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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