Composites Innovation from Europe

Dr. Gunnar Merz, March 27, 2019

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Agenda

Market for Carbon Fiber Reinforced Plastics (CFRP)

Access to CFRP Market

Support by a network CFK Valley e.V. as one example

Composites Innovations by CFK Valley members Aerospace Application: Airbus A350

Construction Industry

One Family House

Spectacular Buildings

Trailer Technology

Recycling of CFRP

Outlook

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2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Industrial

Sport

Aerospace

CFRP Market until 2020

Source: JEC Magazine

M m

t C

arb

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Fib

ers

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Airbus A350 Sports

Construction

Automotive

Transportation and Trains

Ship Building

Wind Energy

Components for Offshore Technology

Importance of diversification into industrial applications

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Challenge: Automation as Key to Mass Production

Source: dpa/Ford

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Network participation shortens the innovation process and reduces risk

Science

- Create Knowledge - Transfer Knowledge

Universities/National Labs

Industry

- Accept risks - Investments

Companies/Start-Ups/Investors

Politics

- Funding - Regulation/Laws

Regional/National governments

Involvement

Stepwise Innovation Process

Entrepreneurial experimentation

Risk involved

Knowledge development

Key role of e.g. Universities

Knowledge diffusion

Transfer of Knowledge by e.g. institutes

Resource Mobilization

Work Force E.g. Crowdsourcing

Capital

Crowdfunding, -lending, -investment

Legitimation

Society Acceptance

Guidance of Search

Subsidies

Regulations

Market Formation

Based on customer needs

Business Success

Infrastructure in Stade – Broad View

Deep Sea Harbor

Autobahn partly to

Hamburg

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Infrastructure in Stade – Close View

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Airbus Stade / CTC

Composites Technology Center (CTC) Stade – a subsidiary of Airbus

Germany‘s leading center for research and development of complex, large scale CFRP parts

Developer of multiple CFRP components and technologies for the A350

Airbus facility Stade – The company‘s CFRP competence center

Production of vertical stabilizers from

CFRP since the early 1980‘s

Production of A350‘s upper wing cover –

world‘s largest CFRP part (32m length)

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DLR - German Aerospace Center

Research focus on production of large scale CFRP structures

Equipment BALU – Largest research autoclave in the world (length: 20 m, diameter: 5,8 m, 𝑝𝑚𝑎𝑥 = 150 psi, 𝑇𝑚𝑎𝑥 = 400°C)

GroFi – CNC controlled multi-robot facility for AFP and ATL

Fully automated RTM process chain for an automated production of parts up to 1,5 m length

Wind blade production capabilities

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Fraunhofer Institute - IFAM

Research focus on automated assembly of large scale aircraft structures

Equipment Development platform for automated form- and position control

Test stand for automated fuselage assembly using adhesive bonding

High accuracy mobile robot assembly/machining units

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Education R&D

Design

Production Operation Recycling

Reuse of recycled materials

EH&S

Our Members Competencies along the entire composites value chain

BOLLE & CORDS

Elektrotechnik GmbH

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CFK Valley – a global network Countries with members

CFK VALLEY INDIA

2004

2014

2015

2017

2017

2018

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Innovations: Only one of many examples in aerospace application

Collaboration of our members to develop CFRP parts of the Airbus A350:

Upper Wing Cover

Fuselage

Vertical Stabilizer

Upper wing cover: Largest CFRP part (length: 32m) at Airbus produced in Stade

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© CTC GmbH. All rights reserved. Confidential and proprietary document.

A350 Wing Cover Manufacturing

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© CTC GmbH. All rights reserved. Confidential and proprietary document.

Overview – A350 XWB Wing Upper Cover

Largest monolithic CFRP component within Airbus

Length of approx. 32m

Approx. 2t weight

Prepreg based technology

Stringers integrated in co-bonding process

Approx. 300m of stringer per cover

Harmonized process with transnational collaboration

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© CTC GmbH. All rights reserved. Confidential and proprietary document.

Wing Skin Manufacturing

• Technology change in skin lay-up from

automatic tape laying machines to

automatic fibre placement machines

• 12.5 mm wide tows

• Increase of overall process productivity

• Significant reduction of material scrap

• Copper mesh as first layer to protect against

lightning strinkes

© Werner Bartsch

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© CTC GmbH. All rights reserved. Confidential and proprietary document.

Manufacturing and Industrial Implementation

The process has been implemented in a production line with the following main features:

• Fiber placement with high productivity and just in time production

• High quality forming with dedicated machines

• Lay out defined by the process & single movement direction of product

• External referenced automated stringer integration

• No manual transportation or movement of product

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A Carbon mast at the beginning in 2010

The construction engineer Dr. Amer Affan bought a sailing boat with a CFRP mast

He was fascinated by the material and wanted to know if he can use it for construction

2010 he visited the CFK Valley booth at JEC Paris and became a member

Dr. Amer Affan made use of the knowledge of CFK Valley

Today he is a world market leader for CFRP in construction

Source: JEC

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Composites in Construction Vision Award 2014

2014 CFK Valley Vision Award: Dr. Amer Affan (Dubai) Yas Mall Abu-Dhabi

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Composites in Construction More Spectacular Projects

Abu Dhabi Cruise Terminal

Sidra Hospital Qatar

Status March 2019

Museum of the Future in Dubai

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Fire Test

Use of non combustable epoxy matrix

Vision for Composites One Family House

CANNES - PROJECT SITE

INSTALLATION

INSTALLATION

INSTALLATION

INSTALLATION

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Composites in Transportation Cooling truck for food home delivery

CFRP structure allows additional 500 kg load (50 % increase)

Sensors implemented to check integrity of the carbon composites structure

Logistics Innovation Award Winner 2014

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Composites in Transportation CFRP Reefer Trailer

CFRP monocoque structure (13.6 x 2.6 x 0.75 m)

Integration of functions

Pallet carrier

Side protection

Weight reduction

Savings: 3 mt

Reduction of Fuel Consumption up to 25%

Increased load volume

Improved insulation

Reduction of life cycle costs

Source: TTT – The Team Technology

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Composites in Automation Modular Lightweight Gripper System

Development of a lightweight gripper system made from CFRP for robots

Up to 40 – 60 % weight reduction possible

Allows the usage of a smaller, more affordable standard industry robot

Or: Higher accelerations

Currently in implementation phase at Audi

Winner of the CFK Valley Innovation Award 2018

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Composites Recycling Reuse of fibers in new applications

Efficient Waste Collection

CFRP Production Waste and “End of Life”

High Quality CFRP Powder

Pyrolysis Process developed with Dow

CFRP Recycling Center in

Wischhafen

New applications in other plastic materials

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Get to know more about European Composites Innovation Join Composites Convention 2019: FUTURE FACTORY

Our common future

with CARBON

info@cfk-valley.com