New Developments in Carbon Fibre Textiles - easyfairs.com · in the conversion of carbon fibre to...
Transcript of New Developments in Carbon Fibre Textiles - easyfairs.com · in the conversion of carbon fibre to...
New Developments in Carbon Fibre Textiles
Advanced Materials ForumThursday 1st November 2018
Paul McMullanCommercial ManagerSigmatex
About Sigmatex
• Established in 1986, we have over 30 years experience
in the conversion of carbon fibre to advanced textiles
• We are a global business with 4 strategically positioned
production plants and an large network of customers
• We are a technology driven business with the widest
range of CF textile conversion methods in our industry
• We invest heavily in product innovation to ensure we
remain as leaders in the fast evolving composite world
• We serve all major CFRP markets
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Markets Served
40% 40%
20% Other
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Example Projects
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Carbon Fibre Textile Innovation for the Automotive Market
Industry Drivers
• Cost – The single biggest obstacle to CFRP adoption in high volume
• Capacity – Scaling up is capital intensive, major investment will be required
• Cycle times – Ultra low cycle times for CFRP will be required to meet production rate needs
• Quality assurance – Repeatable, low PPM failure levels (6σ)
• Recyclability – End of Life recycling / reuse is a regulatory requirement in many countries
• Integration – Multi-material solutions will necessitate effective compatibility between metals and plastics
• Data – Automotive engineers need good material data to support part design
• Fibre capacity – Can we turn on the tap quickly enough?
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Visual Carbon
• Visual carbon is one of the largest segments of the Automotive
market for CFRP today at >50%
• Consumers and designers alike are growing tired of twill weave,
there is a need to rejuvenate interest through more creative designs
• OEMs can create brand identity through customised patterns
• We believe this will become a major trend for VQ carbon parts
• SigmaDesign is a new service offering dedicated design
consultancy, prototyping and scale production.
• Using Jacquard weaving technology we can offer non-symmetrical
designs, such as company logo’s and graphics.
• Standard catalogue range available
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Ultra low weight UD Tape
Tape Placement technology is gaining traction as a cost effective
production method.
• Proprietary fibre spreading technology developed by Sigmatex
• High volume, high rate process – very cost effective
• Area weights 40 – 200gsm
• Tape widths 18 – 120mm
• Tapes are stabilised, with optional binder or veil applied
• Various HS / IM fibres available
• Excellent lay-down properties
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Flat Tow Weaving
A Novel weaving process developed by Sigmatex to enable the production
of flat fabrics:
• Closed weave with improved cover factor
• Both warp and weft are ‘spread’ and inserted flat (no twist)
• Available in both HS & IM versions
• Area weights from 195 – 280gsm
• Offers improved mechanical performance due to increased fibre
alignment and tow spread – estimated at >10%
• Aesthetically attractive
• Cost effective - <200gsm fabrics using 12K fibre
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Recyclability
Recyclability is an industry issue – Process waste and EOL parts are often not
economically viable to recover. Sigmatex has tackled this issue head on.
Our award winning SigmaRF has gained a lot of success due to its patented
process of realigning the carbon fibers back into a directional state.
We are now building on that success by launching a 2nd product in the RF range –
Our non-woven (isotropic) mat in TP hybrid and 100% carbon formats.
• Available in weight ranges 200 – 600gsm
• Thermoplastic hybrid versions – PP, PA6, PA12, PC, etc
• This material is our most economical product
• Fibre source is known and selected in a controlled way to guarantee
mechanical properties
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Lightweighting Excellence
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LX was a ₤7M AMSCI funded project to support the development of a UK
supply chain for advanced CFRP structures into the Automotive industry.
A sophisticated cost analysis tool was developed to assess the true part
cost of CFRP Vs metal structures. It showed the following:
• CFRP was 64% more expensive
• NCF / carbon was 60% of total cost
CFRP Steel
Floor Pan Structure
ARCS
Affordable highRate Composite Structures (ARCS) is an £8M collaborative project that will target a step-change in
cost and rate production of CFRP components for the Automotive sector.
Main Objectives:
• Drive a significant cost reduction in CFRP components for high volume applications – Target is >20% cost down
• Strengthen our knowledge through extensive material characterization (mechanical, drape, permeability, etc.)
• Develop an ultra-high speed NCF conversion process
• Develop a high rate pre-forming cell and materials handling / automation system
• Demonstrate a joined up supply chain capable to deliver high volume production
• Seek exploitation opportunities across other mobility sectors
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Summary:
• Innovation is a critical part of moving CFRP into high volume applications
• Sigmatex are leaders in carbon textile technology – we’re using our expertise and market intelligence to
develop new products to address those challenges
• New visual carbon designs are rejuvenating the world of aesthetical carbon
• Flat tow weaving offers major cost and performance benefits
• Tape placement technology looks set to be a major process method across the CFRP spectrum
• We are leading the recyclability challenge through developing economical textile solutions
• Lower cost NCF materials are essential to meet the price challenge for volume automotive applications,
our new Innovate UK funded project will deliver a step change in cost for high volume automotive parts
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