the future we need to make carbon really work
  • The state of carbon: a dynamic market with untapped potential*
  • Crucial steps for growing the industry
  • Key technologies and trends in materials, manufacturing, and design innovations with the highest impact

Carbon fiber is a highly valuable material with the most innovative technologies in the composites space. However, carbon’s full market potential remains untapped and there is ample room for growth if we make the right plays. In this presentation, we focus on key aspects that will accelerate adoption and expand the industry through advanced engineering and tech innovation. A selection of technology case studies and trends will be discussed from precursor and processing, to manufacturing, new form factors and intermediates, and novel end application development.

Speakers, Jury Members & Final...
avatar for Cecilia GEE

Cecilia GEE

Analyst, Lux Research
Cecilia Gee is an analyst based in Lux Research’s Amsterdam office. She leads the Advanced Materials team and spearheads content on technology innovation and market trends in composites, structural materials, coatings, future materials platforms, sustainability, and textiles. Cecilia... Read More →


Wednesday June 2, 2021 10:00 - 10:25 CEST
Conferences (Hall 6 - Room 611)

10:25 CEST

Innovative stabilization oven concepts for carbon fiber production based on fiber bundle temperature measurements
  • Stabilization
  • oven design
  • temperature measurements

Carbon fibers have excellent mechanical properties at a low density. Despite their outstanding strength-to-weight ratio, carbon fibers are not used in low-cost areas due to their high price. The production of carbon fibers is divided into a multi-zone stabilization and a multi-zone carbonization. Due to the high process time of up to 120 min, stabilization represents a significant share of the total cost.
During stabilization, the precursor is thermally converted into a thermoset state at temperatures between 200-300 °C. The stabilization reaction can be described by three exothermic reactions: cyclization, dehydrogenation and oxidation. These reactions mainly depend on the oven temperature and the degree of fiber stabilization. Thus, a fiber that has already been partially stabilized requires a higher temperature than an unstabilized fiber. An optimal stabilization profile is characterized by the fact that as many reactions as possible take place in a short time without fiber overheating and burning uncontrollably due to the exothermic nature of the reactions. Specially developed circulating air ovens are used for stabilization. A stabilization system consists of several ovens arranged behind each other with increasing oven temperature. Current stabilization ovens are especially designed with a view to homogeneous oven temperature distribution. However, the temperature of the fibre is not measured or considered since there is no commercial system for fibre temperature measurement.
The research results show measurements of the fiber temperature in different zones of stabilization. The fiber temperature is significantly higher than the oven temperature due to the exothermic reactions. Furthermore, the reactions do not take place uniformly over the entire stabilization due to the oven design. Thus, the results offer enormous potential for improving the oven design and the safety of industrial scale lines. In order to demonstrate the potential of an adapted oven design, initial tests were carried out and evaluated.

Speakers, Jury Members & Final...
avatar for Felix POHLKEMPER

Felix POHLKEMPER

Researcher, Institut für Textiltechnik of RWTH Aachen University
Felix Pohlkemper was born in Nordhorn, Germany, in 1990. In 2016 he graduated with distinction in mechanical engineering with a focus on automotive engineering and production engineering at RWTH Aachen University. During his studies he was working at the Institute of Textile Technology... Read More →


Wednesday June 2, 2021 10:25 - 10:50 CEST
Conferences (Hall 6 - Room 611)

10:50 CEST

Polypropylene Large Tow Carbon Fiber Tapes for low cost high volume applications
• Large Tow Carbon Fiber
• Thermoplastic Tapes
• High Volume Applications



The demand for weight and cost reduction is continuously increasing, especially in the field of transportation and logistics. Reinforced thermoplastics are well known in these fields and are widely used. Currently further decrease of costs and weight is hard to achieve due to the optimization of application specific properties and manufacturing processes. In contrast thermoplastic tapes have a high potential to decrease the weight of the application by high mechanical properties. Nevertheless there are only limited materials available and the know-how of material behavior and process integration is barely available. Furthermore, the tape costs are extremely high and not competitive with the already existing short fiber compounds or metal inserts. This study focuses on the usage of new low costs tapes consisting of a polypropylene matrix and large tow carbon fibers. The use of large tow carbon fibers decrease the material costs drastically. On the other hand, it is very important to achieve a high utilization of the fiber in every step of the process chain, including spreading, impregnation, consolidation, preforming and forming, where the mechanical performance of the carbon fiber tapes are often decreased. As a bottom line the good mechanical properties of carbon fiber need to be translated and transferred into applications. These effects on fiber performance are presented and solutions to overcome the described issues are given. The solutions lead to a decreased process time due to less lofting and a higher fiber utilization, resulting in less fiber breakage and ondulation. These optimizations result in a drastic decrease of weight and costs compared to existing solutions. Applications will be demonstrated where high volume applications and cost efficiency come together and are ready for serial production.




Speakers, Jury Members & Final...
avatar for Markus BRZESKI

Markus BRZESKI

CEO, A+ Composites GmbH
Markus Brzeski studied Production Engineering at the University of Bremen. Brzeski has gained valuable knowledge about the processing of processing of composites at Airbus UK. From 2009 to 2014 he was a research associate in the field of roving and tape placement at the Institute... Read More →


Wednesday June 2, 2021 10:50 - 11:15 CEST
Conferences (Hall 6 - Room 611)

11:15 CEST

Hierarchical carbon fibre based composites
  • Why alter interfacial properties?
  • Production of hierarchical structures
  • Implementation and scale up

Fibre surface modifications can address conventional fibre-reinforced composite issues; for instance the formation of critical clusters of fibre breaks, or poor interfacial properties. Hierarchical interphases which modify the failure mode or increase mechanical interlocking can address these issues at the critical fibre-matric interface. Here, we will discuss our research which exploits nanoscale structured materials which are integrated into conventional composite fibre systems.

Speakers, Jury Members & Final...
avatar for David ANTHONY

David ANTHONY

Research Technician, Imperial College London
Dr David B Anthony’s research focus is on carbon fibre modification, synthesis of carbon nanoforms including carbon nanotubes and carbon aerogels, and the development of hierarchical composites/materials. He is currently studying multifunctional composites for structural power applications... Read More →


Wednesday June 2, 2021 11:15 - 11:40 CEST
Conferences (Hall 6 - Room 611)

11:40 CEST

12:00 CEST

Effect of Sizing on the Interfacial and Mechanical Properties of Carbon Fiber (CF) Reinforced Nylons (PA6,6) Composites
  • Benefits of fiber sizing
  • Sizing for carbon fiber
  • Experimental overview & mechanical property summary: carbon fiber and polyamide composite

The interfacial and mechanical properties of fiber-reinforced polymer composites are significantly influenced by the interfacial characteristics of the fiber-matrix interface and can be altered physically or chemically by fiber surface treatment and sizing chemistries. The choice of sizing is considerably dependent upon the polymer resin matrix to ensure the inter-diffusion of sizing interphase with the resin during processing. Similarly, the thickness and content of sizing on fibers also influence the mechanical and interfacial properties of the resulting resin.
The effects of fiber surface-treatment and sizing on the interfacial and mechanical properties of carbon fiber/nylon (PA6,6) composites are presented herewith. Commercial grade un-sized carbon fibers (CF) were sized with nylon compatible and incompatible sizing. Sized carbon fibers were chopped and mixed with neat PA6,6 resin to prepare injection molded test bars for the investigation of mechanical properties. Single-fiber pullout studies determined the interfacial shear strength (IFSS) of the CF/PA6,6 composites. Also, by utilizing an SEM, fractography determined the composite failure mode of the samples.
The results indicate that the choice of proper sizing and its % loading significantly enhances the mechanical properties of the CF/PA6,6 composite samples. Similarly, the interfacial properties (IFSS) of the CF/PA6,6 composite samples demonstrate a significant enhancement as compared to the un-sized CF. On the contrary, the mechanical and interfacial properties of CF sized with an incompatible sizing for PA6,6 resin deteriorated due to poor interfacial adhesion.

Speakers, Jury Members & Final...
avatar for Gilles LEMOIGNE

Gilles LEMOIGNE

Regional Marketing Manager, EMEA, Michelman SARL
Gilles LeMoigne is the Regional Marketing Manager for EMEA at Michelman. He joined Michelman in 2012 as Global Sales Director - Fibers & Composites, transitioned to Strategic Marketing Manager - Fibers & Composites in 2016, and was appointed to his current role in 2019. His over 15... Read More →


Wednesday June 2, 2021 12:00 - 12:25 CEST
Conferences (Hall 6 - Room 611)

12:25 CEST

Mixing materials, technologies and robots in an automated composite production
  • GroFi – a multi-robot plant
  • MES as an enabler
  • intelligent and self-regulated process control

Acquiring higher rates in the production of large scale CFRP components by simultaneously using several robotic units in manufacturing processes is one of the major aims of the DLR Center of Lightweight Production in Stade.
In 2017, the first multi-head process was demonstrate by using two Automated Fiber Placement (AFP) units for an automated manufacturing of a wing-like structure. Significant advantages in the overall layup time were demonstrated. As next step for automating and improving this process, a central Manufacturing Execution System (MES) with extensive functionalities for the planning, simulation, and control of our multi-head manufacturing plant has been developed. Several of its new features were demonstrated in the DLR-internal project PROTEC NSR and can be discussed in this talk.
Through new simulation technologies the DLR can combine different materials and technologies in a production process simultaneously. The necessary maintenance steps are supervised by the MES. Separate inline quality assurance systems are integrated and supplied with online data of the production. Via several virtual twins of the production process we can simulate the robotic movement offline and make a time-optimized planning, furthermore data can be generated that is used by an online production control for an active collision avoidance system. If a robotic unit needs to be restocked or maintained, it can be taken out of the running production process automatically and due to implemented functionalities of a rescheduling step the remaining layup units can go on with the manufacturing uninterrupted.
We will discuss the state of our research and its future topics and applications.

Speakers, Jury Members & Final...
avatar for Markus SCHREIBER

Markus SCHREIBER

Research Scientist, Deutsches Zentrum für Luft- und Raumfahrt e.V.
2015 – Master of Science in Applied Mathematics at the Technical University of Clausthal-Zellerfeld, GermanySince 2015 – Research Scientist at the German Aerospace Center in Stade, Germany, with focus on modelling and software design for the simulation and control of multi robot... Read More →


Wednesday June 2, 2021 12:25 - 12:50 CEST
Conferences (Hall 6 - Room 611)

12:50 CEST

SurFlow: Future Composite Data Highways
  • Game-changing communication technology
  • Added multifunctionallity
  • Black art of electromagnetic surface waves

A breakthrough at TWI has led to the creation of data transfer technology that can be seamlessly incorporated into composite materials to create a high-capacity, resilient data transfer network. SurFlow™ technology uses electromagnetic surface waves to transmit data directly through composite structures. Described as “the future of composite data highways”, SurFlow™ technology removes the need for wires or fibre optics. TWI has a new disruptive technology, which involves passing data through the composite structure itself. SurFlow™ transmits data in the form of electromagnetic waves that travel through composite structures. The system uses no wiring harnesses or fibre optics. By turning a composite into a ‘smart’ composite, the technology integrates a data network into a component’s physical structure. The system is capable of transmitting data at up to 3Gbps and can continue to function even if the composite part suffers damage. The frequency range that has been tested is 2-6GHz, which can be extended to any other frequency ranges needed, depending on the industrial application. Potential applications for smart composites exist throughout industry in almost every sector. For instance, in the automotive sector, where use of composites such as carbon fibre is now extending beyond high-end applications, the technology could significantly reduce the complexity of a vehicle’s internal communications network. In robotics, the technology could be used to enable communication throughout a robotic system without the use of wires. In consumer electronics, the technology would allow a device to instantly connect to a network simply by making contact with the composite’s surface, with no need to plug anything in or detect and connect to a wireless network. Other uses being explored include advanced aerospace applications and real-time composite monitoring, whereby subtle changes in the waveform allow any damage to a smart composite component to be identified immediately.

Speakers, Jury Members & Final...
avatar for Chris WORRALL

Chris WORRALL

Consultant, TWI Ltd
At TWI, Chris is responsible for delivering composites joining, manufacture, processing and testing services to both members and through public funded projects. He has spent 10 years in Japan working in the automotive, aerospace, renewable energy and rail transport industries. Before... Read More →


Wednesday June 2, 2021 12:50 - 13:15 CEST
Conferences (Hall 6 - Room 611)

14:00 CEST

Intelligent adaptive composite production technologies
  • 4.0 industry processes
  • latest innovations in composites
  • adaptive production

The presentation will include 4.0 industry processes and the latest innovations in composites, such as the developed production system for the manufacture of hybrid FRP components “iComposite 4.0”. Multi-material with long glass fibers and continuous carbon fibers are used for load specific designs with cost reduction. Moreover, the multi-stage process is used to establish an control-algorithm to compensate fluctuations of the mechanical properties of the final part during production. Core aspects are the integration of inline measurement technology, modelling and decision algorithms into the production system.

Speakers, Jury Members & Final...
avatar for Philipp WIGGER

Philipp WIGGER

Research Assistant, AZL Aachen GmbH
Philipp Wigger works as a research assistant at the Aachen Centre for integrative Lightweight Production. In April 2018 he got his bachelor's degree in mechanical engineering from the RWTH. He followed this up with a master's degree in plastics engineering, that he finished in July... Read More →


Wednesday June 2, 2021 14:00 - 14:25 CEST
Conferences (Hall 6 - Room 611)

14:25 CEST

The Implementation, Use and ROI of IIoT and AI Technologies in Composites Manufacturing
  • Industry 4.0 Technologies Overview
  • How to Calculate your Smart Factory ROI
  • Case Studies & Implementation Best Practices

Facing increasing market demands, advanced manufacturers must examine methods to support high-rate programs at lower costs. Industrial IoT and AI (Artificial Intelligence) technologies open a new horizon of possibilities for these advanced manufacturers. Real-time, context-aware recommendations and actionable insights driven by AI and real-data collection, allow factories to become smart and to optimize their operations, increase production, reduce costs and stay ahead of the competition, by digitizing and optimizing their complex production environments.
Learn through real-life challenges, implementation examples and best practices:
How AI-based technologies and methods create new opportunities for advanced manufacturers, fitting a range of business models, needs and constraints;
How automation and end-to-end digitization of advanced manufacturing, including additive manufacturing, enable enhanced productivity and efficiency across industrial and business processes, creating a sustainable competitive advantage with a tangible, fast ROI.
In addition to aerospace, other industries are potential targets for the solution including automotive, motorsport, wind energy, mass transit, sporting goods and healthcare.

Speakers, Jury Members & Final...
avatar for Avner BEN-BASSAT

Avner BEN-BASSAT

President & CEO, Plataine
Avner Ben-Bassat is the President & CEO of Plataine, a leading provider of Industrial IoT and AI-based optimization solutions for complex manufacturing environments.Avner leads Plataine’s product vision and global business strategy. Plataine’s solutions are used by leading manufacturers... Read More →


Wednesday June 2, 2021 14:25 - 14:50 CEST
Conferences (Hall 6 - Room 611)

14:50 CEST

AI driven quality assurance for composite parts using ultrasound
  • Business case behind AI
  • Deep Learning assisted defect detection
  • Wider applicability

Premium AEROTEC has developed a deep learning model for defect detection in composite aircraft components based on ultrasound scans. Non-destructive testing is indispensable for the production of CFRP parts in the aerospace industry. For large components, such as the A350XWB fuselage shells, ultrasonic testing is the standard method of detection. Acquisition of data for these parts is already highly automated. Data evaluation is nevertheless fully manual and may require more than one working day per part. Continuous tasks demanding human expertise, to be applied repeatedly across the complete scanned area of each part, requires AI assistance to increase output whilst maintaining quality check standards. The business case for reducing manual overheads, through the automation of data evaluation, mitigates fatigue and other phenomena that decrease quality.
Classical computer vision methods are insufficient to accomplish this goal. With the recent success of artificial intelligence in the field of image recognition, it is now possible to automate defect detection. A general approach to automation using Deep Learning will be presented. A wider applicability of the method to other signal types such as X-ray, CT and active thermography is possible.

Speakers, Jury Members & Final...
avatar for Olaf BEESDO

Olaf BEESDO

Data Scientist, Premium AEROTEC GmbH
Olaf Beesdo has worked for many years within the aerospace industry with particular interest in industrializing the latest technological trends. Currently, he works at Premium AEROTEC GmbH as a Data Scientist. His remit is the analysis and optimization of manufacturing processes with... Read More →


Wednesday June 2, 2021 14:50 - 15:15 CEST
Conferences (Hall 6 - Room 611)

15:15 CEST

15:35 CEST

Composites and their forming processes in the era of Data and Artificial Intelligence: Composite Twins
  • Hybrid-Twins
  • Proper Generalized Decomposition (PGD)
  • Big data

Model order reduction -MOR- allows speeding-up complex calculations, by using reduced bases extracted in the “offline learning stage”, or constructed on-the-fly during the problem solution. The former procedure is at the origin of Proper Orthogonal Decomposition (POD) and Reduced Basis (RB) MOR methodologies. The latter, at the origin of the so-called Proper Generalized Decomposition (PGD) could seem, at first view, unattractive because of the fact that the reduced model is computed during the solution procedure itself. In fact, the PGD efficiency comes from the fact of solving the model by considering the model parameters as problem extra-coordinates, leading to a parametric solution. That solution, in order to circumvent the so-called curse of dimensionality, is expressed in a separated form.
Our recent researches leaded to a non-intrusive solver of parameterized partial differential equations that was successfully employed in a diversity of engineering problems of industrial relevance. Today the so-called sparse variant of the PGD solver allows the efficient computation of such non-intrusive parametric solutions at the very low-data limit. Problems involving moving fronts, localization or geometrical and topological parameters, usually encountered in RTM and SMC composite forming processes, require advanced interpolation schemes.
With such a robust parametric solution available, control, inverse identification, optimization and uncertainty quantification and propagation, all them operating under the stringent real-time conditions are attainable and were properly coupled with data-assimilation to produce efficient DDDAS (dynamic data-driven applications systems), that is, the so-called material and process digital and hybrid-twins.
Within the context of composites modeling, their associated forming processes and their in-service performances, we will prove that hybrid twins allow (i) a natural alliance between physics and data, mathematics and artificial intelligence, (ii) proceeding efficiently at the scarce-data limit and (iii) certifying designs.

Speakers, Jury Members & Final...
avatar for Francisco CHINESTA

Francisco CHINESTA

President of the Scientific Committee and Director of the Scientific Department, ESI Group
Francisco Chinesta is currently full Professor of computational physics at ENSAM Institute of Technology (Paris, France). He was (2008-2012) AIRBUS Group chair professor and since 2013 he is ESI Group chair professor on advanced modeling and simulation of materials, structures, processes... Read More →


Wednesday June 2, 2021 15:35 - 16:00 CEST
Conferences (Hall 6 - Room 611)

16:00 CEST

Future additive and composite manufacturing by using industrial IoT and AI-based optimization solutions
  • digitization
  • data analytics
  • material & asset tracking

Digitization and industrial IoT becoming more and more relevant for the future production of lightweight components in aviation industry. Hence, the Composite Technology Center (CTC) of AIRBUS in Stade, Germany, and Plataine from Tel-Aviv, Israel, are demonstrating advanced IoT solutions for industrial 3D printing in CTC’s “3D Hub”. Operating industrial 3D printer, bringing enhanced digitization, real-time alerts and recommendations to the production process.
Additive Manufacturing offers shorter time to market, greater production flexibility, increased quality and cost reduction for certain low-mid volume production series. In order to deliver parts on time at the highest quality, the CTC deployed Plataine’s software to digitize, automate and optimize the manufacturing process while collecting sensor and machine data for analytics and smart predictions. The solution optimizes spool management & consumption, enhances part traceability, and offers complete visibility and process control. IIoT and digital assistants offer predictive alerts, actionable insights and real-time recommendations to staff, allowing them to further optimize their operations and proactively deal with production challenges.
In general, that brings an automated, intelligent, end-to-end solution for additive manufacturing operations using applications such as tool tracking, material management and shelf-life management. Meanwhile, all production data is stored forming digital threads, recording of the entire production process, from raw material to end-product, creating the basis for the subsequent project phase of applying IoT-based capabilities to further improve the process and to additionally transfer the knowledge to future composite production.

Speakers, Jury Members & Final...
avatar for Walter Ofer ABRAMSOHN

Walter Ofer ABRAMSOHN

Head of Product Development and Product Marketing, Plataine
Walter Abramsohn is the head of Product Development and Product Marketing at Plataine. Mr. Abramsohn has a vast background in technology encompassing both software and hardware solutions. He has held diverse leadership roles spanning from R&D to Product Management and Product Marketing... Read More →
avatar for Jan-Patrick KALCKHOFF

Jan-Patrick KALCKHOFF

R&D Project Manager, Composite Technology Center (An AIRBUS Company)
Jan-Patrick Kalckhoff is working as a R&D project manager in the field of IoT and digitization at the Composite Technology Center of AIRBUS in Stade, Germany.


Wednesday June 2, 2021 16:00 - 16:25 CEST
Conferences (Hall 6 - Room 611)

16:25 CEST

Identifying Costly Design Features and Manufacturability Issues Early in the A&D Development Process
  • Simulation of aerospace manufacturing processes during design to identify expensive features and manufacturability issues directly from 3D CAD model
  • Reduction of late stage design churn and Engineering Change Orders (ECOs) by getting it right the first time.
  • Improvement of your negotiating position with suppliers through increased visibility to costs.

With arguably some of the world’s most complex product development programs, aerospace and defense manufacturers are experiencing considerable pressure to contain escalating product costs as they innovate using the latest materials and manufacturing processes. However, aggressive program schedules and an emphasis on optimizing designs for performance, weight, and safety leaves little time to focus on cost. As a result, extensive cost down initiatives and value engineering activities often commence after initial product release.
The most progressive manufacturers are transforming their processes by leveraging advanced software technology to Design for Manufacturability and Cost (DFMC) early in the design phase.
In this presentation, Steven Peck, a product development technology executive with 20+ years of experience, will describe how industry giants such as Honeywell Aerospace, Boeing, Spirit AeroSystems and others are responding to these market pressures.
He will discuss the application of a solution that enables:
  • Simulation of aerospace manufacturing processes during design to identify expensive features and manufacturability issues directly from 3D CAD models.
  • Evaluation of design trade-off decisions to reduce cost in real time.
  • Reduction of late stage design churn and Engineering Change Orders (ECOs) by getting it right the first time.
  • Improvement of your negotiating position with suppliers through increased visibility to costs.
Following the session, the presenter will be available to provide one-on-one sessions for analysis of your own designs that you can uploaded to a secure portal.



Speakers, Jury Members & Final...
avatar for Steven PECK

Steven PECK

VP, Applications Engineering & Solutions, aPriori
Steven PeckDesign and Manufacturing Technology ExecutiveSteve has extensive experience working within the aerospace & defense industries, consulting with Global Fortune 100 A&D manufacturers on Business & Technology Solutions that improve innovation, product profitability and quality... Read More →


Wednesday June 2, 2021 16:25 - 16:50 CEST
Conferences (Hall 6 - Room 611)

16:50 CEST

Applying machine learning to process and characterisation data of nanoenhanced composites: a means for prediction
  • Machine Learning
  • Characterisation
  • Nanoindentation

This work describes a novel methodology of data documentation in materials characterisation, which has as starting point the creation and usage of any Data Management Plan (DMP) for scientific data in the field of materials science and engineering, followed by the development and exploitation of ontologies for the harnessing of data created through experimental techniques. The case study that is discussed here is nanoindentation, a widely used method for the experimental assessment of mechanical properties on a small scale. Except for technology development and synthesis of new materials and hybrid composite structures, the need of developing new evaluation methodologies is highlighted to assist and accelerate developments. Artificial Intelligence (AI) is a promising candidate to bridge the gap between Research and Development (R&D) and industry by establishing unbiased relations between microstructure and properties. This is majorly appreciated in case of Safe-by-Design requirements regarding mechanical performance, and real-time characterisation. Being representative, k-means, Random Forrest (RF), Support Vector Machines (SVM), k-Nearest Neighbors (KNN) are common Machine Learning (ML) algorithms used in multiclass classification problems for automated classification of microstructures.
This work contributes to nanocomposites design and quality control associated with identifying the optimum inclusion in nanomaterials reinforcement by microstructure assessment. In this direction, Artificial Intelligence can provide a module for enabling fast, in-line, and real-time metrological characterisation of nanoindentation data.
This work has been partially supported by the EU Horizon 2020 Programmes: MODCOMP (GA No 685844), SMARTFAN (GA No 760779), OYSTER (GA No 760827) and REPAIR3D (GA No 814588).

Speakers, Jury Members & Final...
avatar for Elias KOUMOULOS

Elias KOUMOULOS

CEO, IRES
Dr. Elias P. Koumoulos holds a BSc in Chemical Engineering, followed by MSc in Materials Science and Technology and PhD in nanomechanics. To date, he has the authorship of over 70 published papers in ISI journals, 6 book chapters, 90 participations in national/international conferences... Read More →


Wednesday June 2, 2021 16:50 - 17:15 CEST
Conferences (Hall 6 - Room 611)

17:20 CEST

From flax fiber’s structure to pull-winding bio-composites; how we mimic natural fiber strength to produce thin-walled, high strength composites.
• The natural flax fiber structure
• Mimicking flax fiber structure with pull-winding
• What this means for composites



The flax plant has been used for clothing for ages. Recently flax has increased use in bio-composites both for its strength and to encourage more sustainable composite production. However looking closely at the composition of the flax fiber, the arrangement of the cellulose fibrils (micro-fibrilliar angles) demonstrates the advantages of both crosswise and longitudinal fiber alignments to help strengthen the fiber. This structure is mimicked in the pull-winding process, where fibers can be both aligned in the longitudinal and crosswise directions. This alignment possibility allows for profiles to be designed with even less materials and with thinner walls. This enables both a savings in materials and a savings in weight overall. Pull-winding can be used to produce bio-composites as well, using for example flax fibers which completes the full circle of mimicking nature.




Speakers, Jury Members & Final...
avatar for Kim SJÖDAHL

Kim SJÖDAHL

Senior Vice President, R&D and Technology, Exel Composites
Mr. Sjödahl has worked for over 20 years in the composites industry and is currently a Senior Vice President and Head of Research & Development and Technology at Exel Composites, the world’s largest manufacturer of pultruded and pull-wound composite solutions. 


Wednesday June 2, 2021 17:20 - 17:40 CEST
Conferences (Hall 6 - Room 611)

17:40 CEST

Biomimicry - context and opportunities for materials and composites
• Biomimicry (bio = life, mimesis = imitate) is an innovation strategy which consists in being inspired by living organisms to develop technologies and services towards more sobriety, efficiency and sustainability
• Biological composites (like wood, bone and abalone shell) present a variety of properties (strength, lightness, colour, stimuli-responsive …) despite their simple composition. Using only few chemical elements results in complete recyclable and biodegradable materials.
• Source of inspiration for eco-materials and composites for a variety of applications (transports, sports, equipment, building …)



The challenges of the deployment of biomimicry today lie in overcoming specific cases, the construction of generic methodologies, the wider appropriation of this approach by entrepreneurs, industrialists, public authorities, but also by civil society stakeholders. (citizens, consumers, etc.).
The CEEBIOS is positioned as a catalyst for the wealth of national skills in the academic world, education and industrial R&D around biomimicry. Two main working groups dedicated to construction and materials support the emergence of innovative and collaborative industrial projects.




Speakers, Jury Members & Final...
avatar for Luce-Marie PETIT

Luce-Marie PETIT

Project Manager Bioinspired Materials, Ceebios
Engineer in Life Sciences and Biomechanics, Luce-Marie has spent one year in the German Biomimetics Research Network BioKon (fundamental and applied research on bioinspired materials).Wishing to contribute to the development of biomimicry in France and to benefit from French projects... Read More →


Wednesday June 2, 2021 17:40 - 18:00 CEST
Conferences (Hall 6 - Room 611)
 
Thursday, June 3
 

10:00 CEST

Cellulose Nano-Fiber composite - Unveil the wonderful potential as promising material and Visualize in 3D
  • We have acquired nano structure of CNF in composite by stained TEM.
  • Chemical modification is important for affinity control of CNF for composite.
  • Visualizing is effective for comprehensive modeling by 3D printing

Toray Research Center, Inc. (TRC) is a subsidiary company of Toray Industories, Inc. that is a leading company of carbon fiber and advanced composite material and TRC has been independently promoting supporting business with our advanced analytical technology.  TRC has been improving its own analytical technology for advanced materials and parts for over 40 years with having much collaboration with companies, universities and institutes.  Additionally TRC also has been proposing solution to promote and accelerate customers' R&D activity.  At this time TRC would like to introduce sophisticated analyses for advanced composite materials as reference to R&D activity and manufacturing.
Composite materials is usually utilized with reinforcing to improve physical property by adding fiber filler. Recently Cellulose Nano-Fiber (CNF) has been gathering much attention as promising filler derived from biomass. We unveiled nano structure of CNF composite as CNF is dispersed with several 10 nm-size bundled structure by electron microscopic observation of CNF dispersion state and evaluation of physical properties as well as chemical state of CNF itself. Additionally we also applied these analytic methods to the foamed CNF nanocomposite and found chemically modified CNF can support to achieve high ratio of foaming. We will also introduce the result of reconstruction modelling by 3D TEM and visualization of CNF composite by 3D printing.

Speakers, Jury Members & Final...
avatar for Koki MIYAZONO

Koki MIYAZONO

General Manager, Toray Research Center, Inc.
Koki Miyazono was graduated from Kyoto University (M. Sc.) and entered Toray Industries, Inc. in 1998. As researcher in Toray from 1998 to 2018, Miyazono has engaged in research and development of Polymer synthesis, synthetic fiber, polymer processing, carbon material composite advanced... Read More →


Thursday June 3, 2021 10:00 - 10:25 CEST
Conferences (Hall 6 - Room 611)

10:25 CEST

Application of Large Scale Additive Manufacturing for Composite Tooling
• Origin of Large Scale Additive Manufacturing

• Technology Evolution in Processes and Machinery

• Materials Innovations
- Collaboration with Boeing, ORNL, Techmer PM to develop materials for autoclave processing of composites
- Collaboration with Thermwood and Techmer PM to develop advanced materials for autoclave processing

• Applications for Composite Tooling in and out of the Autoclave in Aerospace Composite Manufacturing
- Fleet Readiness Center East, MCAS Cherry Point and Oak Ridge National Laboratory Stretch Form Tooling
- Boeing and Oak Ridge National Laboratory Trim Tool
- Oak Ridge National Laboratory Collaboration with Boeing, BASF, Ford, Tru-Design and Techmer PM to develop an autoclave tool
- ACE Composites and Thermwood collaboration on Composite Tooling
- Boeing and Thermwood Tooling Innovations


Speakers, Jury Members & Final...
avatar for Richard F. Neff

Richard F. Neff

Consultant - CEO, Rick Neff, LLC
Rick Neff is a Consultant in Innovation, Additive Manufacturing, Laser systems and Marketing.  He is a Lehigh Engineer with over 30 years of sales, marketing and business development success.  He is responsible for the commercialization of a new category of large-scale 3D printing... Read More →


Thursday June 3, 2021 10:25 - 10:50 CEST
Conferences (Hall 6 - Room 611)

10:50 CEST

CFIP technology: a new approach for manufacturing continuous carbon fibre reinforced structures by 3d printing
  • The fibres can be placed in all directions following complex trajectories
  • A wide range of materials can be reinforced, including metals and ceramics
  • Different parts made of different materials and by different processes can be integrally joined

Continuous Fibre Injection Process is a new post-process technology which enables to reinforce additive manufactured parts with continuous fibres, multiplying in this way the mechanical properties while keeping the weight. The first step is to design and manufacture a part containing tubular cavities inside. Then, the continuous fibres are injected inside the tubular cavities simultaneously with liquid resin. Finally the part is cured so that the injected resin, once solidified, works as a mechanical interface between the fibres and the rest of the part.
The fibres trajectories are defined by the trajectories of the tubular cavities, which can be freely designed in all directions and manufactured with no limitations thanks to additive manufacturing. This enables to align the fibres to the most efficient direction, so that highly optimised structures with improved mechanical and light-weighting performance can be obtained.
CFIP can be used for any existing additive manufacturing technology and material. Parts made of stiff or flexible plastics, metals or ceramics can be reinforced with carbon, glass, aramid or other existing fibres. Another advantage is that different parts can be integrally joined by injecting the continuous fibres throughout them, achieving an ultra-high joining performance. This allows to efficiently manufacture large and strong structures but also to use the most suitable material and manufacturing technology in each zone of the structure, according to mechanical requirements but also to costs and production targets.
The speech will be focused on explaining how CFIP technology works, including case studies developed in collaboration with companies aimed to demonstrate the potential of CFIP technology in different sectors and applications.

Speakers, Jury Members & Final...
avatar for Marc CRESCENTI

Marc CRESCENTI

Head of CAE and DfAM Line, Eurecat
Marc Crescenti is an industrial engineer specialized in mechanical engineering at the Polytechnic University of Catalonia (UPC). He also holds a master degree focused on design and simulation of composite structures at AMADE Research Group.His scientific and technical expertise is... Read More →


Thursday June 3, 2021 10:50 - 11:15 CEST
Conferences (Hall 6 - Room 611)

11:15 CEST

Opening and Integrating the 3D Printing Platform for Scalable Industry 4.0 Composites Manufacturing
  • 3D Continuous carbon fiber printing
  • Industry 4.0 %G enebaled networking
  • Open chemistry up through PEEK

Orbital Composites is unveiling a new product to address the needs of Industry 4.0 factories. Orbital’s manufacturing platform is designed to aid manufacturers in their transition into the Industry 4.0 and additive manufacturing revolutions. The tight integration of powerful software, modular hardware and a simplified user interface create a product called Orb-S.
Composites factories lack visibility, connectivity, and have rigid control hardware. Robots are increasingly called upon to perform complex tasks. But robots have a large programmability challenge and they require too much human intervention. 3D printing has made some strides in composites printing but has struggled to gain traction beyond prototyping. This is due to too many constraints; printer size, over-priced feedstock, material certification, uneconomical scaling, and lack of interoperability with existing automated processes.
Our platform includes a highly adaptable library of modular hardware. For example: various types of 3D printing end-effectors are supported, including unreinforced thermoplastic, but also chopped and continuous fiber-reinforced thermoplastic and thermoset composites. In addition, other types of non-printing end-effectors can be easily integrated into the platform for processing steps and pre/post automation.
In addition to this library of hardware, the Orb-OS enterprise software platform is introduced for process automation and factory management. The software platform supports industrial internet of things (IoT) end-effectors and cloud robotics. Each piece of modular hardware is network connected and controlled, operating in a real-time synchronous fashion through a unified control center user interface (UI). The software can be run remotely through the browser over a local on-site network, or through a secure cloud.
Orb-OS core features include real-time intelligent monitoring, diagnostics and management,allowing the creation of a digital twin during manufacture of composite parts. The inherent big-data capabilities of the platform allow advanced features such as fault analytics, machine learning and AI-enabled automation. While the Orb-S platform is applicable to composites, it is equally applicable to other manufacturing and automation processes that typically co-exist in an automotive, aerospace or energy-related composites factories.

Speakers, Jury Members & Final...
avatar for Cole NIELSEN

Cole NIELSEN

CTO, Orbital Composites Inc
Cole Nielsen is the founder of Orbital Composites. A start-up focused around 3D Printing advanced composite materials. They are metal, ceramic, and polymer matrix, continuous filament, composites. The applications are aerospace, automotive, and Medical. Orbital Composites will advance... Read More →


Thursday June 3, 2021 11:15 - 11:40 CEST
Conferences (Hall 6 - Room 611)

11:40 CEST

12:00 CEST

How to design and print a 4-meter long structural pedestrian bridge
  • It is printable
  • It is recyclable
  • Low CO2 footprint

With the entrance of new large scale additive Manufacturing (AM) with filled polymers – even combined with continues fiber-, we can open the door to create large structural pedestrian bridges. The use of CFAM (Continues fiber AM) and the ability to print highly loaded polymers enable the use of generative design and completely new ways of bridge design. The use of polymers is a new sustainably way to create fast bridges with lower footprint and the option to eventually recycle the whole bridge. Combining the design and engineering know-how of Royal HaskoningDHV, the novel print technology from CEAD and the material science from DSM we create  a whole new way of bridge design and construction.
The bridge has been modelled parametrically which allows optimization of the bridge and its internal web structure. Using the latest software and own developments in interoperability, we can share the results immediately. With links from the model to high performance FEM software, we were able to combine the characteristics of the material and the advantages of the printer into a 3D printed bridge that has never been shown before.
Combining the design and engineering know-how of Royal HaskoningDHV, the novel print technology from CEAD Group and the material science from DSM we can design and construct bridges completely differently - with lower footprint and the option to eventually recycle the whole bridge.

Speakers, Jury Members & Final...
avatar for Patrick DUIS

Patrick DUIS

Segment Leader Additive Manufacturing DSM, DSM Additive Manufacturing
Patrick Duis is a global segment leader for Transportation Additive Manufacturing at DSM. In this position, he is focused on building an open and partner-driven additive manufacturing eco-system in transportation, providing customers high performance material that enable them to use... Read More →
avatar for Kees VAN IJSELMUIJDEN

Kees VAN IJSELMUIJDEN

senior structural engineer, Royal Haskoning DHV
Kees van IJselmuijden is a senior structural engineer at Royal Haskoning DHV, with more than 25 years experience in design of bridges. Original in concrete and steel and since 2008 also involved in Fiber Reinforced Polymer (FRP) bridges. Based on his initiative a Dutch guideline for... Read More →


Thursday June 3, 2021 12:00 - 12:25 CEST
Conferences (Hall 6 - Room 611)

12:25 CEST

Industry 4.0 - Reinvent the design and realization of high performance polymer functional parts through additive manufacturing in serial production
  • Dedienne 3D Workshop, the first 3D additive production workshop in France for high-performance polymers
  • The creation of the 3d dedienne workshop, for: saving time, accelerating innovation, consuming less materials
  • Co-create together in an additive way


From our experience of more than 25 years in terms of additive manufacturing 3D (in 1995, we set up the first Stratasys printing station, in France) and also from our dynamic of innovations that are an integral part of our Group‘s DNA, we launched, the 6th of February 2020, the Atelier Dedienne 3D to produce, in series, functional and complex parts in additive manufacturing 3D.
Dedienne Multiplasturgy® Group, specialist in the design and manufacture of high performance plastic and composite technical parts, replacing metal parts, becomes THE first French manufacturer to equip itself with the EOS P 810 laser sintering machine for EOS HT-23 material (based on Kepstan® PEKK, Extreme Polymer from Arkema, reinforced with Carbon Fibers). In April 2019, a first machine was put into service, allowing series in additive manufacturing based on Rilsan® Polyamide 11, high performance bio-based polymer, derived entirely from sustainable castor oil and manufactured by Arkema.
Dedienne Multiplasturgy® Group is THE first European equipped manufacturer delivering functional parts and components internationally. So let’s explain why we have chosen the 3D additive manufacturing in series and how it will allow to change the value chain, to go faster on innovation, to save time and to reduce the consumption of materials.
This new technology is perfectly in line with Dedienne Multiplasturgy® Group's focus on providing solutions for lighter parts and metal substitution. It is the perfect innovation to meet the demanding requirements of the aerospace and defense sectors.

Speakers, Jury Members & Final...
avatar for Nicolas JACQUEMIN

Nicolas JACQUEMIN

CEO, Dedienne Multiplasturgy
As a trained engineer, I have evolved in the Dedienne Multiplasturgy® Group, starting with the responsibility of the design office of Plasteure SA and then taking over the General Management of 2 Dedienne entities (moulding and coatings) and since 2012, taking the General Management... Read More →


Thursday June 3, 2021 12:25 - 12:50 CEST
Conferences (Hall 6 - Room 611)

12:50 CEST

Rapid Microwave Additive Manufacturing of Continuous Carbon Fiber Reinforced Bionic Plastics
  • Resonant microwave applicator
  • Microwave additive manufacturing temperature control
  • Load-dependent printing path planning

Continuous carbon fibers are promising reinforcement materials to improve the stiffness, strength properties and design ability of 3D printed polymer parts. However, current additive manufacturing method, also known as 3D printing, have a limited and slow printing speed because of the intrinsic slow and contact needed heat transfer disadvantages of the traditional resistive heating approach. We present a 3D microwave printing method by using the microwave for instantaneous and volumetric heating the continuous carbon fiber reinforced polymer (CCFRP) filament. Moreover, carbon fiber reinforced polymer composites with bionic shape can be printed without the limitation of classic forming tools and complicated multi-steps preparation. This technology allows fabricating bionic CCFRP components with much higher speed compare with the traditional 3D printing technologies. A small-size resonant microwave applicator has been designed and manufactured to heat the CCFRP filament efficiently. The relationship between the printing speed and microwave power is established for precise  control of the printing temperature. A prediction-model and step-PID based temperature control strategy is developed to adapt the variable printing speed during the 3D microwave printing process. Furthermore, a novel 3D path planning method is proposed to pave the continuous carbon fibers along the load transmission paths of the bionic CCFRP under certain load conditions. This technology solves the key problems of 3D microwave printing of continuous carbon fiber reinforced bionic composites and is the next-generation manufacturing approach for the high-performance and complex bionic composite components.


Speakers, Jury Members & Final...
avatar for Nanya LI

Nanya LI

Alexander von Humboldt Postdoctoral Researcher, Karlsruhe Institute of Technology
Nanya Li, Alexander von Humboldt postdoctoral researcher at Karlsruhe Institute of Technology, received his PhD from Nanjing University of Aeronautics and Astronautics in 2017. He has published 20 papers, 26 granted Chinese patents and 1 issued international patent covering 3D microwave... Read More →


Thursday June 3, 2021 12:50 - 13:15 CEST
Conferences (Hall 6 - Room 611)