#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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Novel flame-retardant and recyclable fiber-reinforced composite

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WHILL selects Teijin’s tough, lightweight Carbon Fiber Composite for new last-mile mobility

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Fewer pores, greater impact tolerance: Peter Dornier Foundation Prize 2026 honours material research on fibre-reinforced composite components for aerospace industry

Microscopically small pores that form during manufacture, or barely visible impact damage, can severely impair the load-bearing capacity and service life of fibre-reinforced composite components. Two young researchers have presented groundbreaking work in this field and will both be awarded the 2026 Peter Dornier Foundation Prize: Dr.-Ing. Benedikt Neitzel from the Technical University of Ilmenau for his doctoral thesis on pore minimisation in the RTM process, and Johanna Buschmann, M.Sc., for her master’s thesis, completed at the German Aerospace Centre, on the improved impact tolerance of 3D fabrics compared to 2D laminates.

YKK subsidiary Golden Hill Tower Limited marks 25 years of operations in Myanmar

Golden Hill Tower Limited, a subsidiary of YKK Corporation, celebrated its 25th anniversary with a ceremony in Myanmar on September 21, 2026. The event brought together approximately 230 guests, including senior executives from the YKK Group, to commemorate the company's development since the launch of its serviced apartment business in November 2000.

SHIMA SEIKI to showcase digital product creation at Apparel Sourcing Week

Leading digital textile solutions provider SHIMA SEIKI MFG., LTD. of Wakayama, Japan will exhibit at Apparel Sourcing Week 2026 in Bengaluru, India next month. The exhibition provides a platform for the entire apparel value chain, bringing together manufacturers, brands, suppliers and solution providers in one location.

SNA GZ accelerates its on-demand production strategy with Kornit Digital

SNA GZ is leveraging the Kornit Atlas MAX PLUS to expand its music merchandise production, streamline e-commerce order fulfillment, and grow its print-on-demand business across Europe. This investment increases SNA GZ's textile production capacity by 150% (2.5×), enabling the company to meet growing demand and support its continued expansion.

NEUMÜHLE launches mono-material hoodie designed for textile recycling

With the Circular Mono Hoodie, Zurich-based label NEUMÜHLE introduces a new essential designed around a single-material principle. The textile construction is cotton throughout, right down to the sewing thread. Entirely free from elastane, the hoodie launches as a Limited Drop for CHF 139. Take-back, collection and existing recycling partnerships complement its circular design.