On the world’s stage

Composites in Manufacturing previews a host of revolutionary companies showcasing their latest products and innovations at this year’s JEC World in Paris.

 

We begin our JEC exhibitor round-up with 3A Composites AirexBaltekBanova (hall 6, stand G27), who will introduce its latest sustainable core material innovations at this year's event. The company will present its new PET-based product AIREX T10.60, targeted at wind, automotive, construction, and marine applications. T10.60 is said to bring new environmental and production improvements, while featuring all properties required by high-volume structural sandwich applications.

Elsewhere, Airtech (hall 5, stand G39) TMGC-TX fabrics are triaxial carbon fabrics developed for the manufacture of composite moulds with Airtech Toolfusion resins. This range of quasi-isotropic fabrics are balanced in every layer, avoiding the need for orientation of individual plies in laminate stack. TMGC-TX fabrics are available in a selection of light, medium, and heavy weight fabrics. The heavyweight fabrics allow thickness to be built in fewer layers, with laminate quality for high quality post machining. Airtech TMGC-TX fabrics deliver lower cost tooling solutions with superior performance.

UK composites design and manufacturing solutions specialist, Anaglyph (hall 5A, stand P78) will demonstrate its hand-layup ply placement technology, PlyMatch. PlyMatch uses augmented reality to show the live combined images of actual and target ply outlines and fibre orientation details on a monitor, so that the two can be matched by the operator. PlyMatch is used for the accurate placement of plies in hand lay-up manufacture of composite parts, as well as for monitoring and validation of automated methods. It’s useful in case of complex geometries, with high curvature or enclosed spaces.

Meanwhile, Armacell (hall 6, stand Q83) will parade its latest PET foam innovations at the show. ArmaShape are loose PET-based beads for the manufacturing of ready-to-use 3D shaped foam cores for composite sandwich structures. Starting from recycled PET flakes, the polymer is granulated and further processed by Armacell’s patented technology to produce ArmaShape to the desired density, which is foamed into a mould to produce the finished part. A new technology has been developed for the fusion of ArmaShape that is highly automated and not restricted to a particular density. ArmaShape combines the high mechanical properties of structural foam cores with the advantages of particle foams, offering lightweight and strong 3D shaped foam parts, which are producible in nearly any shape.

Ascent Aerospace: Hybrid InVar and Composite mould

Moving on, Ascent Aerospace (hall 5, stand R86) will use the show to introduce HyVarC, a patent-pending Hybrid InVar and Composite mould. HyVarC layup tooling offers a cost-effective, lightweight, short lead-time solution for prototype and development applications. HyVarC combines a thin Invar backup structure and face-sheet with a bonded, high-temperature composite working surface. The resulting tool is 50% lighter with a 20% shorter lead-time than a traditional Invar layup mould, while maintaining the same superior vacuum integrity and dimensional precision. The hybrid mould capitalises on the desirable performance characteristics of Invar and composites to offer an ideal layup mould for prototype aerospace parts.

Meanwhile, Base Materials (hall 6, stand G74) will launch a number of products, including new toughened and high temperature epoxy tooling boards, a new range of polyurethane tooling boards and matching ancillary products. Base Materials is a provider of rapid prototyping and tooling materials for a wide range of areas including styling, modelling, pattern, tooling and moulding materials for the automotive, motorsport, marine, rail, aerospace, defence, industrial and foundry markets. Base offer epoxy and polyurethane tooling boards, ancillary materials and near net shape castings, that enable it to support its customers from the initial stage of their product development.

bigHead (hall 6, stand E45) returns to JEC World with design engineers on hand to discuss composite fastening applications. The emphasis will be on engineering solutions that avoid the typical compromises between form and function, and ways to improve process efficiency. bigHead’s most recent addition to the team, Dr Lawrence Cook, will be on the stand to offer advice and insight. An expert in composites technology, Dr Cook comes to bigHead having led a number of industry research projects at Cranfield University.

CGTech (hall 5, stand N80) will demonstrate how advanced programming strategies and simulation can lead to better composites parts. The company will also demonstrate Composites 2018, the latest version of VERICUT Composite Programming (VCP) & VERICUT Composite Simulation (VCS). Visitors to CGTech’s stand will also have the opportunity to receive a thorough overview of the steps needed to get from a CAD designed composite part to CNC programs that drive an Automated Fibre Placement (AFP) or Automated Tape Laying (ATL) machine. There will be information on new projects that highlight the implementation and use of machine independent off-line NC programming software for AFP and ATL machines, such as the work being done at NASA's Langley Research Centre using a 16-tow Electroimpact automated fibre placement machine. CGTech will also exhibit its latest version of VERICUT 8.1 software.

Chem-Trend: highly tailored release systems

In the next aisle is Chem-Trend, (hall 5A, stand M22) who develop and produce highly-tailored release systems including cleaners, primers, sealers, and release agents, to increase the productivity and quality output of composite moulding operations around the globe. The Chemlease and Zyvax brands cover industry applications from FRP to advanced composites. Chem-Trend formulates an extensive range of semi-permanent and conventional external release agents, both water-based and solvent-based, as well as specialised internal release agents for particular applications. Zyvax MPP 1006W is a newly developed semi-permanent mould primer formulated for sealing and priming various types of tooling substrates in the aerospace industry. Zyvax TakeOff is a water-based, semi-permanent release agent specifically formulated for aerospace manufacturers and is especially effective for vacuum bagged and autoclave moulding of epoxy carbon fibre prepreg.

Further on, fibre handling and processing company, Cygnet Texkimp (hall 5, stand M70) will use this year’s JEC to unveil its high tolerance reverse roll coating machine and invite manufacturers in the high-end prepreg market to take part in secure trials of the technology. The coater is in the final stages of production at Cygnet Texkimp’s UK R&D headquarters where it will spend the next six months being commissioned for the purpose of trialling precision coating of epoxy resins. The machine is designed to create low area-weight films with a GSM of less than 10µm for the aerospace quality prepreg market and the company reports that initial grinding reps on ceramic rollers have achieved a TIR of less than 0.5µm.

Diab (hall 5A, stand N39) will offer the chance to check out how renowned Croatian ship builder, Uljanik teamed up with the company to substantially reduce the weight of its enormous car carrier ship. With a length of two football fields, the ship can carry 7,000 vehicles and incorporates new technologies that reduce environmental impact while cutting cost. 12,600m2 of steel deck was replaced with sandwich composite materials allowing for a number of advantages, including a deck structure weight reduction by 25%, maintained strength and durability, reduced fuel consumption by 4% or 800 tons increase of cargo intake, as well as reduced carbon footprint. The strength-to-weight ratio of sandwich composite solutions from Diab makes them especially useful in applications where low weight and high strength are essential. Visitors can check out a full-scale sample of the car deck on display at Diab’s stand where you can also meet Diab experts and discover all the possibilities that open up with sandwich composite materials.

With the tailored blank line using the Fiberforge and Fibercon systems, Dieffenbacher (hall 6, stand C31) says it has developed a solution for the large-series production of locally reinforced thermoplastic components. Applications within the aerospace industry include loaded clips and brackets, interiors, seating and other commercial aircraft applications. The new approach will enable cost-saving solutions over metal or traditional composites.

Eastman: cutting and materials handling goes digital

The Eastman Machine Company (hall 6, stand D51) will demonstrate its conveyorised digital cutting and material handling for reinforcement materials, including glass, carbon and aramid as well as nonwoven core materials at JEC. The Eastman conveyor and integrated unwinding, rewinding and parts collection systems play an essential role in streamlining the queue from rolled goods through marked, cut and kitted parts. The Eagle C125 conveyor system features a cutting head inclusive of three cutting knives and stylus pen that can optionally be outfit with a router, one of several supplemental printing systems or bespoke tools. Industry-proven for supplying clean, smooth edges when cutting single- to low-ply layers of most flexible materials as well as unique combinations like Lantor Soric, which have an adhesive layer, protection foil and coremat in one. The microperforated PU belt surface ensures distributed vacuum hold-down and is easy to clean, reducing risk of contamination when cutting dry reinforcements, prepregs or core materials on one system. Rigorous factory acceptance tests at global installations have proven the C125 capable of exceeding 0.5 tons of cut fibreglass per hour when cutting single ply and over 2.0 tons of fibreglass per hour when cutting four-ply. This equates to real operation cutting speeds averaging 90m/minute. This high-volume output also maintains published accuracy and repeatability tolerances over parts exceeding 40m in length and equally when cutting small, intricate patterns. Eastman’s industrial grade design ensures the integrity of critical production specifications are preserved and has proven to exceed production capacity of lighter-duty designs in the market. Also highlighted at the show is Eastman’s JetPRO HR continuous inkjet printer. It is an optional accessory for the conveyor and static table cutting systems. The system features thermal, drop-on-demand inkjet printing technology capable of operating at print speeds of up to 152cm per second. The inkjet interface is available in several languages and is capable of printing characters, linear and DataMatrix bar codes plus custom logos/graphics up to 600 x 600dpi resolution. Easy to change and maintain, the ink cartridge design ensures clean and hassle-free use.

Global pultruder, Exel Composites (hall 5, stand Q13) will showcase composite laminates aimed at next generation, 5G-enabled city infrastructure. These laminates play a key role in the LuxTurrim5G project on Smart City Digital Ecosystem Creation, where Exel is collaborating with partners, including Nokia Bell Labs to develop smart lighting poles designed to create a telecommunications network fit for the world's rapidly growing urban environments. The LuxTurrim5G project has been shortlisted for a JEC World 2018 Innovation Award in the Smart Cities category.

The Fraunhofer Institute for Laser Technology ILT (hall 5A, stand C55) will focus on the latest trends and innovations in laser machining of composites. Researchers at the booth shared with the Aachen Centre for Integrative Lightweight Production (AZL) will demonstrate how lasers can be used for joining, structuring, cutting and drilling composite materials. Fraunhofer ILT will present new developments in laser transmission welding techniques for joining plastics with a metallic component. At the joint booth, researchers will also present new developments in the field of laser cutting and drilling. The challenge here is to minimise the interaction between laser and composite. To achieve this, Fraunhofer ILT relies on pulsed laser beams and very rapidly deflected continuous wave radiation, which penetrates ever deeper into the material over the course of several scans. The same also applies to laser drilling, which the Aachen researchers effectively use to cut form-locking contours into preforms.

Henkel: Locked and loaded with Loctite

Henkel (hall 6, stand G48) says it will continue to drive significant progress in sustainable light weighting technologies with new composite and adhesive products and extended global Composite Lab capabilities. Henkel’s specialists will be available to discuss the benefits of the company’s broad technology portfolio and global service capacities for composite applications in automotive and other demanding industries. Among the highlights on display will be Henkel’s new Loctite MAX 5 matrix resin for carbon fibre reinforced composite wheels. The new technology is designed to replace aluminium in this demanding chassis application and builds on the recent success of Loctite MAX 2 for use in glass fibre reinforced leaf springs. The new resin combines high temperature resistance, excellent toughness and long-term durability with rapid mould filling, thorough fibre impregnation and high curing rates for cost-efficient large volume production. Another spotlight will be on the company’s new Loctite UK 2032 adhesive for multi-substrate designs, following the strong response to Loctite UK 2015 introduced at last year’s JEC. Both adhesives are ideally suited for bonding structural parts made of composite materials with distinctly different coefficients of thermal expansion, from plastics to e-coated steel or aluminium. Loctite UK 2032 and Loctite UK 2015 are specifically designed to meet automotive performance requirements as well as high volume production demands. Furthermore, Henkel will show various demonstration parts moulded in new RTM test tools at the company’s Heidelberg Composite Lab. This includes thick leaf spring test parts as well as parts with a complex 3D geometry.

Camera-based, non-contact precision measurement specialists, Imetrum (hall 6, stand N4) will demonstrate its measurement capability throughout the show. Imetrum’s Video Extensometers can deliver resolutions to better than 3 microstrain/10nanometres. They are also said to calibrate to unparalleled accuracies, with ISO9513 class 0.5/ASTM E83 B-1 possible, even at low strains and gauge lengths. Both the Universal Extensometer for materials testing, and 3D Precision Displacement Tracker for component testing, are based on Imetrum’s Video Gauge software and are characterised by their measurement resolution, accuracy, versatility and efficient workflows.

Metyx (hall 6, stand J6) says it will bring artistic flair in composites to JEC World via an acrylic painted glass fibre sculpture by contemporary Turkish artist Bülent Sancar, titled Spazio Blu, which will be on display during the show. The composite sculptures were designed and created using Metyx’s Tool Centre production facilities located in the main factory in Manisa, Turkey. During JEC World, Metyx will promote its complete range of high-performance glass and carbon fibre technical textiles, manufactured at its factories in Turkey and Hungary, including multiaxial reinforcements, RTM reinforcements, woven reinforcements, and vacuum bagging products.

For the first time ever, Michelman (hall 6, stand K83) will showcase its expanding portfolio of fibre sizing solutions with its own booth at JEC World. On the stand will be Hydrosize, its versatile line of fibre sizing that allows customers to tailor the surface chemistry of reinforcement fibres to the chemistry of the matrix resin, thereby optimising the interface adhesion between the polymers and fibres. This improved interface adhesion helps fibre producers and composite manufacturers produce stronger, lighter and more durable composite parts. The company’s fibre sizing can be applied during the manufacturing process of chopped or continuous strand fiberglass, carbon fibre, natural fibres and fillers, or post-applied when making non-wovens and composite prepregs.

MTorres: manufacturing and automation of large structures

In the adjoining hall, MTorres (hall 5, stand N42) will present the latest R&D developments regarding manufacturing and automation of large structures, with a special focus on fuselages and the new low-cost carbon fibre material based on MTorres’ proprietary new tow preparation process. This ‘new mould-less monocoque manufacturing process’ is a finalist in the JEC Innovation 2018 awards in the category ‘Aerospace-Process’ with the winner being announced during the show. In addition, Russian company JSC Aerocomposite is finalist in the category ‘Aerospace-Application’ for the Infusion Technology for Aircraft Wing. These wings are the first in the world to be built using dry carbon fibre, and they are manufactured extensively using MTorres equipment. A TORRESFIBERDRY, AFP machine and TORRESMILL Routing and Milling machine are used for components fabrication. The outer wing box, central wing box assembly lines and the assembly solution for the integration of the outer wing box with central wing box are also supplied by MTorres.

NTPT, (hall 5, stand F5) specialists in thin ply prepregs, preforms and parts and experts in automation technology, will showcase a full range of thin ply solutions, with a focus on composite parts: tubes, blocks and structural components. Having always offered product development and prototyping services, the company has now established a parts business with a focus on the marine and aerospace sectors. NTPT is working in collaboration with several leading aerospace companies on ultra-light composite components for high-altitude UAVs.

Oxford Advanced Surfaces (hall 6, stand 72) will unveil the latest developments in its Onto product portfolio for use with paints, lacquers and adhesives. The company will be showcasing the use of Onto EP1130 and Onto SB1050 products for use in sporting equipment by reducing cycle times while painting and greatly improving laminate adhesion in a thermoset/thermoplastic composite stack respectively. It will also be unveiling its new adhesion promoter Onto SB2050 for use with MMA-based adhesives on composite and engineering plastics. Designed for use in the automotive market where fast bonding times of a MMA are crucial, the Onto SB2050 product removes the need for any prior surface preparation and on difficult to bond materials, such as Polyamide/Nylon, offers greatly improved adhesive strength when compared to sanding as a surface preparation. Onto surface treatments eliminate the need for sanding as a preparation technique before painting or bonding resulting in rapid increases in production times and reductions in wastage.

Moving on, Porcher Industries’ (hall 6, stand M28) five business units will present market specific technical textile and thermoplastic composite solutions at the show. The company will jointly present a new carbon fibre reinforced thermoplastic airframe component with Stelia Aerospace. The results of extensive R&D by both companies, this strengthening frame for an aircraft fuselage is the first to use a fabric woven from 12K carbon fibre. This development, realised through low-crimp weaving and optimisation of the fibre/matrix interface, allows a more cost-effective 12K reinforcement to replace existing 3K solutions. Porcher Industries will also showcase its technology of dry fibres for AFP offering multiple options of binders (thermoset or high temperature thermoplastic) and carbon fibres for Out-of-Autoclave processes in aerospace and defence.

PRF: RP800 50°C epoxy tooling prepreg system

At this year’s show, the PRF (hall 5, stand E41) team will be presenting its RP800 50°C epoxy tooling prepreg system to the international market. RP800 has a 10-hour cure at 50°C and an out-life in excess of five days at 20°C. PRF’s range of competitively priced tooling systems continues to receive positive customer feedback – particularly on the quality of surface finish in the tool, even after repeated mouldings. This new product has been developed to provide an additional option for customers requiring improved dimensional accuracy of the finished tool. Celebrating 35 years at the forefront of advanced composites, the team will also be discussing additional advances in its wider range of innovative materials: high performance reinforcements, epoxy resin systems, Qiicote mould release and kitting services.

Further on, Refitech and CG TEC will present their new partnership, as well as their innovative carbon fibre product solutions. Both companies will share the Bayern Innovativ stand (hall 6, stand R51) to announce their full cooperation, whereby the affordable innovative composite components from both companies can be purchased easily in their respective web shops. At JEC, Refitech will introduce a new series of round and square connectors as an extension of its standard range of round and square carbon tubes for industrial applications. CG TEC will showcase new multilayer basalt tube combines high-performance basalt fibre, high strength stainless steel tubes, a communication element (optical fibres, coax or copper wires) and optionally a polyamide, polyethylene or high-density polyethylene sheath.

R-TECH Materials (hall 6, stand B65) will showcase its testing capabilities at this year’s event. R-TECH’s polymer and composites laboratories test the mechanical, thermal and chemical properties of non-metallic materials, components and products. These include plastics and fibre-reinforced composites for material approval and characterisation, to identify quality issues, solve processing problems or identify why a product has failed. Having won the JEC Award for Innovation in Testing last year, 2018 promises to be a big year for R-TECH. The company is on track to secure Nadcap aerospace approval and has also teamed up with Zwick Roell to run a second round of its successful training course on mechanical testing of composites.

Crestapol meets Caterham

Scott Bader (hall 6, stand M27) will launch two new brands during JEC: Crestafire and Crestafix. Crestafire covers all products that offer fire, smoke and toxicity (FST) performance for manufacturing fire retardant (FR) composite parts to stringent fire standards required. The extensive Crestafire range includes: FR gelcoats and intumescent topcoats; FR structural adhesives; a variety of FR rated open and closed mould, pultrusion and filament winding resins, compatible with glass, carbon and aramid fibre reinforcements. Other key products and services, supplied directly and via European distributor partners, being promoted by Scott Bader include Crystic Ecogel ultra-low styrene Iso and Iso-NPG spray gelcoats, including the ‘zero’ styrene Ecogel S0 PA grade; Crestomer urethane acrylate and Crestabond MMA primer-less structural adhesives for bonding wood, metal, plastic and FRP composite substrates; Crestapol 1260 urethane acrylate resin for producing lightweight CFRP components with high strength and toughness; and the GelTint service. Visitors to the Scott Bader stand will also have the opportunity to see a Caterham Seven CSR-260 sports car with a custom-made lightweight CFRP roof, infused using Crestapol 1260 resin.

Thermwood (hall 6, stand P46a) offers both 3- and 5-axis CNC machining centres suitable for the production, fabrication and trimming of wood, plastics, non-ferrous metals, composites and other advanced materials. These applications range from machining patterns and moulds/plugs to trimming and machining production products. Thermwood also offers a Large Scale Additive Manufacturing (LSAM) system for 3D printing reinforced thermoplastic composite materials for producing industrial tooling, moulds, patterns, masters, plugs and fixtures for various industries. The LSAM can perform both the ‘additive’ and ‘subtractive’ functions on the same machine. This approach, called ‘near-net shape’, uses carbon fibre-reinforced thermoplastic material to quickly create a part that is nearly, but not exactly, the final shape. The ‘subtractive’ function then machines the part to the exact final net shape.

Elsewhere, Technical Fibre Products (hall 5, stand P32) will exhibit its advanced nonwovens. This year there is a strong focus on the capability of Optiveil nonwovens to deliver an exceptional quality surface finish. Optiveil nonwovens provide a surface finish solution for a variety of composite markets. Optiveil is the ideal candidate for use as a surfacing veil, and has been developed as such. Available in range of fibre types to enable both a variety of aesthetic finishes and CTE matching, it boasts an exceptionally even fibre distribution to ensure uniform resin uptake. The result is a high-quality resin rich surface finish with micro crack suppression and minimum microporosity.

The UK Pavilion (hall 6, stand S72) is a collaboration between the Department for International Trade (DIT) and national partners Composites UK, Midlands Engine, National Composites Centre and Northern Powerhouse. Twenty companies will be showcasing UK excellence in composites with the full supply chain represented. The stand will be a hub of activity throughout the four days of the show - come and meet UK companies and sector specialists. Activities include: on-stand meetings between DIT specialists and overseas inward delegation stakeholders to promote exporting and foreign inward investment; informal presentations, workshops and seminars and a two-hour networking drinks reception with senior stakeholders. Companies positioned on the UK Pavilion include: Barrett Aerospace, Bindatex, CompoSIDE, Composites Evolution, Composites UK, Dow, FAC Technology, GRP Solutions, Heraeus Noblelight, JAI Engineers UK, Lucideon, Midlands Engine, National Composites Centre, Northern Powerhouse, Oxford Advanced Surfaces, Permabond, Richard Hough, STRUCTeam, Surface Generation, Thomas Swan & Co, Tods Aerospace, V-Carbon and Williams F1.

VELOX (hall 5, stand E28) will showcase an extended speciality product portfolio, including a wide range of speciality composites and additives comprising glass reinforcements for closed mould and pultrusion processes, dry carbon reinforcements, formulated epoxy resins and hardeners as well as bio-sourced epoxy resins, structural adhesives and more. The company offers composites solutions for the automotive, aerospace, sports and leisure industries and for industrial applications. VELOX will be representing new as well as long-term partners like Ilium Composites, Chomarat, L&L Products, Atul, CMP, CTP Advanced Materials and Entropy Resins and Umicore - Cobalt & Specialty Materials.

Zünd: the new dual-beam D3 cutter

Finally, Zünd (hall 5, stand T40) will present the latest developments in its highly modular digital cutting systems for composites applications. Centre of attention will be the Zünd dual-beam D3 cutter designed for maximum productivity. With the D3 dual-beam system, Zünd offers an ultra-productive cutting solution. With two beams, each carrying up to three different modules, the D3 system can process any number of materials including multi-layered, woven and non-woven materials, films and fleeces twice as fast as a single-beam system. In combination with the Zünd Cut Centre ZCC user interface and control software, the Zünd D3 is the perfect high-throughput solution for digitally cutting composites. As an example, the ZCC software automatically distributes the workload between the two beams and tool carriages as efficiently as possible.

www.jeccomposites.com

 

Company

JEC Group

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