issue 07/2021

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As a result of the Corona crisis, press manufacturer Wickert sees only a temporary slowdown in the growth forecasts for composite technologies. The company currently sees four trends in system engineering.

The Demand for Composites Will Keep Growing in the Future

Composite-Halbzeuge

Pressen

Duroplaste

Automatisierungstechnik

Hochleistungskunststoffe

Naturmaterialien

Thermoplaste

Trends in Composite Manufacturing

Continuous fiber-reinforced thermoplastic composites have also become established with thin-walled housings for consumer electronics and information technology. Not only do they offer high stiffness and help to reduce weight, but also enable the integration of classy appearance and functions. What is more, if the housings are produced using the hybrid molding process, costs, processing steps, and cycle times can be reduced.

Composites Reduce Weight and Simplify Production of Electronics Housings

Glasfasern / -matten

Kohlenstofffasern / -matten

Kunststoff-Halbzeuge

Kunststoff Werkstoffe

Kunststoff

Faserverbundwerkstoffe

Kunststofffasern

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Lightweight to Fit in a Pocket

CFRP components are often in continuous use under harsh environmental conditions, for example in aircraft and motor vehicles. If any damage occurs, the CFRP structures are simply replaced by new components in most cases. This is mainly due to the high cost of established repair methods. With a newly developed process, defective CFRP structures can now be repaired locally much more easily.

Process for Repairing CFRP Components without Machining

Repairing instead of Replacing

Currently, small wind turbines can hardly be operated profitably in landlocked regions. This drawback has now been overcome by the partners EAB Gebäudetechnik Luckau GmbH and the Chair of Polymer-based Lightweight Design at the BTU Cottbus-Senftenberg: passive smartblades made from 3D-printed molds adapt independently to wind conditions. This is achieved by an intelligent layer structure and its bending-torsion-coupling.

Additive Manufacture of FRP Injection Molds for FRP Components of Small Wind Turbines

Faserverarbeitung

Simulation Produkt- / Formteildesign

Verbundwerkstoffe / Werkstoffverbunde

Finite Methoden

Harze, Epoxid

Windkraft

Analysetools, FEM

Additive Fertigung

Highly Efficient Adaptive  Fiber-Composite Rotor Blades

Teknor Apex presents three halogen-free FR glass-reinforced polyamide compounds with UL94 ratings of V0.

Elektronik

Automotive

Polyamide

Technische Kunststoffe

Glass-Reinforced and Halogen-Free Flame-Retardant

For lightweight applications e. g. in automotive engineering BASF developed carbon fiber-reinforced polyphthalamide (PPA) grades with fillings of 20, 30 und 40 %.

PPA Now with Carbon Fiber-Reinforcement

Lightweight Metal Replacement

Any place where plastic parts slide against one another, primarily in injectors, in the operating room and in patient care, the low-friction and wear-resistant plastics help facilitate the handling of devices.

Covestro Offers New Families of Makrolon

Medizintechnik

Polycarbonat

Materials for Drug Delivery Devices and Surgical Instruments

In the iComposite 4.0 research project, it has been possible to cut the costs for a prototype component by more than 50 percent and throughput time by 40 percent.

Economic Production of Fiber-Reinforced Plastics in High Volumes

Schröder, Susanne

Pressen von Kunststoffen

Self-Regulating Production Plant

To meet stringent flame retardancy demands of areas such as transportation and electronics, components based on thermosets increasingly require a soluble, non-powder flame retardant (FR) due to low layer thicknesses in the final product or due to liquid processing methods. Two flame-retardants developed by Clariant meet these requirements.

Completely Halogen-Free Flame Retardancy of Epoxy-Fiber Composite Components

Füllstoffe für Kunststoffe

Flammschutzmittel

Duroplastische Werkstoffe

Additive

Avoiding Filter Effects of  Flame Retardants

Short glass fiber-reinforced plastics are exposed to complex load cases during the operating time. Therefore, the influence of alternating load and frequency in the form of load spectra on material fatigue is investigated and an integrative computational method for structural design is presented. With this practical approach, a fast fatigue life estimation is possible.

The Influence of Varying Frequency and Load Level on the Fatigue Life of Short Glass  Fiber-Reinforced Technical Thermoplastics

Cumulative Failures Prevention

Climate change and the transport revolution are demanding smart fiber-reinforced composite solutions. In sectors such as the marine industry, infrastructure, and rail vehicle construction, many different fire protection concepts are competing. The composites industry is paying increased attention to recycling.

Fiber-Reinforced Composites Drive Innovation in the Transport and Construction Sectors

Sekundärfasern

Fasern

Composites Are Trendsetters in Lightweight Design

Bio-based plastics can lock away vast quantities of CO<sub>2</sub> in durable, recyclable applications and make a real contribution to climate protection. All that is needed for this is the right product design and a functioning circular economy. By focusing more on this approach, the plastics sector has the chance to evolve into a key industry of a green economy.

How Bio-Based Polymers Can Help Sequester CO<sub>2</sub> for the Long Term

Kunststoffe, biobasiert

Recycling

Biokunststoffe

Kunststoffe, bioabbaubar

Kunststoff-Recycling

Into the Future with Biopolymers

Organo sheets have become established in several industrial sectors for the series production of highly stressed lightweight components. The utilization of waste material is a promising recycling approach.

Feeding Mechanically Recycled Fiber-Reinforced Thermoplastics Back to Production

Mahlgut

Mahlen

Organo Sheet Recycling

In addition to high stiffness, the semi-aromatic polyamide Leona SG series features an improved flowability and a good surface appearance without any additional surface treatment or coating.

Asahi Kasei Introduces a Semi-Aromatic Polyamide to the European Market

Hilfs-und Zusatzstoffe für die Kunststoff-Industrie

Kunststoff-Erzeugung

Excellent Processability and Good Surface Quality

Composite materials are often the key to lightweight design for many applications. However, these hybrid materials face a major challenge where recycling is concerned.

A Research Project Highlights the Recycling Potential of Lightweight Composites

Anlagen zur Composite-Herstellung

Spritzprägen

Bruchmechanische Prüfung

Harzsysteme für Composite-Herstellung

UD-Tapes

Presswerkzeuge, Kunststoff

Qualitätssicherung Kunststoff

Zero-Waste Concept for Carbon SMC

The non fossil fuel-based portfolio offers same high quality and performance for applications in all industries.

Gehäuse aus Kunststoff

Polyethylen

Polystyrol

Kunststoff-Aufbereitung

Standardkunststoffe

Polypropylen

Kunststoff-Regenerate

Borealis Launches Portfolio of Circular Polyolefins

Optics play an increasingly important role in plastic components. Glossy and even surfaces are decisive for an attractive appearance. With glass fiber-reinforced polyamides (PA), these requirements can usually only be achieved with an additional coating. A PA specially developed for surface design offers an alternative approach.

Aliphatic High-Performance Polyamide for Plastic Surfaces

Spritzgießen

Oberflächentechnik

Glossy Components without Painting

Thermoplastic tapes are expected to shape the next generation of thermoplastic composites. This calls for highly accurate tape stacking. Engel contributes this technology to achieve a breakthrough by combining high-precision control software with camera technology in tape stacking.

Software-Based Tape Stacking with the Aid of Camera Technology Paves the way for Thermoplastic Composites

Kameras

Optische Mess- und Prüfverfahren

An Eye for the Essential

Carbon fiber-reinforced plastics (CFRP) are being used in more and more components. Their production is also becoming more and more effective. In the event of damage, however, business continues to be carried out manually. For this reason, greater automation is desirable when repairing CFRP. Automated laser processes could be one way of doing this.

Automated Repair of Carbon Fiber-Reinforced Plastics

Laserschweißen

Laser Substitute Manual Work

Threaded inserts ensure a secure connection of hybrid components. Under continuous load, effects can occur with thermoplastics due to pressure and temperature, which means that a durable screw connection is no longer guaranteed. Such effects can be prevented by thread inserts with a special surface structure.

Structuring of Surface Ensures Reliable Anchoring of Thread Inserts in Organic Sheets

Reduced Settling Behavior in Multi Material Components

A number of examination methods can be used to identify weaknesses caused by incorrect fiber orientation. In particular, the fiber volume content and fiber distribution permit conclusions to be drawn regarding the stiffness and tensile strength behavior. A new ultrasound method offers the flexibility to capture these parameters on the finished component.

Methods for Determining the Fiber Orientation in Reinforced Plastics

Ultraschall-Sensoren

Messtechnik

Computer-Tomografie-Systeme

Optische Mess- und Prüftechnik

Ultraschallprüfgeräte

Röntgenprüfgeräte

Software für Optische Messtechnik

Groundbreaking Ultrasound  Shear Waves

Many people have good ideas and intentions. Few have the courage and determination to put them into practice. The young rezemo entrepreneurs Julian Reitze and Stefan Zender are one successful example. In 2019, some three years after their start-up was founded, the company was already producing well over one million compostable coffee capsules per year.

A Start-up Produces Organic Coffee Capsules Made of Wood and Plant Starch in Millions

Successful with Wood