Thermoplastic Composites: Innovation by SMEs Aldert Verheus www.lightweight-structures.com 16 December 2015, Brussels
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Thermoplastic Composites:
Innovation by SMEs
Aldert Verheus www.lightweight-structures.com 16 December 2015, Brussels
Introducing myself
•! 1987: TNO Plastics and Rubber Research Institute •! 1996-2004: co-operation of Delft University of
Technology and TNO •! 2005: privatisation •! 2007: management buy-out with 2 investors to
expand from engineering to production •! 2014: sales of 50% shares to Russian entrepreneur
•! 2012: creation of CompTape B.V. as material supplier, again with Russian investment
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Composites
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Evolution of lightweight construction materials
Wright Flyer (1903) Fokker 8 (1927) wood / linnen wood / linnen / steel Boeing 7E7 (2007) DC-2 (1934) 60% composites steel / aluminium
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Composites: plastics reinforced with strong fibres
Glass/polyester Carbon/epoxy not very lightweight lightweight
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7.9 Mt composites vs 275 Mt plastics worldwide
Composites Plastics in total
(Sources: JEC and PlasticsEurope)
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Composites in transportation
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Composite hopper car (glass/polyester)
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Composite tank container (glass/polyester)
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Lightweight trailer (just a little composites though!)
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BMW i3 carbon composite body - heavy batteries
BMW partners with SGL to produce carbon fibre components at plants in Bavaria.
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Thermoplastic composites
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Innovation challenge: upgrading of thermoplastics to composites
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Clever example: hybrid gas bottle
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Automotive development: composite bumper beam
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Automotive development: composite bumper beam
…. and other automotive components (after years of investigation): In general: 1. Without carbon fibre not that lightweight 2. With carbon fibre too expensive 3. Mass production technologies still under
development 4. At the end of the day volume probably too low to be
interesting to multinational material suppliers
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!. which is good for SMEs!
•! Development of industrial applications
•! Overmoulding of composites
•! Re-design of injection moulded products: adding local reinforcement with tapes
•! Low-cost low-volume tape manufacturing: CompTape B.V.
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applications
Comparison of materials
(source: Hull)
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