Textile Leadership

from to
Reset
2 results
(c) Gestamp
23.08.2022

Green fiber-reinforced composites instead of steel for chassis parts

Gestamp, Fraunhofer Institute for Chemical Technology ICT and its project partners are facing the scientific challenge to implement mass production of green fiber chassis parts. The broad Eco Dynamic SMC consortium brings together expertise from the aerospace, automotive and scientific industries.

Mobility demands are subject to constant change. Due to new emissions regulations and increasing electric mobility, lightweight construction and safety continue to be drivers for future automotive and mobility applications. The sustainable use of limited resources and the mandatory reduction of CO2-emissions during the production process and the lifetime of the vehicle are now the focus of development, in addition to the performance of the individual parts of a vehicle.

Gestamp, Fraunhofer Institute for Chemical Technology ICT and its project partners are facing the scientific challenge to implement mass production of green fiber chassis parts. The broad Eco Dynamic SMC consortium brings together expertise from the aerospace, automotive and scientific industries.

Mobility demands are subject to constant change. Due to new emissions regulations and increasing electric mobility, lightweight construction and safety continue to be drivers for future automotive and mobility applications. The sustainable use of limited resources and the mandatory reduction of CO2-emissions during the production process and the lifetime of the vehicle are now the focus of development, in addition to the performance of the individual parts of a vehicle.

Gestamp is comitted to create a vehicle that is better for the environment and safer, to contribute to the mitigation of climate change. The focus is on the production of a lighter car, so that it emits less emission during its use. For this reason, Gestamp, Fraunhofer Institute for Chemical Technology ICT and several other consortium partners have collaborated to make the ECO Dynamic SMC project a tangible reality.

Thanks to its good material properties, recyclability and worldwide availability, steel is still often the material of choice in the automotive and mobility industry, and will certainly continue to be so in the future. However, the trend is also towards new materials that expand the range of materials and fulfill the motto "the right material in the right place". Fiber-reinforced composites offer excellent lightweight construction potential and safety features. The use of recyclable materials leads to a good balance between energy consumption, profitability and sustainability.

Fiber-reinforced materials are currently used in large numbers for body parts, but not for chassis components in the automotive or aerospace industry. The Eco Dynamic SMC project addresses this issue by developing a closed engineering loop for an automotive chassis control arm for a high volume production and a suspension part of a motor glider, substituting steel with fiber-reinforced material with the aim to implement the CF-SMC Technology for dynamic and safety relevant chassis components in high volume productions.

Initiated in October 2021 and funded by the German Ministry of Energy and Climate Protection, Eco Dynamic SMC (Grant Number: 03LB3023A) will address the scientific problem of developing a comprehensive continuous engineering process for fiber composite reinforced components that meet OEM approval procedures. The broad Eco Dynamic SMC consortium brings together expertise from the aerospace, automotive and scientific industries. Cooperation between universities, academic institutes and companies from various relevant sectors promotes the transfer of technology and experience across industry borders. Gestamp is the head of the consortium of Eco Dynamic SMC project.

Today, a continuous development process is established for metals and the procedure is defined based on available material data for manufacturing, product simulations and specific material parameters addressing e.g. formability, durability, stiffness, strain rate behavior or weldability.

Starting with the development of a digital shadow from the raw material manufacturing to be aware about the fiber content and weight of the material stack before the transfer into the tool. Substantial material characterization will be the groundwork for the integration of the material properties and fiber orientation from manufacturing process into the product development simulation. At the end of the development, a prototype will be manufactured and tested as component and on a test vehicle to evaluate the mechanical and acoustic behavior.

In the second project stream, a suspension part for a motor glider is developed by following the same strategy of the closed loop of process and product engineering.

In addition to the development cycle, the Eco Dynamic SMC project is dedicated to other core aspects such as a good CO2 balance, a recycling concept, optimized use of materials, reduced energy consumption and the careful use of resources.

Eco Dynamic SMC Consortium
The project consortium consists of: Fraunhofer Institute for Chemical Technology ICT, Karlsruher Institut für Technologie, DG Flugzeugbau GmbH, Koller Formenbau GmbH, Schmidt & Heinzmann GmbH & Co.KG, Toray Industries Europe GmbH, Vibracoustic SE, Gestamp Autotech Engineering Deutschland GmbH.

Associated Partners: BMW AG, Premium Aerotec GmbH

Gestamp
Gestamp is a multinational company specialized in the design, development and manufacture of highly engineered metal components for the main vehicle manufacturers. It develops products with an innovative design to produce lighter and safer vehicles, which offer lower energy consumption and a lower environmental impact. Its products cover the areas of bodywork, chassis and mechanisms.

The company is present in 24 countries with more than 100 production plants, 13 R&D centers and a workforce of nearly 40,000 employees worldwide. Its turnover in 2021 was 8,093 million euros. Gestamp is listed on the Spanish stock exchange under the ticker GEST.

Fraunhofer Institute for Chemical Technology ICT
The main campus houses more than 100 laboratories, pilot plants and test centers on a total area of 21 hectares. The research orientation enables us to combine research and development activities in this area with large demonstration plants. The focus is on the scalability of processes, on the transfer of research results from the laboratory to the pilot plant scale, and in some cases on pre-series application.

Customers and project partners are chemical and process engineering companies, automotive manufacturers and their suppliers, the plastics processing industry, material manufacturers, recycling companies, companies from the energy and environmental sectors, customers from the security industry, the construction industry and the aviation sector.

Source:

Gestamp; Fraunhofer ICT

Foto: Pixabay
20.06.2022

Techtextil 2022: Innovation Awards for Automotive, Medicine & Apparel

After a Corona-related break of three years, the leading trade fairs Techtextil and Texprocess are once again presenting the renowned Innovation Awards. The award-winning new developments from areas such as New Products, Sustainability and Automation demonstrate: Textile innovations and technologies provide impulses for many branches of the industry and promise market and sales success far beyond their own sector. 13 winners from seven categories will be honored at a public awards ceremony at Techtextil and Texprocess on 21 June, 2022.
 

After a Corona-related break of three years, the leading trade fairs Techtextil and Texprocess are once again presenting the renowned Innovation Awards. The award-winning new developments from areas such as New Products, Sustainability and Automation demonstrate: Textile innovations and technologies provide impulses for many branches of the industry and promise market and sales success far beyond their own sector. 13 winners from seven categories will be honored at a public awards ceremony at Techtextil and Texprocess on 21 June, 2022.
 
As is the case for many other industries, times are challenging for the textile industry: the consequences of Corona, the Ukraine war, strained supply chains, sustainability issues, rising energy prices and recruitment problems - the industry is under pressure from many sides. But more than almost any other industry, it is also very adept at meeting these challenges with new ideas, developments and business models. This year's Innovation Awards at the leading trade fairs Techtextil and Texprocess are another example of this. With their new products, materials, solutions and processes, the 13 award winners are demonstrating in an exemplary manner that textile innovations are the ideal way to create market opportunities and boost future business revenues, out of the challenges of the present.

Techtextil Innovation Award and Texprocess Innovation Award
The Techtextil and Texprocess Innovation Awards will be presented on 21 June, 2022 in Hall 9.0. Textile innovations selected by international expert juries will be awarded prizes and presented publicly on the four days of the trade fair in Hall 9.1 (Techtextil) and 9.0 (Texprocess), in some cases for the first time.

World's first: first woven heart valve without postfabrication
In the "New Product" category, the Techtextil Innovation Award goes to the Institute of Textile Machinery and High Performance Material Technology (ITM) at the Technische Universität Dresden. Together with medical product manufacturers and heart surgeons from the Cardiovascular Center Würzburg and the Universitätsklinikum Würzburg, textile researchers from the ITM have succeeded in developing the world's first woven heart valve that does not require a single seam or other joining technique. "Our new development should also help children with heart valve defects in the future by growing with the heart of the young patients - avoiding repeated surgical interventions," says Dr.-Ing. Dilbar Aibibu, research group leader for biotextiles and medical textiles at ITM. Worldwide, cardiovascular diseases are among the most common causes of death; several million people die from them every year. When patients receive heart valve replacements, artificial mechanical or biobased solutions are usually used. If ITM has its way, the woven valve, which won the Techtextil Innovation Award, should become a beneficial alternative in the future.

Reuse of waste from a natural source
In the "New Material" category, RBX Créations (France) receives the Innovation Award for a novel cellulose fiber made from hemp waste. The material, named Iroony®, was developed with regard to the following question: Hemp is now grown either to make fiber or to produce hemp oil - but could not the two be combined? RBX Créations has now succeeded in developing a process for extracting cellulose from the waste of oilseed hemp. Spun into textile fibers, it can be used to produce sustainable textiles, packaging and other "green" products. The award is given to RBX Créations for its continuous and successful efforts to convert waste from a renewable source into a valuable cellulose fiber that meets the highest sustainability standards.

Fiber shielding technology for hospitals, electric cars and server farms
The Techtextil Innovation Award in the "New Technology" category goes to Aachen-based FibreCoat GmbH and Deutsche Basalt Faser GmbH from Sangerhausen (Saxony-Anhalt) for the joint development of an aluminum-coated basalt fiber. It combines the strength of basalt with the electrical conductivity of aluminum. According to FibreCoat, electromagnetic shielding as wallpaper in buildings in hospitals or server farms, among other places, should be up to 20 times cheaper than with conventional aluminum foil thanks to the new development. Another attractive and particularly fast-growing market is shielding solutions for electric cars. Robert Brüll, CEO of FibreCoat: "For a young company like ours, winning the Techtextil Innovation Award is an important milestone. We are honored to receive this prestigious award from the independent jury of experts. In particular, the confidence of our customers and visibility gained as a result are crucial for a start-up like FibreCoat on the road to market success."
 
More sustainable hygiene products such as diapers
Kelheim Fibres GmbH from Kelheim in Bavaria and the Saxon Textile Research Institute (STFI) in Chemnitz receive the Techtextil Innovation Award in the "New Concept" category for the development of novel, thermally bonded nonwovens based on cellulose for the production of reusable products with high absorbency. Consumers should no longer have to choose between high-performance or environmentally friendly products. Nature and performance of hygiene products go hand in hand thanks to the innovation of Kelheim, STFI and the Berlin-based start-up SUMO. Dr. Marina Crnoja-Cosic, Director New Business Development at Kelheim Fibres: "It is a great honor and pleasure for us to receive the Techtextil Innovation Award together with our partners. We see the award not only as a distinction for the project presented, but also as recognition of our innovation strategy. After all, in dialogue with partners we can react more quickly to current trends, develop in a more targeted manner and accelerate the commercialization of innovative solutions."

Waste from the automotive industry as a resource
Another Techtextil Innovation Award in the category "New Approaches on Sustainability & Circular Economy" honors a process that uses natural leather waste from the automotive industry to produce innovative textile coatings. It was developed by CITEVE, the Technology Center for Textile and Clothing in Portugal, and partners ERT Têxtil Portugal, CeNTI and CTIC (all Portugal). After CITEVE researchers discovered that cutting operations in the automotive industry generate a large amount of natural leather classified as waste, they sought a solution to reuse it. The expert jury recognizes the development as a successful industrial symbiosis: "Waste from one industrial sector is used here as a resource in another. The work of the CITEVE researchers thus supports an important trend toward a resource-efficient, environmentally friendly and sustainable textile industry."

Compostable textile coating
The Techtextil Innovation Award in the category "New Approaches on Sustainability & Circular Economy" goes to the textile research institute Centexbel (Belgium) for a bio-based and compostable dispersion for textile coatings and printing inks. The new development does not require solvents and brings a completely new type of polymer for coatings and printing inks to the market. According to the expert jury, the innovation is an important step for the textile coating industry towards more products based on renewable resources.

Fashion from pineapple peel
The Italian company Vérabuccia is honored in the "Performance Fashion Award" category for an innovative production process for the fashion and design sector. The patented process is designed to transform fruit waste into fashion highlights. A first material is the so-called "Ananasse". According to Vérabuccia, the special feature of this is that unlike other plant leathers, which tend to imitate real animal leather, it retains the original appearance of a pineapple skin; this emphasizes the origin of the raw material. With the Techtextil Innovation Award, the jury honored the unconventional thinking of the young Italian label, whose originality proves that innovative and appealing fashion can be developed from surprising materials.
 
100 percent compostable binder for nonwovens
In the "New Technology" category, the company OrganoClick (Sweden) receives the Techtextil Innovation Award for the development of a 100 percent bio-based binder for nonwovens applications that is made from waste components and is therefore said to be fully compostable. The innovation is designed to replace plastic-based binders. Because nonwovens are often made from non-degradable plastics, the Swedish company specializes in developing compostable material alternatives from wheat bran, fruit or crab shells, among others. This convinced the jury of the Techtextil Innovation Awards: "OrganoClick receives the award for its efforts to find bio-based raw material alternatives to replace oil-based materials."

Formaldehyde-free & bio-based coating system
The third award in the category "New Approaches on Sustainability & Circular Economy" goes to Deutschen Institute für Textil- und Faserforschung Denkendorf (DITF) from Baden-Württemberg and the company TotalEnergies - Cray Valley (France). Together, they have developed a novel, formaldehyde-free coating system. It is based on non-toxic hydroxymethylfurfural (HMF) derived from biomass waste. These HMF-based dip formulations are capable of replacing formaldehyde-based adhesion promoters on a one-to-one basis. For background: in tires, conveyor belts or V-belts, rubber materials are reinforced by cord. The quality of such cord composite systems with high-strength fibers such as polyester, aramid or polyamide and rubber is determined by the adhesion properties of the fibers to the matrix. In the established manufacturing process, adhesion promoters made of resorcinol-formaldehyde-latex (RFL) are used. However, formaldehyde has been classified by the EU as a proven carcinogen and mutagen since 2014. The jury therefore welcomes the health and environmentally friendly new development. It contributes to a more sustainable textile industry and the reduction of harmful chemicals.

Source:

Messe Frankfurt Exhibition GmbH