#Composites

2020-11-19

SGL Carbon and Koller Kunststofftechnik manufacture composite windshield for BMW Group

Skeletal windshield design based on injection molding with carbon fiber profiles (Source: Composites united)

Already in August, SGL Carbon received a multi-year order from Koller Kunststofftechnik GmbH for the production of novel carbon fiber profiles for serial use in windshields for a future high-volume model of BMW Group.

Carbon fibers combined with injection molding replace conventional steel construction

SGL Carbon supplies innovative carbon fiber profiles

Serial use in a future high-volume model of BMW Group

Construction method offers great potential for use in other automotive projects

The profiles are particularly flexible fiber tows, pre-impregnated with thermoplastic resin in various dimensions. They will be compiled by SGL Carbon on the basis of its own 50k carbon fiber at its site in Innkreis, Austria, and subsequently processed by the injection molding experts at Koller to form a skeletal plastic component. The composite component will replace the previous steel-based windshield. Production of the carbon fiber profiles will start in the remainder of 2020 and will then be ramped up gradually over the next few years for the BMW Group model launch.

In the vehicle, the windshield is a connecting element between the roof frames and thus has an important stabilizing function. The carbon fiber profiles add the required stiffness and crash safety to the component. At the same time, they help to significantly reduce the weight of the roof and thus also support the driving dynamics. The injection molding process also enables particularly complex and material-efficient structures. In the BMW Group model, this innovative component concept will cut weight by 40 percent compared to conventional steel designs of the component while creating important space for cable ducts and sensors.

The production of the carbon fiber profiles themselves is also particularly geared to material and process efficiency in large-scale production. The profiles consist of several smaller fiber strands, the so-called rods, and are manufactured using the modern continuous pultrusion process. During product and process development it was one key objective to ensure that material loss during production is almost completely avoided.

"At SGL Carbon, we have been working on the development of thermoplastic carbon fiber profiles for use in injection molding for some time already. This development work is now beginning to pay off. Due to the many advantages and competitive costs, we see a great potential for the technology to be used in other automotive projects too," explains Sebastian Grasser, Head of the Automotive Segment in the Business Unit Composites - Fibers & Materials at SGL Carbon.

Thermoplastic carbon fiber profiles and tape of SGL Carbon (Source: Composites united)

"Innovative lightweight construction with hybrid designs has developed into a strategically conclusive concept for Koller Group's OEM customers," confirms Max Koller, CEO of Koller Group. "SGL Carbon's high level of material expertise, combined with the process know-how of KOLLER Kunststofftechnik and KOLLER Formenbau, create the basis for a promising future in innovative lightweight construction technologies. With this order, the BMW Group has confirmed its confidence in the successful cooperation between SGL and Koller; we are particularly pleased about this", said Max Koller.? ?The Koller Group is a globally operating technology company with plants in Europe and China, as well as NAFTA. The Koller Group develops and manufactures lightweight construction, tools and serial components, primarily for the automotive industry.

SGL Carbon decides to restructure its Carbon Fibers business unit

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SGL Carbon evaluates strategic options for the carbon fibers and appoints Dr. Denis Hinz as new head of the business unit

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MEL Composites supports ELA Aviation with advanced composite materials

MEL Composites is supplying advanced composite materials and process consumables to ELA Aviation for the production of its next-generation gyroplanes. The collaboration underlines MEL Composites’ growing role in advanced aerospace mobility, providing lightweight materials designed to improve aircraft performance, manufacturing efficiency and structural reliability.

DYNEEMA® and NP Aerospace advance personal protection for military servicewomen

Dyneema®, owned by Avient Corporation, an innovator of materials solutions, is supplying its high-performance unidirectional (UD) materials to world-leading armor manufacturer NP Aerospace, enabling the production of armor systems designed specifically to fit the female body. With 2,000 new armor systems, including 4,000 plates, made in the United Kingdom (UK) and delivered in June 2026, this collaboration addresses a long-standing lack of high-quality personal protection specially built for female defense and security personnel.

JEC World 2026 confirms its standing as the unmissable event for composites and their applications

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Cotton made in Africa partners receive top marks in independent verifications

Cotton made in Africa® (CmiA) and CmiA Organic are two internationally recognised standards that aim to promote sustainable development in the African cotton sector south of the Sahara. To ensure the standards’ credibility among brands, retailers, and consumers, independent verifiers evaluate compliance on the ground. The verification results for 2025, now published in the Aggregated Verification & Implementation Report, were very strong: The verifiers awarded consistently very good remarks regarding management, people, prosperity, and the environment.

Bangladesh: Italian textile machinery mission stops in Dhaka and Chittagong

Technological upgrading and the transition toward higher value-added production are driving the new Italian industrial mission to Bangladesh. This year, the mission will split between the country’s two main manufacturing hubs, where Italian manufacturers will meet the leaders of the local textile supply chain in two strategic stages: July 7th in Dhaka and July 9th in Chittagong.

Yarn Expo Shenzhen 2026 closes doors, advancing sustainable and innovative sourcing in South China

Yarn Expo Shenzhen 2026 served as a strategically positioned mid-year sourcing platform for the Greater Bay Area, highlighting Shenzhen’s role in connecting regional demand, supply and innovation exchange across the textile value chain. During the three-day fair, over 20,000 visits were drawn from 74 countries and regions[1], as exhibitors and buyers engaged with new developments in greener, performance-led, and value-added yarn and fibre solutions. Held in conjunction with Intertextile Shenzhen Apparel Fabrics and PH Value, the fair underscored the benefits of closer synergy and new materials across yarn, fabric and apparel platforms for the South China market.