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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)