Composites

2020-01-29

Celebrating excellence in composites at JEC World 2020

JEC Innovation Awards celebrate the fruitful cooperation between players of the composite community. Started in 1996, the JEC Innovation Awards have, over the past 24 years, brought in 1,900 companies worldwide.

198 companies and 475 partners have been rewarded for the excellence of their composite innovations. The JEC Innovation Awards reward composites champions, based on criteria such as partner involvement in the value chain, technicality or commercial applications of innovations. Also, the JEC Innovation Awards have built strong partnerships in India with IRCEP, in China with CCE for more than 15 years.

An exciting time for the composites industry? 

“Innovation is an essential part of this industry – it's how we invest in our future. The top priorities for players in the composites value chain include product solidity, safety, and durability. That is why the JEC Composites Innovation Awards are more than just an awards ceremony. They are meant to inspire all participants, the whole industry and shed light on the excellent work carried out by the prize winners,” said Franck GLOWACZ, Innovation Content Leader at JEC Group.

A cutting-edge selection process and a prestigious jury

After pre-selecting 33 finalists, the jury now has one month to select a winner in each category. The very high-caliber innovations created by talented professionals will then be recognized at the awards ceremony.

The international jury represents the entire composites value chain, includes:

  • Anurag BANSAL, Manager Global Business development, ACCIONA Construction S.A
  • Christophe, BINETRUY, Professor, EC Nantes
  • Robert BUCHINGER, Business Development Advanced Industry Systems, Swarco
  • Chantal FUALDES, Head of Airframe Certification, Executive Expert Composite Airframes, Airbus
  • Karl-Heinz FULLER, Manager hybrid materials, concepts and AMG, Daimler
  • Sung HA, Professor, Hanyang University
  • Deniz KORKMAZ, Ph.D. Composite Technologies Director, EMEA, Kordsa
  • Brian KRULL, Global Director of Innovation, Magna Exteriors
  • Yann PENFORNIS, Managing Director, Multiplast
  • Henry SHIN, Director - R&D Composites Innovation Centre, KCTech
  • Kiyoshi UZAWA, Professor/ Director (Ph.D.), Innovative Composite Centre

Finally, an online voting process will be held for each category to choose a second-place winner for the general public's favorite innovations. The public is able to vote online with the following link: http://innovationawards.jec-world.events. Votes will be opened on February 1st.

The awards ceremony will take place during JEC World 2020 on Wednesday, March 4, 2020, at 5 pm, on the Agora stage (Hall 5).

Finalists companies from around the world by categories below

Category Additive Manufacturing

Scalable Composite Robotic Additive Manufacturing

Electroimpact (USA)

https://www.electroimpact.com/

Associated partners: Northrop Grumman Systems Corporation (USA), Siemens Digital Industries Software (USA)

SCRAM is an industrial true 6-axis continuous fiber reinforced thermoplastic 3D printing system, enabling the tool-less rapid creation of aerospace grade integrated composite structures.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Additively manufactured highly reinforced continuous fiber composite parts.
  • True 6 axis fiber reinforcement tailoring to the load path.
  • Dramatic reduction in composite part lead time.
  • Able to create highly integrated, complex, multi-material composite structures.
  • Innovative composite designs that may not be producible by other methods.

CFIP Technology

Eurecat (Spain)

https://www.eurecat.org

Associated partners: AIRBUS (Germany), ASICS (Spain), HP (Spain)

CFIP is a new post-process technology which enables to reinforce with continuous fibres parts made of any material and by any manufacturing technology

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • The fibres can be freely placed in all directions following complex trajectories
  • A wide variety of materials can be reinforced, including metals
  • It provides very high mechanical properties and lightweighting performance
  • It enables the efficient manufacturing of large and strong structures...
  • and also of multi-material and multi-process structures (integral joining)

Rapid 3D Microwave Printing of Lattice Composites

Karlsruhe Institute of Technology (Germany)

http://www.kit.edu/english/

Associated partners: Fraunhofer ICT (Germany), HBH Microwave GmbH (Germany)

Developed the world’s first prototype of an ultra-high speed 3D microwave printer SERPENS. The bionic and free-standing lattice composite structures are printed by the SERPENS.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • 10 times higher printing speed than state of the art printers
  • Possibility to print thick continuous carbon fiber reinforced filaments
  • Printing of free-standing lattice truss and bionic structures
  • Highly energy efficient and cost saving technology
  • Load-dependent printing path generation for continuous FRP

Category Aeronautics

Innovative solutions for welding of TP composites

Institut de Soudure Groupe (France)

https://www.isgroupe.com/en/Pages/default.aspx

Associated partners: Arkema (France), Hexcel (France), Latecoere (France), and Stelia Aerospace (France)

ISW is a new solution developed and patented by Institut de Soudure Group and ARKEMA, providing very high performance welding for thermoplastic composites.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • High performance welding (join coefficient of 85% min)
  • No susceptor remaining at welding join
  • Dynamic solution fully automated
  • Fully monitored process
  • Can be used with any thermoplastic matrix and any fiber

High-Rate Manufacture of Aerospace Composite parts

Solvay (UK)

https://www.solvay.com

Associated partners: Boeing (USA)

A new material and associated process increasing the manufacturing rate of small to medium parts by 10-20 times while maintaining aerospace performance and quality and reducing the final part cost.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Increased manufacturing rate: 10-20 fold
  • Automation-ready materials and processes
  • Aerospace structural performance
  • Reduction in recurring manufacturing costs
  • Lower CAPEX investment for manufacturing

Intelligent Resin Infusion System (IRIS™) Demo

Spirit AeroSystems (USA)

https://www.spiritaero.com/

Associated Partners: the Advanced Forming Research Centre (UK)

Fabrication process for composite aerostructures combining self- heated tooling, resin infusion, and advanced automation to reduce equipment and materials cost and improve rate and design integration.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Self-heated tooling enables up to 20% cycle time reduction utilizing conduction
  • Up to 30% operating cost savings: reduced capital, floor space, & energy usage
  • Integrated part design leads to lower assembly cycle time and cost
  • Combined inspection and metrology cell reduces validation time up to 50%
  • Automated stringer consolidation/forming/trimming cell improves rate

Category Automotive

Pultrusion for popularization of CFRP Body Parts

Hyundai Motor Group (South Korea)

https://www.hyundaimotorgroup.com/

Associated Partners: Kolon (South Korea)

This innovation sheds light on challenges of for mass production automotive application with a new pultrusion process.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Lightweight : To reduce 11.8Kg(-65%) compared to steel member(18.0kg - 6.2Kg)
  • Safety : To ensure passenger safety from HV BAT fire in worst case of accident
  • Performance : Maximum axial load 410kN / Maximum anchorage Load 1,700N
  • Corrosion : To prevent galvanic corrosion using Glassfiber in surface
  • Cost efficient / In-Serial process for high volume automotive application

Overmolded organosheet bolster

Valeo (France)

https://www.valeo.com

Associated Partners: Daimler (Germany)

An overmolded organosheet bolster designed for mass production (300000 parts/year), compliant with aesthetic aspect requirement, mechanical properties and recyclability.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Weight saving -30% versus previous generation
  • Function integration (Engine Air intake)
  • Enhanced mechanical properties (Good behaviour to front crash)
  • Aesthetic aspect
  • Organosheet is fully recyclable

Lightweight FRP center tunnel (LehoMit-Hybrid)

Volkswagen AG (Germany)

https://www.volkswagen.com

Associated Partners: . Ing. h.c. F. Porsche AG (Germany), ), INVENT (Germany), Schneider Form GmbH (Germany), Technical University of Braunschweig – Institute of Engineering Design (Germany

Innovative cost-efficient structural hybrid thermoplastic automotive body component suitable for high volume production, introducible prior to cathodic dip coating with respective joining technology.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Structural thermoplastic composite body-in-white part prior to painting
  • Lightweight savings and one-shot production suitable for derivates from one mold
  • Cost-efficient application of thermoplastic tapes
  • Unchanged downstream processes (assembly and dip coating)
  • Novel thermoplastic joining technology for multi-material body

Category Construction, Infrastructures & Civil Engineering

CL RESTRAP

CARBO-LINK AG (Switzerland)

https://www.carbo-link.com

Thin, cured CFRP prepreg tapes continuously wound in a loop to form a flexible carbon strap. Highly customized solution to reinforce concrete girders of any size in any infrastructure lasting forever.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Shear reinforcement is delivered directly to the concrete not after deformation
  • No bonding necessary: simplified logistics, fast installation, cost reductions
  • Flexible solution to reinforce various structures: no compromise in properties
  • Material properties far outweigh alternatives: reduced cost, highly efficient
  • Small panel heights and non-intrusive installation = diverse infrastructure use


GlasCurtain ThermPH+

GlasCurtain inc. (Canada)

https://www.glascurtain.ca

Leveraging Thermoset Polyester Fibreglass-Reinforced Plastic (TP- FRP), GlasCurtain has designed and engineered the highest thermally performing curtain wall system in the world: ThermPH+.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Thermal Performance (U-Value)
  • Low Carbon (Embodied and In Situ)
  • Structural Performance
  • Corrosion Resistance
  • Thermal Comfort

APP/APN: Hybrid Thermal Insulation Sheet

Hankuk Carbon (South Korea)

https://www.hcarbon.com/eng

Semi-non-combustible thermal insulation, dimensional stability, anti- oxidation treatment.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Dimensional stability due to glass fiber
  • Semi-non-combustion by Al-foil application
  • Good ventilation from using glass paper and surface treatment
  • Improved heat insulation
  • Improved mechanical / chemical stability

Category Design & Furniture

Gladiator Hybrid Composite Beverage Carrier

AB InBev (Belgium)

https://www.ab-inbev.com/what-we-do/innovation.html

Associated partners : Flex/design (Netherlands) and Hulens Engineering (Belgium)

Gladiator Hybrid is a new & disruptive beverage carr ier which is sustainable, durable and returnable. Aim ing to replace cardboard boxes and plastic crates, the Gladiator brings the best of both worlds.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Reusable, returnable and recyclable
  • Durable at low costs
  • Lightweight and convenient
  • Suitable for the beverage industry
  • High versatility creating branding opportunities

Formcore – PEER Chair

Airex (Switzerland)

https://www.3accorematerials.com

Associated partners : Gaugler & Lutz (Germany) 3A Composites Core Materials (Switzerland), Format Engineers Ltd (UK), KWS GmbH - CUBIC (Austria), troi.composite components (Austria), and the University Innsbruck (Autria)

Formcore is a core material technology, developed for the production of free-formed sandwich elements without the support of costly molds or tools.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • cost neutrality for single items free-formed sandwich elements
  • material saving because of no need for molds
  • weight saving for curved sandwich elements because of resin saving
  • optimized recycling possibilities because of reversible thermal composite proc
  • easily accessible technology due to low tech infrastructure application

Mass-produced flax fibre roofs

Mecelec (France)

https://www.mecelec.fr

Associated partners : IDI (France), IMU (France), JC DECAUX (France), MGI, Polyprocess (France), SF Composites (France), Terre de Lin (France)

The 1st application of flax fibre BMC for mass production. The Morris column dome, was designed, tested & launched in under a year.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Controlled environmental footprint
  • Use of a bio-sourced flax mat
  • Compromise between mechanical properties and optimised costs
  • Rapid market launch
  • Easier mechanical assembly

Category Maritime Transportation & Shipbuilding

Structural Flow Media for infusion process

Chomarat (France)

https://www.chomarat.com

Associated partner :Groupe BENETEAU (France)

G-FLOW™ is an internal ?ow media made with 100% glass ?bers for infusion process. Its innovative design brings unprecedented flow performance and superior mechanical properties. 

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • High isotropic permeability
  • High mechanical performance
  • Less waste, less resin consumption and less disposal cost
  • Good drapability
  • Overall cost savings (labor and material cost savings, reduction of cycle time)


Norsepower Rotor Sail Lightweight Solution

Gurit UK Ltd (UK)

https://www.gurit.com

Associated partners : Comaxel Sp. z o.o. (POLAND), Gurit (Switzerland) & Norsepower Oy Ltd. (FINLAND)

Norsepower Rotor Sail Solution, helps freight and passenger vessels to reduce fuel costs by 5-30 %, by enhancing the propulsion system of a vessel by using wind as an auxiliary propulsion measure.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Reducing fuel costs
  • Reducing emissions
  • Compatibility with environmental regulations
  • Short payback time compared to alternatives
  • Sustainability image benefits

Design-for-disassembly of bonded composite foils

RESCOLL (France)

https://rescoll.fr/

Associated partner: SEAIR (France)

Composite foil for motor boats that can be bonded to the engine to increase the amount of lift produced at the stem and debonded-on-command to allow engine maintenance, reuse or upgrade 

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Smoother and quieter navigation
  • Fuel reduction
  • Reversible assembly method without hales & drilling
  • Quick and reliable disassembly method
  • Clean surfaces after debonding

Category Process

Functional paint films for composite manufacturing

Corso Magenta (France)

https://www.corso-magenta.com

Associated partners: GeM research laboratory - Nantes University (France), Multiplast (France)

In mold application of dry paint film, primer or topcoat, leading to a drastic reduction of cycle time, lower environmental impact, and new functionalization opportunities.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Paint layer functionalization
  • Precise paint thickness control
  • Reduce cycle-time in composite manufacturing
  • Eliminate worker exposure to VOC
  • Reduces painting’s environmental impact

Line for tailored Thermoplastic Composite Blanks

ENGEL AUSTRIA GmbH (AUSTRIA)

https://www.engelglobal.com

Associated partner: FILL GmbH (AUSTRIA)

The line, consisting of a pick-and-place stacking cell and a heating- and-cooling consolidation unit, is capable producing a tailored thermoplastic blank within a cycle time of one to three minutes.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Highly efficient production of thermoplastic tailored composite blanks
  • Tape orientation and thickness variation in the blank for best weight saving
  • Precise control of gap and overlap between tapes using a vision system
  • Base layer and combination of different tape materials are possible
  • The materials and the processing lead to components that are fully recyclable

In-Process Inspection for AFP

FIVES MACHINING (France)

https://www.fivesgroup.com

Associated partner: National Research Council of Canada (Canada)

The Fives/NRC In-Process Inspection Platform is based on an innovative measurement sensor and real time processing software pipeline which facilitates responsive monitoring of the AFP layup process.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Automation of the inspection process
  • Saving up to 30 % of processing time
  • Real time inspection 3D surface profiling and defect detection
  • Inspection process performs concurrently to the part layup
  • Fitting DMAIC standard

Category Railway Vehicles & Infrastructure

COHLE Carbon Catenary Composite Light Rail System

Cecence Ltd (UK)

https://www.cecence.com

Associated partners: Atkins (UK), Brecknell Willis - Wabtec (UK), UK Tram (UK)

A composite overhead line catenary system for Light Rail utilising carbon fibre allowing for an increased aesthetic through a 50% reduction in support poles and no requirement for a tensioning system.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Faster, lighter and more cost effective to install
  • Improved aesthetic through decreased infrastructure clutter
  • Opportunities for more creative design and styling and option for bio composites
  • Reduced maintenance and no requirement for a tensioning system
  • An integrated solution incorporating cabling, support structures and connectors

Project BRAINSTORM

Far-UK Ltd (UK)

https://www.far-uk.com

Associated partners: Composite Braiding Ltd (UK), Transport Design International Ltd (UK) and the Warwick Manufacturing Group - University of Warwick( UK)

Light rail getting lighter! Very lightweight composite tubes in a novel design for light railcar structures produce lower investment and manufacturing costs, as well as reducing carbon emissions.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Significantly lighter than its metallic equivalent
  • Cost competitive in full production to a metallic equivalent
  • Modular design assists repair and all inherently recyclable at end of life
  • Reduction in carbon emissions and infrastructure wear
  • World-leading technology from a British Consortium

DESTINY Thermoplastic resin Train Front end

Stratiforme Industries (France)

https://www.stratiforme.com

Associated partners: ARKEMA (France), ASMA (France), Plateforme CANOE (France), CREPIM (France), IMT LILLE - DOUAI / ARMINES (France) and STELIA COMPOSITES / AIRBUS (France)

The DESTINY project aims to launch a new range of components for commercial aircraft interior fittings and rail applications based on thermoplastic composites.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Parts lightening : 15% weight reduction for equivalent mechanical properties
  • Possibility of end-of-life resin recovery
  • Use of resin respectful with latest health and safety standards
  • Compliance with the regulatory and normative standards for aeronautics and rail
  • Common resin system applicable for external and internal fittings

Category Recycling

Closed Loop Recycling of Epoxy Composites

Cobra international co.,ltd. (Thailand)

https://www.cobrainter.com

Associated partners: Aditya Birla Chemicals Limited - Advanced Materials (Thailand), Starboard Co. Ltd (Thailand), The Maui Fin Company - MFC (USA)

Cobra and Aditya Birla Chemicals present a sustainable solution for closed loop recycling of infused epoxy mould tools and thermoset epoxy RTM watersports fins for Starboard and MFC.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Contributes to circular economy and a sustainable world
  • Groundbreaking thermoset composite recycling
  • End of life recycling and recovery of composite components
  • Closed loop recycling process enabled
  • Production tooling recycled in house

Catering Standard Unit in modular composite design

Comprisetec GmbH (Germany)

https://www.comprisetec.com

Associated partners: CTC GmbH - An Airbus Company (Germany), Helmut Schmidt University - Institute of Manufacturing Technology (Germany), Polynt Composites Germany GmbH (Germany), Spiriant GmbH (Germany), and the Technical University Hamburg - Institute of Polymer Composites (Germany).

The use of special developed SMC enables a weight reduction combined with longer lifetime due to improved robustness. In addition the use of recycled carbon fibres lowers the environmental impact.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Weight reduction
  • Carbon fibre recycling
  • Low CAPEX
  • Noise reduction
  • Flight safety

Ultimate Speedboard

University of Applied Sciences and Arts Northwerstern Switzerland (Switzerland)

https://www.fhnw.ch/en/startseite

Associated partner: On AG (Switzerland)

The product developed is a sole construction for a performance running shoe made out of Sheet Mould Compound (SMC) with recycled carbon fibres from previous aerospace and automotive applications.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Energy storage / return during running
  • Lightweight sole construction
  • Cost efficient material and production
  • Sustainability with recycled carbon fibres
  • Second life of carbon fibres

Category Space

Satellite structure with ampliTex™ and powerRibs™

Bcomp Ltd. (Switzerland)

https://www.bcomp.ch

Associated partners: ESA (Netherlands), IRS Stuttgart (Germany), Quantis (Switzerland), RUAG Space (Switzerland)

A demisable satellite structure panel made from high-performance ampliTex™ and powerRibs™ bio-composite technologies, that meets the stringent requirements of the space environment at TRL5.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Performance: high specific stiffness, lightweight
  • Safer: fast demisability improves ground safety
  • Versatile: radio-transparent, near-zero CTE, high vibration damping
  • Resilient: high resistance against UV, cryo-temp, fatigue and thermal cycling
  • Economical: sustainable and cost efficient materials for a fast- growing industry

Lightweight & Liner-less Carbon Subscale Cryotank

Hankuk carbon., ltd.(South Korea)

http://www.hcarbon.com/eng/

Achieved 30% of the space launch vehicle weight reduction by replacing the current fuel tank to renewal liner-less carbon composites cryotank.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Lightweight
  • Manufacturing technology without liner for Korean satellite launch vehicle type
  • 8-10 times higher impact resistance than steel tank
  • Lower weight

Flax-based thermal protection for space launcher

Linéo SAS (France)?https://eco-technilin.com/fr/

Associated partners: ArianeGroup (France) & CompositAdour (France)

Our innovation is an external thermal protection for space launcher made of composite material based on flax fibers. It is a breaking technology to meet environmental requirements and to reduce costs.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Cost effective
  • Very low density (0.6-0.8 g/cm3)
  • Orientation of the fiber where needed
  • Out of autoclave and cocuring
  • Processable with AFP application

Category Sports & Health Care

Amparo Confidence Socket

Amparo GmbH (Germany)

https://www.amparo.world

Associated partners: Pennstate University (USA), Fraunhofer IAP (Germany), Global Engineering Teams (Germany), Hasso-Plattner-Institut für Digital Engineering GmbH (Germany) & Rensselaer Polytechnic Institute (USA)

Amparo is redefining prosthetic socket technology. Confidence Socket is an innovative off-the-shelf product, that was created to provide a simpler, faster and more economic fitting process.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Cost-effective
  • Faster process
  • Portable tools for remote use
  • Off-the-shelf pre-assembled product
  • Remoldable up to 10 times

Spike-Less CFRTP Sprinting Shoe

ASICS Corporation (Japan)

https://corp.asics.com

Associated partners: Innovative Composite Center of Kanazawa Institute of Technology (Japan), Nagase ChemteX Corporation (Japan) & Suncorona Oda Co.,ltd. (Japan).

A breakthrough shaping methodology using pre-formed randomly- oriented ultra-thin CFRTP tapes: Result=finest detail molding is now possible with CFRTP as accomplished in this spike-less sprinting shoe

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Revolutional spike-less structure was designed for efficient power transmission.
  • Ultra-thin CFRTP tapes were developed by industry's first manufacturing systems.
  • New CFRTP provides the finest detailed moldability and material waste reduction.
  • New CFRTP reduces production cost without sacrificing any mechanical property.
  • Well-balanced combination between lightweight and bending stiffness

Automated production hybrid composite bike frames

REIN4CED (Belgium)

https://www.rein4ced.com

Associated partners: bicycle brand - customer of REIN4CED (Belgium), Celanese International Corporation (USA), Dieffenbacher GMBH Maschinen- und Anlagenbau (Germany), Fraunhofer Institute for Chemical Technology (ICT) (Germany), KU Leuven (Belgium), Netherlands Aerospace Centre (NLR) (Netherlands), Toray Advanced Composites (Netherlands), Van Wees UD and Crossply Technology (Netherlands).

Intelligent & optimized composite design capabilities with innovative hybrid material concept for tough composites. Fully automated production process for cost-efficient high-performance CFRTP parts.

(c) 2020 JEC
(c) 2020 JEC


Key benefits

  • Lightweight hybrid thermoplastic composite material
  • High performance and tough (impact-resistant) bicycle frames
  • One-stop-shop for the supply chain: from design to manufacturing in Europe
  • High reproducibility and full traceability
  • Increased safety for workers (production) as well as cyclists (end consumers)



 




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