JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 125

To new horizons, with composites

In early 2019, Pilatus greatly expanded its capacity for cutting
prepreg materials with a new Zünd G3 L-2500 cutting system.

a production run of 500 planes.
Its successor, the PC-12, which
has been sold globally more
than 1,650 times since 1994,
is the most popular single-engine turboprop aircraft on the
market.
Pilatus began using carbon-fibre parts early on in its history
of manufacturing airplanes.
Already for the PC-6, first
GFRP and CFRP components
were laid up by hand, albeit
still in limited quantities.
In the aircraft industry, almost
everything revolves around
weight reduction. As a result,
more and more parts are made
from carbon and glass fibre.
Major advantages of these
materials are their high rigidity
and toughness, as well as their
wear resistance. The challenge,
however, lies in balancing
weight, stability, and cost. "In
addition, there are factors such
as payload and usable space
that have to be maximized as
much as possible." At Pilatus,
no load-bearing parts are made
of CFRP, but the company's
R&D is busy working on that.
The PC-24 uses composites
mainly for interior and exterior
cladding. The engine casings
and wingtips are also made
of carbon fibre, as are landing
gear doors, air ducts, various

pipes, covers, and trailing
edges on wings.
Prepreg, the future
of aircraft manufacturing
The starting point for these
aircraft parts is pre-impregnated carbon fibre. Endless,
pre-impregnated fibres are
consolidated through pressure
and high temperature. These
prepregs offer high durability
and rigidity, are flame retardant, and resistant to fatigue and
environmental degradation.
Prepreg is delivered in rolls by
refrigerated trucks and stored
in freezers at -19 degrees C
(-2.2 F).
The material is taken out of
the cooler the night before to
bring it to room temperature
for processing. It can remain
at room temperature for five to
20 days before the resin begins
to react and cure. Pilatus
processes around five rolls of
approximately 90 m2 daily, or
about 90,000 m2 per year. The
rate of consumption is steadily
increasing: today, more than
half of all CFRP and GFRP
components produced in the
company's plastics department
are installed in the new PC-24.
For cutting prepreg, Pilatus has
relied on Zünd digital cutting
for more than 15 years. The

The cut pieces
are kitted and
stored at -19°
Celsius.

PN-series cutter purchased at
the time continues to reliably
perform its duties; however,
increased demand for carbon-fibre components began
to exceed capacity, which led to
the addition of a state-of-theart Zünd G3 L-2500 in 2019.
The G3 system single-ply cuts
materials for the respective
components in a largely automated process, and labels cut
pieces with an integrated inkjet
module.
Once cutting is completed,
the parts are kitted and put in
cold storage until further processing. Depending on rigidity
and strength requirements, a
component can consist of up
to 350 layers. If no DXF file
is available for parts or their
individual layers, a digitizer
comes into play to allow for
easy capture and digitization
of part templates placed on
the digitizing table. Even
minor changes to components
previously released by the
engineering department can be

N°133 March - April 2020

easily carried out and digitized
using this system.
Material efficiency
is always a concern
Another factor in Pilatus'
success has been the focus
on implementing permanent
productivity increases.
Patrick Rohrer explains: "When
dealing with cost-intensive materials such as carbon or glass fibre,
material efficiency and optimization are always a concern. We are
constantly working to increase
utilization and thereby reduce
waste - particularly since we
still have few options for recycling". In the meantime, waste
rates have been reduced from
30% to 20%. The highly efficient nesting features in Zünd
Cut Center-ZCC software play
an important role in this.
Cut parts are statically nested,
which means that parts, or
rather their individual layers,
are nested to create a set layout
used repeatedly to complete
the entire job. To further in-

/ jec composites magazine

125



JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020

Cover
Edito
“For the past 130 years, every aspect of tire performance has been improved, except for one”
Contents
NEWS
In brief
Agenda
Aerospace
BUSINESS
Strategy - Selling your business, Part 1: maximizing value on both sides of the deal
Trends - Automotive: what will be tomorrow’s reality?
Boatbuilding - Maritime and shipbuilding sector: a niche market with growth potential
China - China’s glass fibre industry is entering a new cycle
MANUFACTURING
Fabrics - GaplessWeave process for higher-quality carbon fibre fabrics
Electric vehicle - The potential of epoxy SMC in electro-mobility battery systems
Simulation - New updates for the Composite Materials Module’s users
Aerospace - lnfused primary structures: the gateway to tomorrow’s air mobility
Aircraft interiors - New core filler for aircraft interiors: reduced material, weight and manufacturing costs
Sustainability - Eco Impact Calculator, a Life Cycle Assessment tool for the composites industry
PREVIEW JEC WORLD 2020
- EDUCATION & KNOWLEDGE
- MARKET OVERVIEW / Fact & figures
- AT THE FOREFRONT IN JEC WORLD 2020
- VIEW FROM THE TOP
- INNOVATION
- SUSTAINABILITY
- END-USE MARKETS
- PROCESS & AUTOMATION
- INTERNATIONAL
SOLUTIONS
Book - Composites in infrastructure
Construction - Composites joining science and religion
Urban equipment - Composite infrastructure products: a new alternative for the construction industry
Aeronautics - To new horizons, with composites
Aeronautics - Thermoplastic composite bracket for aircraft engines
Off shore wind energy - Taming the offshore winds
Biocomposites - Where are natural fibre composites heading?
Natural fibres - The challenges of building large structures from flax fibre composite
TECHNOLOGY
Resin - Properties and composite applications of nanocalcitemodified epoxies
Inside the lab - Architected Material and Structures (AMS), a team from Navier Laboratory (Ecole des Ponts ParisTech/IFSTTAR/CNRS)
FMEL - Fibre-metal elastomer laminates – Lightweight components with superior damping characteristics
Index
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - CF
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - CB
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - “For the past 130 years, every aspect of tire performance has been improved, except for one”
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 10
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Aerospace
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Strategy - Selling your business, Part 1: maximizing value on both sides of the deal
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 16
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Trends - Automotive: what will be tomorrow’s reality?
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 18
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 19
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Boatbuilding - Maritime and shipbuilding sector: a niche market with growth potential
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 21
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - China - China’s glass fibre industry is entering a new cycle
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 24
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Fabrics - GaplessWeave process for higher-quality carbon fibre fabrics
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 26
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 27
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Electric vehicle - The potential of epoxy SMC in electro-mobility battery systems
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 30
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 31
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Simulation - New updates for the Composite Materials Module’s users
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 33
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Aerospace - lnfused primary structures: the gateway to tomorrow’s air mobility
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 36
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Aircraft interiors - New core filler for aircraft interiors: reduced material, weight and manufacturing costs
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 38
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Sustainability - Eco Impact Calculator, a Life Cycle Assessment tool for the composites industry
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 40
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 41
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 42
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 44
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - EDUCATION & KNOWLEDGE
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 46
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - MARKET OVERVIEW / Fact & figures
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - AT THE FOREFRONT IN JEC WORLD 2020
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 50
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 51
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - VIEW FROM THE TOP
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 54
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - INNOVATION
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 59
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 62
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 64
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 66
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 68
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 69
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - SUSTAINABILITY
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 71
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - END-USE MARKETS
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 73
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 74
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 75
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 76
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 77
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 78
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 79
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - PROCESS & AUTOMATION
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 81
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 82
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 83
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 84
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 85
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 86
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 87
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 89
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 90
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - - INTERNATIONAL
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 92
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 93
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 94
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 95
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 105
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 108
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 110
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 111
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 112
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 113
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 114
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Book - Composites in infrastructure
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 116
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 117
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Construction - Composites joining science and religion
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 119
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 120
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 121
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Urban equipment - Composite infrastructure products: a new alternative for the construction industry
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 123
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Aeronautics - To new horizons, with composites
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 125
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 126
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Aeronautics - Thermoplastic composite bracket for aircraft engines
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 128
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Off shore wind energy - Taming the offshore winds
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 130
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 131
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 132
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Biocomposites - Where are natural fibre composites heading?
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 134
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 135
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Natural fibres - The challenges of building large structures from flax fibre composite
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 137
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 138
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Resin - Properties and composite applications of nanocalcitemodified epoxies
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 140
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 141
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 142
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 143
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 146
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 147
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Inside the lab - Architected Material and Structures (AMS), a team from Navier Laboratory (Ecole des Ponts ParisTech/IFSTTAR/CNRS)
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 149
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 150
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - FMEL - Fibre-metal elastomer laminates – Lightweight components with superior damping characteristics
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 152
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 153
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 155
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JEC COMPOSITES MAGAZINE - Issue #133 - March/April 2020 - 158
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