JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 11

JEC innovation Awards Winners 2018

NEWS

Aerospace - Process
Moldless process to manufacture one-piece parts
Winner: M. Torres Diseños Industriales SAU (Spain)

MTorres developed a new manufacturing process for large composite structures with fullyintegrated reinforcements in a final single part. The process introduces a new mould-less approach,
where elementary composite components are prefabricated and joined together to create an initial structure geometry that acts as a mould for the
external structural skin. The initial structure then remains inside the final product as an additional structural component. This allows for a co-curing
process for both the skin and the initial components, creating a single final structure. Initially focused on the manufacturing of fuselages, the process
offers relevant weight savings for the final structure due to:
- The elimination of fasteners inside the structure;
- A critical reduction in the manufacturing costs,
- More flexible geometry and reinforcements consuppressing most of the assembly tooling needfiguration;
ed for such a structure.
The innovation in two lines : New manufacturing process for large monocoque composite structures with fully-integrated reinforcements and
without the need for complete moulds.

Aerospace - Process
Complex structural applications
for MAI sandwich technology

Winner : Airbus (Germany) and its partners, BMW Group (Germany), Technical University of Munich
(TUM) (Germany), Neue Materialien Bayreuth GmbH (Germany), Werkzeugbau Siegfried Hofmann
GmbH (Germany), BASF SE (Germany), Foldcore GmbH (Germany), Neenah Filtration (Germany)
and SGL Carbon GmbH (Germany)
Based on the concept design from the early stage of the project, a cross-industry net-shaped 2.5D sandwich demonstration part was created, including an injection-moulded surface feature. The project team, with partners along the process chain, responded to the demand to produce this
challenging part for structural applications based on carbon fibre-reinforced thermoplastic materials. The first trials showed that even unidirectional non-woven skin layers loft during the process when the material is in the molten state, which is needed to achieve the required drapeability and
bonding with the core layer. To prevent these unacceptable voids from occuring in a structural part, a new process was designed.
The innovation in two lines : Production of a cost-effective, complex 2.5D thermoplastic composite sandwich structure with a very short cycle
time of less than 5 minutes for aerospace materials and 2.5 minutes for automotive materials.

Automotive - Process
Series production of a rear panel module
made of carbon composite
Winner : Audi AG (Germany) and its partners, Voith Composites GmbH & Co. KG (Germany), Dow
Automotive (Switzerland), and Zoltek Corp. (United States)
The innovation presented is the new Audi A8 carbon rear wall structure, which was successfully developed together with Voith, Dow and Zoltek
in a very short time and produced in a fully-automated serial production with capacity for more than 300 parts/day. In terms of overall dimensions, the ultra-high-strength, torsionally-rigid rear wall made of carbon fibre-reinforced plastic (CFRP) is the largest component in the occupant cell of the new Audi A8. It contributes 33% to the torsional rigidity of the total vehicle and is still 50% lighter than before. Between 6 and 19
fibre layers with individual orientations are stacked one on top of the other. This ensures a load-optimized layout to optimally absorb longitudinal and transverse loads as well as shear forces.
The innovation in two lines : A structural composite suspension component producing significant weight savings using an industry-first patented prepreg/SMC/steel overmoulded manufacturing process, designed applying newly developed computer-aided engineering (CAE) technology.

N°121 May - June 2018 /

jec composites magazine

11



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #121 - May 2018

Cover
Edito
Opinion: Lighter, faster, smarter
Contents
NEWS
In brief
JEC World 2018 Report
JEC World 2018 gathered the whole composites industry in Paris
JEC innovation Awards Winners 2018
Startup Booster - A springboard for innovative talents
Injection - lnjection moulders who have made bioplastics work
Agenda
BUSINESS
Acquisition - Huntsman acquires Nanocomp Technologies
Simulation - "We want to bring the story of composites to the end user in a different way"
Trends - Overview of the North Amaerican composites market
MANUFACTURING
Additive manufacturing - The Energica dashboard reinvinted through professional 3D printing and composite materials
Prototyping - Injection moulding: running tests earlier with 3D printing
Mass-production - Fast RTM: a techincally and economically optimised solution
Covers - Opportunities for composite profiles in the residential housing market
SOLUTIONS
Building - CompoHouse, the demonstration building made of composites
Construction - Textile concrete makes thin, large-sized curtain walls possible
In the world
TECHNOLOGY
Multi-material - High-confidence performance predictions for hybrid thermoplastic composite applications
Experimental techniques - 3D tectile-reinforced composites: from manufacturing to structural design
Index
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JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Cover
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 2
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Edito
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Opinion: Lighter, faster, smarter
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 5
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Contents
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 7
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - In brief
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 9
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - JEC innovation Awards Winners 2018
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 11
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 12
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 13
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 14
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 15
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 16
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 17
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 18
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 19
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Startup Booster - A springboard for innovative talents
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Agenda
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 22
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 23
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Acquisition - Huntsman acquires Nanocomp Technologies
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 25
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Simulation - "We want to bring the story of composites to the end user in a different way"
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 27
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Trends - Overview of the North Amaerican composites market
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 29
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Additive manufacturing - The Energica dashboard reinvinted through professional 3D printing and composite materials
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 31
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Prototyping - Injection moulding: running tests earlier with 3D printing
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 33
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Mass-production - Fast RTM: a techincally and economically optimised solution
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 35
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 36
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 37
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 38
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 39
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 40
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 41
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 42
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 43
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 44
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 45
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 46
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 47
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Covers - Opportunities for composite profiles in the residential housing market
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 49
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 50
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 51
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 52
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 53
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 54
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 55
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Building - CompoHouse, the demonstration building made of composites
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 57
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 58
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Construction - Textile concrete makes thin, large-sized curtain walls possible
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - In the world
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 61
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Multi-material - High-confidence performance predictions for hybrid thermoplastic composite applications
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 63
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 64
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 65
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 66
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Experimental techniques - 3D tectile-reinforced composites: from manufacturing to structural design
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 68
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 69
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 71
JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 72
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