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Technical Conferences [clear filter]
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)