#Yarn & Fiber

2020-12-03

Continental Structural Plastics perfects carbon fiber RTM process, launches production programs

After winning a JEC Innovation Award in 2016 for its Lincoln MKS Decklid Concept – a TCA Ultra Lite® outer panel and a carbon fiber RTM prototype inner – Continental Structural Plastics (CSP) has fine-tuned its carbon fiber RTM (CF-RTM) process to the point that a premium automaker will be using the technology for closures on future vehicle platforms. These doors will feature both inner and outer panels as well as structural reinforcements molded using CSP’s advanced CF-RTM process.

When CSP set up its Center of Excellence for Lightweight Technologies and Carbon Fiber Processes in Pouancé, France, in 2013, the goal was to develop processes to make the use of carbon fiber in high volume applications affordable and feasible. Since then, the CSP team in Europe has been working on developing a high-performance CF-RTM process that would result in high-strength, ultra-light-weight components to help OEMs address stringent CO2 emissions regulations. Specifically, the team has been focused on improving cycle time, utilizing automated preforming and lowering the cost of the carbon fiber materials.

“We have been targeting a 3-minute cycle time using 100 percent recycled carbon fiber. With our multi-material decklid concept, we demonstrated this was totally possible,” said Marc Philippe Toitgans, director, Research & Development CSP Europe. “Now we are proud to say we have collaborated with major OEMs in the United States and Europe on carbon fiber RTM programs and will see the first commercial applications of this technology very soon.”

From CAE analysis, flow simulation, preform process, mold design and full automation, CSP has built best-in-class expertise to support major structural and Class A CF-RTM programs for closures and other BIW applications. CSP’s key differentiators are based on:

100 bars of injection pressure, and up to 1,500 tons of pressure for closure applications

High fiber content (greater than 50%) for structural applications

20-second injection time

Management of variable thicknesses

Weight savings of up to 30% when compared to aluminum

To support several carbon fiber RTM programs that will begin as soon as the end of 2020, CSP and parent company Teijin are investing in a dedicated CF-RTM production line in Palmela, Portugal. The initial investment of €5.5 million will include the installation of compression presses, RTM injection units and a bonding cell.

“We are excited to be working hand-in-hand with our customers in Europe to demonstrate our RTM capabilities,” said Ricardo Barros, CSP/Inapal program manager. “The level of industrialization and automation we are installing in Palmela is second to none for similar carbon fiber applications.”

In addition to reducing component weight and cycle times, the CSP team in Europe has been pursuing a number of methodologies that will result in more sustainable manufacturing processes. Working toward a net zero emission target, CSP Europe is working on tomorrow’s CF-RTM process with a primary focus on natural or recycled fibers, thermoplastic/bio-sources, advanced resins, and reduced scrap and waste.

“Our goal is to keep working on a sustainable value proposition with a focus on net zero CO2 emissions,” said Philippe Bonte, president, CSP Europe. “We will achieve this via advanced manufacturing technologies and the use of renewable materials with the aim of becoming a positive contributor to the global environment.”

“Production is a product”

From technical textiles and AI-driven robotics to the limitations of textile circularity: Professor Dr Thomas Gries looks back on more than two decades of development at ITA Aachen. In the interview, he explains why production technology remains a decisive success factor, discusses international collaborations and innovation ecosystems, and shares his views on the transformation of production landscapes and the challenges facing an increasingly regulated industry.

“We need to move away from the price trap and return to a value-driven mindset.”

With its new Textile Innovation Center, KARL MAYER is sending a strong signal for innovation, collaboration, and the future of textile applications. In this interview, Karl Josef Mayer discusses new opportunities in warp knitting, the processing of staple fibres, recycling, the changing role of machinery manufacturers, and why the textile industry must once again focus more strongly on the value of textiles. by Oliver Schmidt

“Innovation, resilience and international experience remain the great strengths of the Swiss textile machinery industry”

Geopolitical uncertainty, growing competitive pressure from China, new free trade agreements and the shift towards a circular economy are currently reshaping the global textile industry. In this interview, Cornelia Buchwalder discusses the current mood within the Swiss textile machinery sector, the industry’s distinctive innovative strength, new market opportunities in India and Asia, and the technological trends that could shape the upcoming trade fair cycle leading up to ITMA 2027.

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.

Grasim Industries announces fresh investment of ₹3094 Crore to expand Lyocell capacity

Grasim Industries Limited, the flagship company of the Aditya Birla Group and a global leader in cellulosic fibres, today announced an investment of ₹3,094 crore, for Phase II Lyocell capacity of 110K TPA at Harihar, Karnataka. This expansion will consist of 2 lines of 55K TPA (150 Tons per day) each. The first line is expected to be commissioned by 2028, and the second line is expected to be commissioned by 2030.

EDANA launches landmark continence report to mark the start of the World Continence Week

Today marks the official commencement of the World Continence Week. To honour this global awareness initiative, EDANA has published a comprehensive report titled "The Central Role of Absorbent Hygiene Products in the Management of Adult Urinary Incontinence: Benefits, Costs and Environmental Impact." The World Continence Week (WCW) is an annual global initiative dedicated to raising public awareness about incontinence and bladder or bowel health issues. Traditionally held in June, this awareness week aims to shed light on a condition that affects millions of people worldwide but is frequently kept secret due to widespread social stigma, embarrassment, and taboo.

Mario Jorge Machado re-elected President of EURATEX

The EURATEX General Assembly has re-elected Mario Jorge Machado as President of EURATEX, renewing its confidence in his leadership at a crucial moment for the European textile and clothing industry. The sector is facing rising costs, global competitive pressure and an increasingly challenging transition towards sustainability and digitalisation.

ITM 2026 makes happy participants with its international and qualified visitor profile

ITM 2026 International Textile Machinery Exhibition, one of the most prestigious meeting points of the textile machinery sector, attracted attention in its first three days, particularly with its diverse international visitor numbers. Industry professionals from all over the world had the opportunity to closely examine the latest technology machines and solutions displayed in operation. Thousands of visitors from approximately 100 countries, primarily Egypt, Pakistan, India, Uzbekistan, Syria, Turkmenistan, Tajikistan, Morocco, Algeria, and Tunisia, met at the Tüyap Fair and Congress Center for new investment and cooperation opportunities.

KARL MAYER presents a textile TEXTRONIC® innovation at ITM 2026

With highly efficient machines and continuous textile innovations, KARL MAYER underscores its role as a reliable partner for discerning top-tier customers. Just in time for ITM 2026 in Istanbul, the industry leader is introducing a true innovation: an eyelash lace with its characteristic fringed look – combined with a previously unattainable 4-way stretch. While the established fabric could until now only be produced as rigid version or with one-dimensional stretch, the new elasticity in both dimensions expands the possibilities for cross-band panel fabrics.