JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 31

Thermoplastic composites: the path towards zero CO2
In the fi eld of numerical simulation tools,
major progress has resulted in more reliable
engineering than ever. With the aim of reducing
the time-to-market of TPC materials,
R&D actions are needed to establish a clear,
achievable road map towards the decarbonisation
of EU transport. Th ree strategic pillars
are required to meet this goal. Th e fi rst pillar
is the high processing temperature. Automated
high-speed processing of TPC helps
reduce production cycle times. Nevertheless,
higher temperatures are needed to process the
high-performance thermoplastics being investigated
in the aerospace industry (e.g., PEEK,
LMPAEK and PEKK). Th e second pillar is
the strong dependence on fossil-based constituents
(polymers, fi bres, cores). Bio-based
sourcing is still a controversial topic and the
regulations and steps required for material certifi
cation have not been completed. Further
research is necessary to improve our knowledge
of renewable resources for biocomposites
in order to speed up their maturity and
reduce the current gap. Last but not least, the
third pillar involves the introduction of functionalities
in composite materials to reduce
the weight of structural parts and components
for electrifi cation of all forms of transport and
to develop sustainable composite materials for
applications in mobility, such as fi re retardants,
electrical and thermal conductivity, and electromagnetic
shielding.
The SMART5G project for smart mobility
Th e introduction of vehicle electrifi cation
currently calls for a combination of customisable
functionalities to improve the mechanFocus
Th
e SMART5G consortium is made up of
ITERA Mobility Engineering, ELIX Polymers,
AIMPLAS and the Universitat de
València. Th e SMART5G project is conducted
within the framework of the national funding
programme Smart Strategies for Urban
and Metropolitan Mobility under number N
B97620496.
emissions in transport
Focus
The LIGHTCAR project
The LIGHTCAR project is connected to the Smart
Specialisation Strategy of the Valencian Community,
known as RIS3, which is coordinated by the Regional
Ministry of Innovation, Universities, Science and Digital Society. It is specifi cally
connected to companies involved in manufacturing processes, the automotive
and mobility industry, and capital goods. The LIGHTCAR consortium is made up of
Industrias Alegre acting as coordinator, ITERA Mobility Engineering, Sinfi ny Smart
Technologies and AIMPLAS. This project is co-funded by the Valencian Innovation
Agency (AVI), under the Strategic Projects in Cooperation programme.
ical, fi re-retardant, radome and electromagnetic
shielding properties of the batt ery pack
while simultaneously reducing its weight and
cost, improving its safety mechanism, and
increasing batt ery range. AIMPLAS is participating
in the SMART5G project, which is
totally aligned with the sustainability, weight
reduction and safety of the next generation
of electric vehicles for the urban mobility
industry. Th e SMART5G project addresses
new technologies for promoting sustainable,
connected, safe and smart mobility applied
to private and delivery vehicles, which will
reduce CO2
emissions while guaranteeing
user safety. Within the project, thermoplastic-based
electronic housings made of long
fi bre thermoplastic pellets, ABS reinforced
with carbon fi bre, with dual functional properties
such as fl ame-retardant additives and
EMI particles, will be developed to guarantee
fl ammability properties and EMI shielding
in the range of 5 GHz. Finally, a batt ery
module will be manufactured to validate the
material processability and advanced properties
achieved for upcoming mobility market
requirements.
The LIGHTCAR project,
reducing total battery
pack weight up to 70%
In line with the goal of reducing the weight of
parts in the automotive industry, AIMPLAS is
leading development of thermoplastic composites
within the LIGHTCAR project with
the aim of equipping polypropylene and polyamide
polymer matrices reinforced with long
carbon fi bres with the key functionalities of
fi re retardancy and EMI shielding. Unidirectional
reinforced tapes will be used to replace
the metal batt ery pack with a lighter material
to reduce the total weight of the part by up to
70%. In order to share the results with industry
and implement them, the LIGHTCAR project
is also focused on designing a high-speed,
fl exible production cell to manufacture parts
with the novel materials developed. Th e cell
will have the capacity for automated integration
of electronic components without losing
sight of material sustainability and recyclability,
as well as optimisation of costs and resources
in the manufacturing process itself.
Th e steps in the LIGHTCAR process are
shown in the following fl ow chart:
More Information
www.aimplas.net
References
[1] https://www.marketwatch.com/
press-release/composites-marketsize-share-growth-trends-andforecast-2022-2030-2022-03-17
[2]
Advani, S. G., and Hsiao, K. T. (2012).
Manufacturing Techniques for Polymer Matrix
Composites (PMCs). Oxford; Cambridge;
Philadelphia, PA; New Delhi: Woodhead
Publishing Ltd
[3] Advanced thermoplastic composites
and manufacturing processes Krawczak,
Patricia; Maffezzoli, Alfonso | Frontiers Media
Frontiers in materials, 2020-07-09, Vol.7,
p.166
N°147 September - October 2022 / jec composites magazine
31
Feature Automotive
http://www.aimplas.net

JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022

Cover
Edito
Creating the interior of “The most beautiful building in the world”
Contents
NEWS
In brief
Agenda
Perspectives - Creating a forum to work together
Opening - New fibreglass factory in the heart of Central Asia
BUSINESS
Graphene - Effectiveness of graphene nano-platelets in composites
Carbon fibre - Sinopec intends to lead by example in China
Glass fibre - China promotes the use of glass fibre in construction
MANUFACTURING
Additive manufacturing - Towards a digital twin of UD tapes for automated fibre placement
Testing - Optical data rectification and ML-aided impedance analysis for quality assurance of carbon fibre
FEATURE AUTOMOTIVE: How are composites driving the future of automotive?
- Transportation - Thermoplastic composites: the path towards zero CO2 emissions in transport
- Compounding: Cutting-edge FDC technology reduces costs and CO2 emissions
- Pressure vessels: Enabling superior storage efficiency for Type 4 tanks with FPP dome reinforcements
- Battery: A new generation of battery packs with a recyclable epoxy SMC casing
- Lightweighting: Serial CFRTP structural part for BMW body-in-white application
- Natural fibre: Towards lightweight flax fibre-reinforced automotive headliners
SOLUTION
Sustainability - Upcycling gives a boost to coffee waste management
Defence - On field applications with composites
TECHNOLOGY
Ceramic: Cerapreg – a new concept for cost-effective reinforced ceramic composites
Index
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JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Cover
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 2
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Edito
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Creating the interior of “The most beautiful building in the world”
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 5
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Contents
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 7
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - In brief
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Agenda
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Perspectives - Creating a forum to work together
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Opening - New fibreglass factory in the heart of Central Asia
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 12
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 13
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Graphene - Effectiveness of graphene nano-platelets in composites
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 15
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 16
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Carbon fibre - Sinopec intends to lead by example in China
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 18
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 19
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Glass fibre - China promotes the use of glass fibre in construction
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 21
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 22
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Additive manufacturing - Towards a digital twin of UD tapes for automated fibre placement
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 24
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Testing - Optical data rectification and ML-aided impedance analysis for quality assurance of carbon fibre
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 26
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 27
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 28
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 29
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Transportation - Thermoplastic composites: the path towards zero CO2 emissions in transport
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 31
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Compounding: Cutting-edge FDC technology reduces costs and CO2 emissions
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 33
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 34
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Pressure vessels: Enabling superior storage efficiency for Type 4 tanks with FPP dome reinforcements
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Battery: A new generation of battery packs with a recyclable epoxy SMC casing
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 37
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 38
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 39
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Lightweighting: Serial CFRTP structural part for BMW body-in-white application
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 41
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 42
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 43
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 44
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Natural fibre: Towards lightweight flax fibre-reinforced automotive headliners
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 46
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 47
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Sustainability - Upcycling gives a boost to coffee waste management
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 49
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Defence - On field applications with composites
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 51
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Ceramic: Cerapreg – a new concept for cost-effective reinforced ceramic composites
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 53
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 55
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 56
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