Maximilian Hacker is 25 years old and the owner of BRComposites. He absolved his training as procedural mechanics of plastic and rubber technology, specialized in fibre composites.

 Activities previous to his self-employment:

1. Fischer & Entwicklung Landshut
2. Pilatus Aircraft Schweiz
3. Company with Formel 1 experience   (company name is not mentioned because of legal reasons)

CE: COMPOSITES EUROPE Team

MH: Maximilian Hacker

CE: Please introduce yourself. Who are you and what is your responsibility at BRComposites?

MH: BRComposites has exists for two years now. We are a young and very innovative company with a continuous strong growth. Furthermore, we think that  well-trained employees and to the original rules of craftsmanship are very important.

I am proud to say that we are already training employees. In my opinion there is still a lack of skilled workers in the composites industry.

We develop and offer individual production to our customers. Productions up to 10,000 standard parts are easily possible. In this way the volume of production is growing. Our production is done without autoclaves and everything is hand-made.

BRComposites

CE: So how did you experience the COMPOSITES EUROPE 2011 show? What are your impressions?

MH: This is the first time for BRComposites as an exhibitor at the COMPOSITES EUROPE. Actually we have been planning the first exhibition in 2016. At least that has been the conclusion of a family dinner. However, by coincidental, I got a phone call from the COMPOSITES EUROPE team the next day. During this conversation I received information about a funding possibility through BMWi. Because of the funding possibility and the sponsoring by Jost Chemicals, which is a close partner, we decided to book a booth for the COMPOSITES EUROPE 2011.

Mr. Hacker was reacting spontaneously when we asked him about his feelings as participant of the CE 2011. He was euphorically describing the exhibition as gigantic. The company had a huge success, a great number of good meetings and contacts. The booth was constantly busy because so many visitors were interested in their products. In his opinion, the exhibition service and the whole organisation was very commendable.

We closed the interview by talking about the presentation of innovations brought by BRC.

BRComposites presented flexible carbon protectors which is already used e.g. by the v. The jacket (have a look at the picture) in the background is specially made for extreme mountainbikers and is equipped with flexible carbon protectors. All visitors have been wondering what kind of material this is. However, we could not get any detailed information.

Thank you so much for the interesting and open conversation with Mr. Hacker.

Q: Please introduce yourself – who are you, what are your responsibilities at Scheurer Design & Eng.?

A: I worked as F1-Composite Engineer during the past 10 years. My career started at Sauber. 2005 I moved to  Toyota F1 based in Cologne. 2009 I launched my own company Scheurer Design & Eng. My current role is CEO and CAD-Designer.

Q:  Could you give us a quick overview of Scheurer Design & Eng.?

A: We do mainly CAD-Service, Composite Design, Production Support. Our main business is motorsport. We’re currently involved in two F1 Teams and different LeMans Teams. Next to them we do interesting projects in the marine sector. We work very close with our production partner “Germa Composite”. In this way we’re able to deliver high quality composite products to our customer.

Q: What kind of projects have you undertaken for clients?

A: Mecca Clock Tower (Carbon Clock Hands & Crescent)
     Lotus F1 car design
     …the ongoing projects are confidential

 Q: How did you come to be involved in the Mecca clock project and what challenges have your experienced with this project?

A: The German CEO Hannes Waimer of Premier Composite Technologies based in   Dubai  contracted us. We started with designing the up to 23m long carbon fiber clock hands. This project included mould design, composite engineering, ply flattening and we provided ply books for the shop floor. 2010 Premier called us to support them doing the biggest Crescent ever been built. The size of the mould was similar to a big yacht mould. The most challenging thing on this project was simply the size of the parts. It was a great experience for us to see what’s possible with using composite materials.

Q: Looking to the future, where do you think the composites industry is headed? What are you looking forward to seeing?

A: It would be great to see more composite material in the architecture sector. Light and  strong is what we need if we like to  have buildings up to one  kilometer high in the future.

Q:  Please, name some of your favourite composite  components?

A: Oxeon’s TexTreme carbon fabric! Great material and it looks good.

Q: Finally, are you looking forward to the Composites  Show in Stuttgart?

A: It’s a great show. Good solution to meet interesting people.

The International AVK Conference in the ICS International Congress Center Stuttgart has a brand new concept.

In two series of lectures, prominent experts offer their insights into the many and diverse applications for fibre reinforced plastics. In order to reflect the needs of the different interest groups even more closely at the conference, the two series are divided into thematic blocks presented by executives and technology specialists respectively.

The speakers will focus on current developments and innovations in technologies, materials and new processes as well as on the general condition of the GRP and CRP market.
Some of the fascinating lectures include:

• “Structural lightweight applications made from thermoplastic composites” by Joachim Graefe, Quadrant Plastic Composites AG
• “Thermoplastic composites for the A350 XWB” by Dr. Klaus Edelmann, Airbus Operations GmbH.
• Dr. Walter Aichholzer of Mercedes-Benz talks about the SMC decklid used in the premium automotive segment.

AVK represents the interests of all companies and institutions in the value chain involving components made of fibre-reinforced plastics and engineering thermosets

In a special lecture block “Research for practical application” professors from renowned universities and institutes report on trends, comparative studies of materials, series manufacturing applications and the wide range of design possibilities offered by fibre reinforced plastics.
The conference closes with a panel discussion titled “The future of fiber composites and plastics in the automotive sector” in which well-known participants from the automotive industry and its suppliers consider the current state of technology.

Have a look at the AVK conference programme now here.

You can register online here.

The Airbus A320 NEO is to be launched in 2015 and consumes 15 percent less fuel than the current model (photo: Airbus/Fixion).

The undisputed top model was the Airbus A320 NEO. The medium-haul aircraft featuring a new type of engine (NEO = New Engine Option) is to be launched in 2015 and its fuel consumption will be roughly 15 percent lower than that of the current model. One order placed by the Malaysian budget airline Air Asia attracted a great deal of attention: the airline ordered 200 Airbus A320 NEOs to the value of EUR 12.8 billion – the largest single order in the history of the EADS subsidiary.

The fact that the low-consumption aircraft is in such demand is due in part to its consistent use of fibre-reinforced composites to reduce weight. Components made from aramid fibre-reinforced plastics are used, for example, for the lower fuselage panelling. In addition, the front edge of the tail fin and the panelling covering the transition from the fuselage to the tail fin are made of glass fibre-reinforced plastic. The rest of the tail unit and most of the flaps are constructed from carbon fibre-reinforced plastic (CFRP). The A320 is therefore the first production civil aircraft in which this material is used for the entire tail unit.

Numerous Airbus suppliers will be coming together at the international Composites Europe (CE) trade fair in Stuttgart from 27 to 29 September 2011, underlining the significance of the event as a platform for fibre-reinforced composite solutions for the aerospace industry. Fibre placement systems and tape laying systems from MAG, for instance, are used for the production of fuselage parts, wing elements, turbine casings, stabilisers and other structural elements. The Preiss-Daimler group in partnership with Diehl Aircabin produces body shell parts for both Airbus and Boeing from glass fibre mesh and plastics using an innovative processing method.

SGL Carbon is also investing in this field. At the end of May the company opened an ultramodern pilot plant for researching into further potential applications for carbon fibres in the aerospace industry. The EUR 11 million facility is a central part of the “AirCarbon” project sponsored by the Federal Ministry of Economic Affairs and Technology (BMWi) in which, for the first time in Europe, industrial partners headed by the SGL Group are working specifically to develop carbon fibre reinforced innovations for the aerospace industry.

A few weeks ago we met each other again and he told me that development went well but he had some challenges regarding german law for using rims on
german streets. Although there are no thermal problems by heating the discs i.e. government gave him note that these kind of rims are not desired.

However, he started a new project: Innovative Process for manufacturing Carbon Composites

In combination with research and development on carbon wheels an innovative process for resin infiltration was discovered. This RCI-process combines the
advantages of classical autoclave process (simple moulds) with the advantages of RTM-process (short time). Suitable applications for structural carbon parts manufactured by RCI-process are in aerospace, automotive, sports or medicine.

Therefore cooperation partners for development are welcome. Get more information on: http://www.at-carbon.de

Wish you a nice Wednesday,

Frank

BUFFALO, New York – October 13, 2010 – Eastman Machine Company, a U.S. based manufacturing company specializing in cutting equipment, announces that it has appointed RH Schneidtechnik (Solingen), Germany, to represent its line of automated cutting systems, material handling equipment and design software.

RH Schneidtechnik specializes in cutting technologies, applications and engineering consultation for the composites, technical textile and apparel industries. RH Schneidtechnik’s central European location will enhance Eastman’s sales, service and support network for new and existing customers throughout Germany, Switzerland, Austria and the Netherlands. Eastman and RH Schneidtechnik will coordinate efforts to establish a demonstration showroom and technical service support center servicing all European customers by the end of 2011.

Eastman has installed over 1000 automated cutting systems worldwide. Automated cutting systems offer optimum material yields while reducing labor and operating costs for manufacturers cutting single and multiple-ply composite and industrial fabrics in the aerospace, transport, marine, apparel and safety industries.

Equipment available from Eastman:

• Static Cutting Table – capable of marking, drilling and punching virtually any flexible material at speeds of up to 60 inches per second (152.4 cm/s).
• Conveyor Cutting System – continuous conveying cutting system designed for cutting pattern pieces that can exceed the length of the table with speed and accuracy
• Multi-Ply Cutting System – capable of cutting up to 5cm (MPC-5000) and 7cm (MPC-7000) of compressed material for high volume throughput
• A variety of straight and round knifes; rotary shears and end cutters suitable for hundreds of materials

For more information on RH Schneidtechnik, please visit www.rh-schneidtechnik.de or COMPOSITES EUROPE 2011 in hall C2 stand J17 in Stuttgart, Germany.

Eastman Machine Company (www.eastmancuts.com) established itself more than a century ago as a world leader in developing advanced techniques and innovative technologies for the cutting room. Today, Eastman delivers engineering-based solutions that make real differences to facilities using new and high-tech materials. Eastman’s world headquarters are located in Buffalo, New York, U.S.A. with sales offices, agents and distributors around the world. The company was established in 1888 and is a fifth-generation, family-owned business with a broad base of elite customers in the wind energy, marine, composites, military, aerospace and industrial fabrics industries.

The material properties, structural design, the design and the manufacturing process determine the quality of a lightweight structure significantly. Therefore, the entire development chain to be considered on mass production and product approval and use of the material and product development.

The research focuses on

Þ     New materials and composite materials

Þ     Manufacturing and joining technologies from the perspective of lightweight

Þ     Functional integration

Þ     Construction and interpretation

Þ     Non-destructive and destructive test methods

more Info: http://www.fraunhofer.de/institute-einrichtungen/verbuende-allianzen/Leichtbau.jsp

About the Fraunhofer LBF
With its comprehensive expertise in the fields of structural durability, adaptronics and system reliability, the Fraunhofer LBF develops, evaluates and implements customised solutions for all safety components – ranging from the materials to whole systems and from the first idea to the product. It works in conjunction with the associated System Reliability and Machine Acoustics department (SzM) of the Technical University Darmstadt and benefits from the experience of a team of around 300 staff. Cooperation projects with renowned partners exemplify its particular closeness to the industry. Automotive and commercial vehicle engineering, rail transportation technology, shipbuilding, machine and plant engineering, aviation, energy technology and other sectors utilise the proven expertise and cutting edge technology provided in the laboratory and testing areas that extend across more than 17,000 m².

Contact:
Prof. Dr.-Ing. Andreas Büter

Spokesmen of the Fraunhofer Lightweight Construction Alliance
Fraunhofer Institute for Structural Durability and System Reliability

In February 2009, the third generation of the permanently occupied Neumayer research station in the Antarctic inaugurated, with the target, to gather long-term and precise data of climate, geophysics and environment in the Antarctic. The operation is designed for 25-30 years, the entire project will cost 39 million €.Besides the main directions of meteorology, geophysics and atmospheric chemistry that are researched since the 1980s, there have been five years, research on infrasound and since 2005 on marine acoustics. All interior rooms of the station are composed of containers which are conjoined with each other, without adjacent inside walls or with a gangway connecting passage, depending on the room size and which all are adjacent to a central connecting passage. All bottoms, ceilings and walls of these living containers have been bonded with COSMOPUR 890/805 to a high strength connection onto the steel frame. The produced container has to withstand a load of 3.000 kg (certified by the “Germanische Lloyd”), cold resistance up to -60°C with sufficient flexibility and flame retardant properties of the adhesive according to Wheelmark (verification certificate of SEE-BG). COSMOPUR 890 / 805 by Weiss Chemie + Technik fulfils all these conditions.

Weiss Chemie + Technik is a producer of adhesives and special cleaners for the manufacturing of PVC-, aluminium- and wood windows and doors.
They furthermore offer a wide range of products for the fields of industry, automotive, navy and trade. Meet them at COMPOSITES EUROPE in Essen  show (14-16 September 2010) in Hall 10-11/C04.

Webcams at Neumayer Station III: http://www.awi.de/NM_WebCam/

The effects that composites have on the environment are also subject to scrutiny.  In response to this trend the AVK (Industrievereinigung Verstärkte Kunststoffe e.V. (The Association of Reinforced Plastics)) took the initiative and formed a “Sustainability” team last year. The objective is to create a platform to discuss experiences and to learn more about the real impact composites are having on the environment and in turn the risks and opportunities they present us with. It is hoped that an evaluation of composites as an eco-efficient solution will be the outcome.

Gabriel Thomas from Ticona GmbH, also The Managing Director of the AVK and Ben Drogt from DSM Composite Resins are the initiators of this team. 
The International AVK Conference traditionally marks the beginning of the COMPOSITES EUROPE.  This is the place where 500 international experts spend two days talking about relevant subjects regarding fibre-reinforced materials.

Also exhibiting at CE 2010 is the French company Nidaplast Composites, the designer of extruded polypropylene honeycomb materials, and who is a leader in terms of sustainable development.  Nidaplast’s goal is the reduction of greenhouse emissions and will therefore reveal a “CO2 balance sheet” for the first time showing the level of CO2 emitted during the life-time of thermo-plastic honeycomb structures.

The honeycombs are light-weight (95% hollow space) and are sandwiched between two panels, thereby making this sandwich structure economical and environmentally friendly. “Nidaplast honeycombs provide advantages for the protection of the environment: firstly their consumption of raw materials is low, and secondly they are lightweight. These factors contribute to lowering the level of greenhouse gases emitted during manufacture and also during transport,” explains Luc Nuttens, the company’s Head of Product Development.

The “CO2 balance sheet” confirms Nidapast’s commitment to providing its clients with solutions in the field of environmentally-friendly design. The “CO2 balance-sheet” was developed by the French Environment and Energy Management Agency ADEME and is a standardised method for the measurement of greenhouse gas emissions resulting directly or indirectly from an activity.

Part 2:

Food safe insulator
Sandwich elements feature exceptional insulation characteristics when a fiber-reinforced composite (GRP) is combined with PU or XPS foam. The decisive factor in this respect is the composite material’s low thermal conductivity, which also gives it a distinct advantage over steel sheeting and aluminum. It can thus be used to build effectively insulated refrigerated containers and refrigerated vehicle bodies. For example, the insulation effect in a sandwich element consisting of two-millimeter thick layers of GRP and a fifty-millimeter thick layer of polyurethane foam can be compared with that of a forty-millimeter thick cavity block wall. As the material is also optionally produced with a pore-free surface, it can also be used for temperature-controlled transportation, haulage of foodstuffs and in vending trucks. Fitted as an interior face sheet, it can be very easily cleaned and leaves no residues and is thus able to comply with strict hygiene requirements. LAMILUX fiber-reinforced composites are also food safe, which means they do not release toxic substances into foodstuffs. This quality is substantiated by test certifications.

Highly resistant and an attractive surface finish
In addition to these important features, LAMILUX materials also excel due to their long service life and their durability. When used as a component in sandwich elements, they provide such an efficient stabilizing effect that side walls and floors are easily able to withstand the high compressive and flexural stresses experienced in the trucking industry. GRP roofing will also not be dented as a result of a heavy hailstorm. Another advantage lies in the fact that if damage should still occur, even on a large scale due to an accident, the damaged parts can be easily repaired or whole GRP sections can be replaced. Excellent resistance to UV light, weathering and corrosion also ensure a long service life and color fastness. These outstanding characteristics have been demonstrated by extensive, internationally recognized test methods such as the XENO test, long-term weathering tests, and the salt spray test in compliance with DIN EN ISO 9227.
In addition to these physical and chemical properties, fiber-reinforced composites also impress due to their attractive surface finish. Besides high-gloss and high-grade finishes, the material can be manufactured in a variety of colors, such as those in the RAL and NCS color systems, or customer-specific colors. GRP offers the advantage that color particles are worked directly into the material during the production process. As a result, applying a subsequent paint finish is unnecessary. Moreover, the surface won’t chip due to corrosion or mechanical effects, unlike conventional paint finishes on steel sheeting or aluminum.