JEC World is the global showcase for composite innovations attracting exhibitors from around the world. Composites in Manufacturing takes a look at some of the companies that will be promoting their latest products during the show.
We begin our round-up with machine tool builder, Breton (hall 6, stand D34). Its latest generation Matrix 800 is a high dynamic multi-tasking 5-axis machining centre, featuring travels of 2,000 x 2,500 x 800mm and is suitable for those composites machining applications that require high productivity combined with utmost precision. The robust monoblock machine design allows for high dynamics to be exploited with superior and dependable accuracy.
When applications call for wet cutting, the machine is delivering high-pressure coolant trough the tool and on peripheral spindle nozzles. Through dedicated conveying chutes, the coolant is recovered on special separation systems which are precisely tuned to provide the right filtration for any material.
As with all Breton machines for composites, the Matrix 800 features a special protection for drives, head and spindles through specific seals and pressurisations that have always distinguished its machines as a byword of their reliability and consistency over time.
This new Matrix 800 is engineered to support Breton’s proprietary technologies, such as Accusink (Automated accuracy control on Countersink machining), Accuthick (Contactless ultrasonic thickness inspection) and core cutting via ultrasonic blades or knives.
Next up, Evonik (hall 5A, stand J40) will present Rohacell foam which is setting new milestones for structural foam cores in aviation and aerospace applications. It is ideal for use in the growing area of automated production of sandwich design CFRP composites. This versatile high-performance foam core material solution is providing the aerospace industry with increased opportunities in efficiency, both time and cost savings, over conventional classic methods of using hollow structures or honeycomb designs.
Visitors to Evonik’s stand can learn more about use of the rigid foam material in automated production, as well as explore current applications of Rohacell in sandwich design composite structures. A partial composite helicopter main rotor blade produced by Van Horn Aviation for the 206B JetRanger helicopter will be on display. The blade was fabricated with a Rohacell 71HERO foam core and Toray carbon fibre, then autoclave co-cured. Cutaway sections on the blade enable visitors to view interior construction. Also on display is the core of a section of an aircraft wing demonstrator, featuring a puzzle-joint connection design, from Pronat Aerospace.
Oxford Advanced Surfaces (hall 6, stand S52) specialises in surface treatment. The company says it is now on target to treat 1 million square feet of composites with its patented Onto adhesion promoter that replaces sanding or abrasion for surface preparation.
By removing abrasion as a surface preparation for composites, Onto delivers improvements in quality and a reduction in processing times of up to 90%. This produces cost savings and productivity improvement. Simple to use, Onto supports the volume manufacturing of composites in all areas of advanced manufacturing, while also being easy to use with complex shapes.
The incorporation of Onto into the production process will remove the requirement for sanding prior to painting. Sanding or abrasion as a surface preparation is slow and labour-intensive, risks damaging parts and dirty in that all the dust needs to be extracted.
The patented technology of Onto has already been proven in demanding applications and is specifically designed to exploit the maximum potential of modern materials. It provides a practical approach to surface preparation that reduces processing time, reduces cost, improves adhesion, and is easily repeatable.
Continuing on, the Eastman Machine Company (hall 6, stand D59) will be demonstrating its latest Eagle C125 conveyor cutting system in Paris. The system minimises overall factory space required, but maintains complete cutting automation for industrial cutting applications.
The Eagle C125 conveyor is a CNC ply-cutting system engineered for single- to low-ply automatic cutting of flexible fabrics; composite reinforcements like fiberglass, carbon and aramid; industrial fabrics and insulations, as well as traditional textiles. It has the ability to continuously convey rolled material goods with consistent speed and control.
The C125 conveyor system is an ideal choice for companies who need to cut long parts, require continuous conveying or simply want to minimise the material handling commonly associated with a static table cutting system. It features cutting speeds up to 152cm/second.
Continuing on, Sharp & Tappin (hall 6, stand S60) will return to JEC World to showcase its innovative ranges of Compcut composite machining solutions which are continuing to win plaudits and customers within materials test centres and R&D departments throughout the UK and increasingly in Europe too.
Visitors will be able to explore the well-established Compcut range of Advanced composite plate saws, including the popular Compcut 200 ‘entry level’ model, which offers smaller test centres a very affordable, yet highly precise, easy to use composite machining option.
The major feature at this year’s show will be the European launch of the new Compcut Precision Composite Router (PCR) range – a ground-breaking ‘hybrid’ machining solution that combines both routing and CNC milling functions to meet the challenge of cutting highly precise ‘dog bone’ and ‘open hole’ compression test samples from the ever-increasing range of complex composites, including ceramic matrixes. The Router concept evolved from a programme of extensive testing and development trials run in conjunction with the UK’s National Composites Centre.
Sharp & Tappin’s confidence in its Compcut product range will be reinforced in a very practical way by encouraging stand visitors to take the ‘Compcut Challenge’ and bring along their own selection of composite samples to witness for themselves the quality and precision that can be attained by the Compcut 200 unit that will be in operation on stand.
McClean Anderson is a diverse company performing all aspects of design and building machines in house. All the electrical, mechanical and software systems it uses are developed and built at its Schofield, WI facility. It also has a world-class service team, with service technicians travelling the world at least half a dozen times a year.
McClean Anderson says it introduced the first computer-controlled filament winding machines in 1976 and has stayed on the cutting edge with continuous R&D since, with the 2020 introduction of new filament winding control software called Ocelot. The software system was developed for current necessities and the direction the filament winding industry is taking. The future of the industry is more custom automation, communication and integration with external software and hardware systems.
Ocelot (above) uses Beckhoff PLC as the controller and EtherCAT protocol for communication with the drives, and other external hardware systems. It also provides OPC communication. Since most of the filament winding programmes are developed on the machine using Windows-based pattern development software SIM WIND 2.5 - it utilised the Windows framework to develop its front-end using Windows WPF and Beckhoff ADS .NET Library achieving a simple, efficient system that is easy to customise. The company also chose the Beckhoff platform because of the PC and EtherCAT-based CNC solution offered. This makes the filament winders open, flexible and high-performance machines. McClean Anderson also has the ability to run a dual system using Ocelot and the Beckhoff CNC on the same hardware.
Airtech (hall 5, stand E32) will introduce its new large-scale additive manufacturing capabilities along with newly formulated resins for low and high temperature printing. Airtech’s new Print-tech, full-service tooling manufacturing solution, leverages 45 years of polymer extrusion and manufacturing expertise to address the needs of the large-scale thermoplastic composite 3D printed tooling industry.
The high throughput and relative low-cost manufacturing method of fused deposition modelling (FDM) is used to create large tooling structures and surfaces for low to high temperature lay-up moulds, trim or assembly fixtures, or masters. These demanding tooling applications require the structures and the materials they are made from to be durable and dimensionally stable.
Airtech has also developed a new series of innovative polymer composite resins, Dahltram, for use in large scale 3D printing that has addressed the need for lower CTE and a more robust service life when used at low or high temperatures, including use in an autoclave.
Cecence is a JEC Innovation Award finalist for a second consecutive year - this time for its composite overhead line catenary system and support structure for light rail applications.
The design incorporates a carbon cable with end fittings which interface between the current system when hooking up to a curved section of cabling. The system comprises a series of composite clips and support cables, made from carbon, glass and other composite fibres, clamps manufactured using hot compression moulding, and 3D printed ancillary components using rubberised, high strength materials.
The solution allows for the spacing of the support poles to be doubled, halving the amount of vertical infrastructure and providing a better environmental aesthetic, and the composite cable is not prone to sag in the same way as existing metallic catenary systems. The use of composites means that the components are not subject to corrosion and have a longer lifespan and the system is lightweight and efficient to install.
At present, this system is designed to work on all straight lengths of track and is most applicable to light rail. Discoveries made in this project and elements of it in particular include a renewed understanding of structural loads and composite cantilever systems and how they may well have a use in heavy rail.
At PRF Composites, (hall 6, stand E41) the team will be presenting their latest innovative prepreg system RP542-4 to European and global visitors. Now in manufacture, PRF’s new RP542-4 prepreg system is producing excellent results on unidirectional and woven carbon fabrics. The PRF team will be discussing this new product, which has been designed as an intermediately toughened system to complement PRF’s RP542-1 and highly toughened RP549 systems, alongside its full range of highly recommended prepreg materials with visitors at the show.
Also showing on the stand will be PRF’s wider range of advanced composite materials: high performance reinforcements, epoxy resin systems, Qiicote mould release, kitting services and more.
Scott Bader (hall 6, stand M27) will exhibit its adhesive, resin, gelcoat and tooling ranges at JEC. Products include Crestafire, Scott Bader’s composite fire, smoke and toxicity (FST) system for the rail, marine, and building and construction markets. Visitors to the stand will have the opportunity to see an internal passenger train door manufactured with the new EN45545 certified Crestafire system: Crestapol 1211 Urethane Acrylate resin and Fireguard Gelcoat 78PPA.
An automotive spoiler manufactured in Japan and bonded together with Scott Bader’s Crestabond adhesives will also be on display. Scott Bader’s adhesive ranges include Crestabond and Crestomer structural adhesives, along with Crestafix bonding pastes. Other key products include: Crystic Ecogel ultra low styrene spray gelcoats, including the ‘zero’ styrene Ecogel S0 PA grade; Crestapol resins for tough lightweight carbon fibre components and Crestamould matched tooling systems.
Also on the Scott Bader stand will be a hologram unit showcasing the first ever carbon fibre curved pultruded bumper beam used in the new 2020 Chevrolet Corvette Stingray, and manufactured using Crestapol urethane acrylate resins.
Altair (hall 5, stand E86) a global technology company providing solutions in product development, high-performance computing and data analytics, has announced it will present its methods and solutions aligned to the design, optimisation, and simulation of composite structures and materials at JEC World.
During the event, Altair will present development and simulation-driven design processes and solutions, driving modern design and manufacturing of composites from capability to capacity. In addition to offering visitors insights into the Altair solutions via on-site demonstrations and use case examples, Altair will host a conference session featuring presentations from Altair experts and customers.
The Altair stand will also highlight a 3D-printed lattice top fairing of a MotoGP motorcycle by KTM Technologies as well as demonstrations of the new capabilities for composite design utilising Altair HyperWorks and much more.
But Saertex (right) also constantly optimises processes and products in terms of its own sustainability. At JEC World the company will be highlighting the latest sustainability activities in the company. The measures include optimised delivery routes by new production locations, a certified environmental management system and new recycling management of fibres and intermediates.
When it comes to product innovation, the manufacturer of multiaxial fabrics will present its new Carbon Chopped Strand Mat (CSM) for the very first time. This is a recycling product made of carbon fibre residues of the edges that are needle punched. Due to its thermal expansion characteristics and good drapeability, it is appropriate as an economical alternative for carbon fibre fabrics for mould construction. It can furthermore be used as centre layer for sandwich laminates and more.
Flatbed cutting specialist, Zünd (hall 6, stand D27) will present digital cutting solutions at the show this year. Capable of delivering the utmost in cut quality, Zünd cutting systems are geared towards fully-automated production; even so, they allow for gradual implementation with a wide array of semi-automated options.
Raw materials including carbon or glass fibre, semi-finished products, such as prepreg or thermoplastic organo sheets, honeycomb, foamcore and related materials – they are all part of the wide variety of materials used in the composites industry. What is said to make Zünd cutters unique is that all of these materials can be cut on a single, multi-functional cutting system.
Moving on, the Metyx Group (hall 6, stand J6) is showcasing its expanded range of EN 45545 rated FST RTM reinforcements for lighter and stronger FRP laminate solutions for the rail sector. In addition to Metycore FS and Metycoremax FS RTM glass fabrics, FST rated technical fabrics now available also includes Metyx carbon fibre biaxial fabrics in a carbon-PET foam sandwich system. All three technical fabric solutions, which are suitable for the infusion of fire rated FRP parts, have been tested and approved as part of complete fire retardant (FR) liquid resin and gelcoated FRP laminate systems which meet the rail industry’s EN 45 545 fire standard for composites used in rolling stock.
Also on the stand Metyx will also be showcasing high performance applications using Metyx Tycor a fibre reinforced core sheet material which reduces overall weight without losing any structural integrity.
Examples of more recent successful applications include Tycor being specified in lightweight FRP trench covers and underground fuel storage tank covers and as main bulkheads in the marine sector. Tycor is a dry fibre wrapped PIR foam core, which achieves its final end use properties though the vacuum infusion process, such as VARTM and RTM. Tycor fibre reinforced cores provide design engineers and convertors with an alternative reinforcement material to balsa and conventional PVC foam cores.
Huntsman (hall 6, stand M31) will use JEC World to highlight its range of solutions. Pressure vessels based on Araldite composite solutions with high thermo-mechanical performance, alongside leaf springs using its Araldite epoxy resin system and Vitrox RTM polyurethane resin system will be on show.
The booth will also feature the Rimline HC+ polyurethane resin system, enabling ultra-lightweight automotive interior components from fiberglass reinforced material, and the new Rimline FC rigid foam technology for composite cores.
For the wind energy, marine and outdoor assembly industries, Huntsman will show applications of its latest acrylic adhesives. These will feature a wind-blade repair application using Araldite 2050 epoxy resin and a mock-up sandwich panel structure for boat-building utilising the non-sagging, high gap-filling Araldite 2023 epoxy resin. Huntsman’s new Epibond epoxy adhesive will also be featured. These solutions were developed to meet changing engineering, regulatory and economic requirements within the aerospace industry.
Finally, Huntsman will unveil a new electrically conductive adhesive modified with Miralon carbon nanotube materials and demonstrate its CNT-based Miralon sheets that can be embedded in composite structures, such as heat-generators, and require very low voltage.
Trelleborg Applied Technologies (hall 6, stand P50e) is showcasing its latest material innovation in its epoxy tooling board range called TC760X which combines a dust-free manufacturing experience, reducing airborne particles and environmental impact, with improved production efficiency and reduced finishing time.
Trelleborg’s TC760X is designed for use in the manufacture of carbon fibre tools with applications including master models and direct to part tooling. The material is dimensionally stable and can be machined to a high-quality surface that requires virtually no secondary finishing or polishing before use offering faster production times and reduced overall costs.
On display will be the full range of epoxy tooling board solutions from Trelleborg meeting a broad range of customer requirements, with the company also demonstrating its CNC machining capabilities at its UK and US facilities providing customers with a full end to end solution.
Smart Tooling provides formable, reusable tooling solutions for manufacturing composite parts with complex geometries for the aerospace and defence industry. Smart Tools improve quality, reduce labour hours, decrease consumables, and increase throughput - essentially, Smart Tools enable the manufacturing of composite parts better, cheaper, and faster.
Visitors to (hall 5, stand M72) will be able to see Cygnet Texkimp’s high-speed Multi-Axis Winder in action. The Cheshire-based fibre handling expert and custom machine builder will showcase a full-scale working model of the technology which is used to wind fibres such as carbon, aramid and glass quickly and accurately into strong and lightweight composite parts.
The Multi-Axis Winder is capable of producing linear structures such as tubes and masts quickly by laying down multiple tows at once around an inner core. It is part of a range of high-speed winding products developed by Cygnet Texkimp and including the 3D Winder which is mounted onto a robot and can produce more complex, curved components. Both address the need for faster, lower-cost ways to manufacture consistent and repeatable composite parts.
The technology enables composite part manufacturers to run dry fibres as well as pre-impregnated tapes at fast speeds with a high level of control and accuracy. Additionally, the machine covers the same footprint as an average-sized car and is expected to generate lots of interest with manufacturers considering alternatives to braiding and filament winding.
With around 1,500 British companies involved in the sector, the UK’s Composite Leadership Forum predicts that the UK’s market for composite products will grow from £2.3 billion in 2015 to £12.5 billion by 2030, driven by the need to develop lightweight structures for energy efficiency and costs savings to meet carbon reduction targets. On Wednesday, 4th March a networking reception sponsored by Midlands Engine will take place on the UK pavilion. The event will welcome European and international clients to forge ever closer ties.
Finally, Aro PR and Marketing (hall 6, stand S52), specialists in raising the profile of engineering, scientific and composites companies, will be showcasing its reputation-building services at JEC World Paris. The award-winning agency has successfully developed strong relationships with editors and publishers within Europe and globally.
The publications Aro works with are specialists within a variety of industries, including composites, aerospace, automotive, medical, energy and transport. These cover technical, national, regional and local media as well as all social media channels.
The Aro team will be available at the show to talk you through its media relations services as well as your other PR and marketing needs; from awards applications and social media to copy writing and web design and SEO.
