5.3.2014 Industrialization of the carbon composite industry | JEC

5.3.2014
Industrialization of the carbon composite industry | JEC Composites
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26 Apr 2011
Industrialization of the carbon composite industry
High-performance composites are in great demand in various sectors but their high
cost is still a deterrent. Carbon composite experts from the SGL Group shares their
viewpoint on issues such as industrialization challenges, the carbon fibre market, cost
analysis and automation, citing two examples from the car industry and one from the
aeronautics industry. Part one.
Jones Snowboards wins ISPO award for
their carbon reinforced Ultracraft
splitboard
PlastiComp adds LFT pultrusion line for
carbon fiber reinforced thermoplastics
Business
(Published on March-April 2009 – JEC Magazine #47)
1- DR JAN VERDENHALVEN CHAIRMAN CARBON FIBERS & COMPOSITES, SGL TECHNOLOGIES GMBH
2- DR MICHAEL HEINE, DIRECTOR PUBLIC FUNDING SGL GROUP, SGL CARBONGMBH TECHNOLOGY
& INNOVATION
In the 19th century, engineers around the world like Diesel, Edison, Stevenson, Daimler and
Bosch, only to mention a few, lived up to the challenge of their times and set a technological
basis for what is now well known as the age of industrialization.
What is the meaning of
"industrialization”? The following
definition was found in a
standard dictionary:
"Industrialization means the
transitioning process from handmade to factory based
production, which is based on
machines and is rapidly
spreading into all economic
sectors."
The carbon fibre market
It is worth benchmarking the
carbon composite industry
versus this definition. Let’s first
have a look at the industry’s current situation.
Historically, the carbon composite industry has not shown a very impressive growth rate. Its
stable 7% p.a. growth (Fig. 1) is relatively low compared with other industries like electronics or
biochemistry. Since 2004, a step change to higher growth rates above 15% has been observed,
though this seems to be driven by the obvious mega-trends of rising energy and raw material
costs, as well as concerns for global warming.
SPECIAL FEATURE
Innovations and Know-How at JEC Europe
2014
JEC Europe is famous for all the innovations
launched at every session. Every event sets
new benchmarks. 2014 brings more
composite penetration in every historic
application sectors and in new ones. Here
are few of these innovations and technical
highlights. More are to come on our website
and many others will be announced during
the Show which will take place in Paris from
March 11 to 13.
Follow this link to see them
AGENDA
March
The key growth segments are in industrial applications (mainly wind energy) and aeronautics.
Compared with other materials however, these materials are still extremely marginal (Fig. 2).
From exotic to large-scale production
We have to admit that our products are still considered to be pretty “exotic”. What are the
reasons for this and what can we do to change this? Table 1 lists standard requirements and
criteria for traditional material markets. It shows the performance of the carbon composite
industry against such criteria.
Obviously, the industry has to significantly improve its reliability and efficiency in the years to
come to meet the standards of traditional materials.
M
T
W
T
F
S
S
2
9
3
4
5
6
7
1
8
10
11
12
13
14
15
16
17
24
31
18
25
19
26
20
27
21
28
22
29
23
30
Portugal
06 Mar 2014
12th World Pultrusion
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06 Mar 2014
5th International Seminar
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Composites Biopolymers
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EDITORIAL CONTACTS
To send information to our editorial
service, please contact:
Frédéric Reux
Editor-in-Chief
Send Inquiry
Franck Glowacz
Technical Editor
Send Inquiry
While basic carbon fibre and intermediate material technologies are already quite developed and
though part of our industry is reasonably wellstructured, the main issues concern the
components or part manufacturing (see Fig. 3).
markets. Unfortunately, such a statement
is based on a fundamental
misunderstanding. At best, carbon fibres
stand for 25% of the cost of a final part in
industrial applications. Downstream
manufacturing, which represents more
than 75% of the total part cost, is actually
responsible for hiking up costs (Fig. 4).
Therefore, the answer to the cost issue is
not cheaper carbon fibre. As shown in Fig.
5, the manufacturing cost of carbon fibre
is driven by raw material, energy and
infrastructure costs (plant cost and
depreciation). Labour cost is only 8%.
and industrialization. Carbon fibre
manufacturing is already an almost
unmanned process. It is the
“industrialization” of the downstream
industry that will make carbon fibres more
cost effective as we move forward into the
future.
Contrary to carbon fibre production,
significant cost reductions and process
improvements are possible in the
downstream business. To demonstrate this,
we would like to explain the process
chain of the SGL Group, starting with the precursor and ending with the carbon composite part
(Fig. 6).
Our vision is to become the leading global supplier of carbon fibres and composites (CFC) with a
broad material base and a fully-integrated process chain.
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5.3.2014
Industrialization of the carbon composite industry | JEC Composites
Contact:
More information: www.sglgroup.com
Back
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Industrialization of the carbon composite industry | JEC Composites
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