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1969 Even before Neil Armstrong, Hexcel materials make first footprints on moon. The footpads on the Apollo 11 Lunar Landing Module are made of crushable honeycomb foil by Hexcel.
1970 When Concorde, the world’s first commercial supersonic aircraft, enters service it contains materials from a variety of Hexcel locations.
Market Leaders Must Continually Invent
>> Looking back Early attempts at making honeycomb used a corrugation process which was slow, inefficient and had size constraints. Roger Steele patented a novel method to apply lines of adhesive to aramid paper and expand honeycomb that is still the standard today. When Douglas Aircraft said they needed a fiberglass core, he developed woven glass prepreg to replace his original paper design. Year after year, Hexcel has advanced the state -of-the-art, accumulating over 400 patents along the way.
Lesson? Pioneers can’t look for trails, they need to forge them.
>> Looking forward: In 2007, Hexcel won the prestigious JEC innovation award for applying its patented HexWeb® Acousti-Cap™ to a jet engine nacelle. This unique honeycomb core with cell inserts has, after years of study by NASA, been deemed a significant improvement over the current state-of-the-art methods of dampening jet engine inlet noise. It is now being incorporated in a number of new and existing aircraft, such as the Boeing 777, 787 and 747-8.
Traditional carbon composite parts, such as the intake fan blade on the new GE turbofan, require precisely placed sheets of prepreg to be stacked on a mold and cured in a high pressure/temperature autoclave for hours. High speed tape-laying machines are employed in
making large structures such as aircraft wings and fuselages. However, neither method is gener-ally applicable to making smaller, odd-shaped parts like window frames and internal brackets. In 2007, FAA approval was received for the first aircraft part made with our patented HexMC® system. HexMC® is carbon fiber prepreg, cut into flakes and layered in a blanket-like form. Loaded into a molding press, it allows for high-volume shaping and curing of lightweight structural parts that would otherwise need to be made from more expensive and heavier titanium for similar perfor-mance. Using the HexMC® process, Hexcel now offers turnkey finished composite parts that meet FAA certification requirements starting with only the customer’s desired load, envelope and mounting profile. Hundreds of parts made this way have been incorporated into the Boeing 787, and thousands of addi-tional parts are likely on future aircraft designs.
Also in 2007, HexTool® was introduced to the tooling market. Most large composite aircraft struc-tures have traditionally required tools made of a very expensive and extremely heavy Invar® alloy because its low coefficient of thermal expansion is close to that of carbon
1958 Atlas Missile & U.S. Airforce moon probe used Hexcel Honeycomb. Our materials were also used in the U.S. Mercury space program.
1959 Hexcel goes public – I.P.O. of 50,000 shares for over-the-counter trading.
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1981Hexcel plays a vital part in the construction of the Columbia space shuttle, supplying materials for the nose cap, payload doors and wings.
1986Hexcel plays a major role in the historic non-stop, round-the-world flight of the Voyager aircraft.
1971Hexcel begins manufacturing skis, bringing together a number of the company’s materials and technologies into a single finished product.
1974Hexcel convinces design engineers at Cincinnati Milacron to build the five-axis, numerically-controlled (“NC”) honeycomb carving machine, which allows Hexcel to begin supplying complex, contoured parts such as the speed brakes on the F-15 fighter.
A350XWB 52%
787 50%
A380 23%
A340-500 17%
A330 12%
777 11%
A320 10%
767 6%
757 5%
737 5%
747 2%
DC-10 2%
A-310 2%
707 1%
CompositeUsageRatio(basedonestimatedweight)
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>> Looking back:
1996-98 The combination of Hexcel, Ciba Composites, Hercules Composites, along with select Fiberite product lines gives Hexcel the most comprehensive array of technologies, qualifications, geographic mix and vertically integrated capabilities in the industry. This leaves the company well positioned for growth and diversification.
abankruptcythatcouldhavebeenavoided.AfterSeptember11,2001,wedidnotwait.Wereducedourworkforcebyover30%,raisednewcapitalandrefinancedourentiredebtstructure.Lesson?Greatwindsdon’t
guaranteesmoothsailing;thebeststrategiesmustalsoincludeexecution,agility,adaptationandawillingnesstorethink/reinvent.
>> Looking forward: Theunexpectedtwo-yeardelayofthecomposite-intensivesuperjumboAirbusA380aircraftcombinedwitha35%dropinourballisticsalescreatedtheequivalentofarecessionintwoofourkeymarkets.Tomaintainourtrackrecordofmarginandearningsexpansion,wechosetorespondaggressivelyratherthanwaitforarebound.Wesoldourballistics,
electronicsandarchitecturalweavingbusinesses,becausetheirlong-termprospectswerelesscompellingthanthoseofcompositematerialsforaerospaceandwindenergy.Weclosedtwoplantsandtookoutsignificantoverheadcoststooffsettheincomelostfromthesebusinesses.Andwerestructuredourorganizationfromthreeglobalbusinessunitstoonetobecomeapurelyfocusedcompositescompany.
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>> Looking back:
>> Looking forward:
Chairman and CEO
Hexcel’s Board of Directors (Left to Right standing: Front Row – D. Hurley, J. Graves, J. Campbell,
S. Derickson, J. Beckman, L. Brubaker; Back row – A. Bellows, D. Berges, K. Foster, D. Pugh
Composite Materials
Carbon Fibers:
Industrial Fabrics and Specialty Reinforcements:
Prepregs:
Other Fiber-Reinforced Matrix Materials
Resins
Structural Adhesives:
Honeycomb:
Engineered Products
Investments in Affiliated Companies
Commercial Aerospace
Space & Defense
Industrial Markets
2007 Compared to 2006
Gross Margin:
Selling, General and Administrative (“SG&A”) Expenses:
Research and Technology Expenses:
Business Consolidation and Restructuring Expenses:
Other Expense, Net:
Operating Income:
Interest Expense:
Non-Operating Expense, Net:
Provision (Benefit) for Income Taxes:
Equity in Earnings from and Gain on Sale of Investments in
Affiliated Companies:
Income from Continuing Operations:
Income (Loss) from Discontinued Operations, Net
2006 Compared to 2005Net Sales:
2006 Net Sales
2005 Net Sales
December 2006 Program
Livermore 2004 Program November 2001 Program
Employers’
Accounting for Pensions (“FAS 87”), Employers’ Accounting
for Settlements and Curtailments of Defined Benefit Pension Plans
and for Termination Benefits (“FAS 88”), Employers’
Accounting for Postretirement Benefits Other Than Pensions (“FAS
106”) Employers’ Accounting for Defined Benefit
Pension and Other Postretirement Plans — an amendment of FASB
Statements No. 87, 88, 106, and 132(R)
Liquidity:
Credit Facilities:
Financing Activities:
Financial Obligations and Commitments:
Operating Activities
Investing Activities:
Accounts Receivable Inventories
Product Warranties
Deferred Tax Assets
Accounting
for Income Taxes (“FAS 109”),
Considering the Effects
of Prior Year Misstatements when Quantifying Misstatements in
Current Year Financial Statements
Uncertain Tax Positions
Accounting for Uncertainty in Income
Long-Lived Assets and Goodwill
Share-Based Compensation
Accounting for Stock-
Based Compensation
Accounting for
Stock Issued to Employees
Commitments and Contingencies
Interest Rate Risks
Interest Rate Swap Agreements
Cross-Currency Interest Rate Swap Agreement
Foreign Currency Exchange Risks
Foreign Currency Forward Exchange Contracts
Utility Price Risks
Fair Value
Measurements (“SFAS 157”)
The Fair
Value Option for Financial Assets and Financial Liabilities –
Including an amendment of FASB Statement No. 115
Business Combinations (“SFAS 141(R)”)
Business Combinations
Noncontrolling Interests in Consolidated
Financial Statements—an amendment of ARB No. 51
The accompanying notes are an integral part of these consolidated financial statements.
The accompanying notes are an integral part of these consolidated financial statements.
The accompanying notes are an integral part of these consolidated financial statements.
The accompanying notes are an integral part of these consolidated financial statements.
Inventories
Property, Plant and Equipment
Goodwill and Other Intangible Assets
Goodwill and Other Intangible Assets
(“FAS 142”)
Software Development Costs
“Accounting for
the Costs of Computer Software Developed or Obtained for Internal
Use.”
Nature of Operations
Principles of Consolidation
Reclassifications
Use of Estimates
Cash and Cash Equivalents
Investments
Consolidation of Variable Interest
Entities (“FIN 46R”)
Debt Financing Costs
Share-Based CompensationShare-
Based Payments
Accounting for Stock
Issued to Employees
Currency Translation
Revenue Recognition
Accounting for Performance of Construction-Type and
Certain Production Type Contracts
Product Warranty
Research and Technology
Income Taxes
Accounting for Income Taxes.
Accounting for Uncertainty in Income Taxes – an
interpretation of FASB No. 109,
Concentration of Credit Risk
Derivative Financial Instruments
Accounting for Derivative Instruments and
Hedging Activities (“FAS 133”)
Accounting for
Certain Derivative Instruments and Certain Hedging Activities
Self-insurance
Recently Issued Accounting StandardsFair Value
Measurements (“SFAS 157”)
The Fair
Value Option for Financial Assets and Financial Liabilities –
Including an amendment of FASB Statement No. 115
Business Combinations (“SFAS 141(R)”)
Business Combinations
Noncontrolling Interests in Consolidated
Financial Statements—an amendment of ARB No. 51
EBGI
European Architectural Business
,
BHA Aero Composite Parts Co., Ltd.
Guarantor’s Accounting and Disclosure Requirements for
Guarantees, Including Indirect Guarantees of Indebtedness of Others,
Asian Composites Manufacturing Sdn. Bhd.
TechFab LLC
DIC-Hexcel Limited
Senior Secured Credit Facility
6.75% Senior Subordinated Notes, due 2015
European Credit and Overdraft Facilities
Aggregate Maturities of Notes Payable
Estimated Fair Values of Notes Payable
“Accounting for Leases.”
Employers’
Accounting for Pensions (“FAS 87”), Employers’ Accounting
for Settlements and Curtailments of Defined Benefit Pension Plans
and for Termination Benefits (“FAS 88”), Employers’
Accounting for Postretirement Benefits Other Than Pensions (“FAS
106”) Employers’ Accounting for Defined Benefit
Pension and Other Postretirement Plans — an amendment of FASB
Statements No. 87, 88, 106, and 132(R)
U.S. Defined Benefit Retirement Plans
U.S. Postretirement Plans
European Defined Benefit Retirement Plans
Retirement and Other Postretirement Plans - France
Net Periodic Pension Expense
Defined Benefit Retirement and Postretirement Plans
Deferred Income Taxes
Net Operating Loss Carryforwards
Uncertain Tax Positions
Accounting for Uncertainty in Income
Common Stock Outstanding
Secondary Offerings of Common Stock and Conversions of
Mandatorily Redeemable Convertible Preferred Stock
Prior to adoption of SFAS 123(R)
Accounting for Stock-Based Compensation
, Accounting for Stock-Based
Compensation — Transition and Disclosure
Adoption of SFAS 123(R)
Non-Qualified Stock Options
Valuation Assumptions in Estimating Fair Value
Restricted Stock Units – Service Based
Restricted Stock Units – Performance Based
Stock-Based Compensation Cash Activity
Shares Authorized for Grant
Employee Stock Purchase Plan (“ESPP”)
Plus incremental shares from assumed conversions:
Cross-Currency Interest Rate Swap Agreement
Interest Rate Swap Agreements
Foreign Currency Forward Exchange Contracts
Foreign Currency Options
Environmental Matters
Lodi, New Jersey Site
Lower Passaic River Study Area
Kent, Washington Site
Omega Chemical Corporation Superfund Site, Whittier, CA
Litigation
Austrian Exotherm Claim
Hercules Claim
Product Warranty
Disclosures
about Segments of an Enterprise and Related Information,
Geographic Data
Note:
Significant Customers
December 2006 Program
Livermore 2004 Program
November 2001 Program
2007
2006
Internal Control-Integrated
Framework
Internal Control - Integrated Framework