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.

The energy policy of the German government includes giving greater support to offshore wind farms. The remuneration for this power is to be raised to 15 cents per kilowatt hour. Operators of onshore wind turbines will continue to receive up to 10.2 cents per kilowatt hour. 0.5 cents are paid for power from new wind parks if the old equipment went online before 2002. The new turbine should also deliver twice the amount of power than the old one.

Example of how the crystal structure could be used in the rotor blade of a wind turbine. (Photo: Wüstefeld)

These factors therefore represent healthy prospects for the future of the wind power sector. The manufacturers of fibre-reinforced composites are also expecting to benefit from this development – because modern wind turbines are inconceivable without glass and carbon fibre-reinforced plastics. The organisers of the international Composites Europe (CE) exhibition, to be held from 27 to 29 September 2011 in Stuttgart, recognised this early on and are giving the industry the platform it deserves. Well-known producers and processors of fibre composites for the wind energy sector and the relevant machine producers and suppliers get together each year at the event.

But it is not only the presence of the big names which makes a visit to the exhibition so worthwhile. Jens-Hagen Wüstefeld from Starnberg, for instance, has developed a crystalline structure as a lightweight construction element. It yields an 85 percent reduction in weight, lower manufacturing costs, outstanding rigidity and design flexibility in comparison to a solid material. Starting out with a geometric concept, he made a three dimensional lattice from triangles, similar to a crystal structure. Any forces applied to such a symmetrical grid are distributed optimally to adjacent surfaces and edges.

These lightweight elements can be manufactured to any scale, from any materials and in any form – including those appropriate for wind turbines. The resulting reduced weight of the tower would allow the foundation to be simplified. And the lower weight of the rotor would result in lower bearing loads and therefore reduced wear and greater efficiency in the entire turbine. The reduced amounts of materials required would also reduce production costs. Individual segments can easily be joined together, simplifying both transportation and erection.

In collaboration with the machinery manufacturer Voith, the Audi engineers are setting up the industrial-scale manufacture of fibre-reinforced materials for the series production of cars; their main goal is to develop a fully automatic process chain. With series production their ultimate target, both partners are devoting themselves not only to the creation of processing engineering and mass production methods for conventional fibre-reinforced plastics but also to the development of new and innovative high-tech materials.

The long flap of the folding top cover and the large rear side panels of the Audi R8 GT Spyder are made from CFRP. (Photo: Audi)

To date, Audi has only used CFRPs in its high-priced super sports cars such as the Audi R8 GT Spyder. The long flap of the folding top cover and the large rear side panels of the recently launched 560 PS version of the sports car are made from CFRP. The material is also used in the modified front spoiler, in the fixed rear spoiler and in the new rear bumper. These components account for total weight savings of 5.5 kilograms.

“Low-fat vehicles” featuring fibre composites will also be highlighted at the international Composites Europe (CE) trade fair, to be held from 27 to 29 September 2011 in Essen. The BMW partner SGL Carbon will be there to demonstrate its expertise. The company supplies the carbon fibres for the Megacity Vehicle. This is the first time in which CFRP parts have been used in large-scale series production. This takes the company a step closer to producing affordable lightweight vehicles suitable for mass production based on fibre composites – putting BMW a nose ahead in the technology race. This is shown by the efforts of the rivals who are doing all they can to catch up. Take Audi, for example: it has set up an interdisciplinary carbon fibre research unit at its Neckarsulm plant aimed at adapting the CFRP technology processes for use in series production. The sister marque Lamborghini has also set up a research unit for carbon fibre technologies at the new Advanced Composites Research Center (ACRC) in Sant’Agata Bolognese.

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.

I just got information that in 2011 AVK-conference set up a new new concept.

Compressed into two lecture series high-level speakers inform about various applications of fiber reinforced plastics. Thematically, the two series be divided into decision-makers and technicians blocks. In this way the needs of stakeholders are met even more.

• Structural lightweight applications of thermoplastic composites by Joachim Graefe, Quadrant Plastic Composites AG
• Carbon-thermoplastic manufacturing for the A350 XWB – From Idea to Series Production by Dr. Klaus Edelmann, Airbus Operations Ltd.
• SMC tailgate, which are used in automotive premium segment by Dr. Walter Aichholzer, Mercedes-Benz.

These are just some Topics for 2011 convention. As I am a big supporter of panel discussions I am looking forward to this: “Future prospects of fiber reinforced plastics in the automotive”.
Stuttgart is well known for Automotive so I guess there will be some interesting heads discussing this.

See you there!

More Information:
International AVK-Conference
26. bis 27. September 2011
ICS Internationalen Congresscenter, Stuttgart
http://www.avk-tv.de/

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

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.

Part1: 

Weight can only be reduced in truck bodies, trailers and containers if innovative materials are used extensively in side walls, roofs and flooring. Such materials are far superior to conventional materials such as steel sheeting and aluminum, particularly due to their light weight and stability. Fiber-reinforced plastics are pointing the way forward in this respect. These composite materials feature a low mass per unit area while offering optimum strength, even when layers are thin.
These materials may be integrated into all sections of truck bodies, trailers and freight containers and can widely replace materials such as aluminum and steel sheeting. The ultra-light, extremely sturdy composite material serves as interior and exterior face sheeting in sandwich elements which are used to build roofing and side walls. Floors are also lined with fiber-reinforced composite sheeting, so that they are able to withstand heavy loads. Such sheeting could serve, for instance, as anti-slip decking with granular aggregate.

Strong and lightweightThe robust, lightweight, high-tech material mostly consists of fibers and resin. The material’s physical and chemical characteristics are determined by the type of fiber and the fiber arrangement it features, such as woven fabric or multiaxial fabric, and by the kind of resin formulae used in production.
The result is a long-lasting, sturdy, ultra-light material which optimally reduces tare weight when used in trucks and containers, and, consequently, heavier payloads can be carried. Fiber-reinforced composites compare favorably with conventional materials regarding their typical use as face sheets in sandwich elements. Whereas steel 0.6 millimeters thick has an absolute weight of 4.7 kilograms per square meter, LAMILUX’s 2.0 millimeter-thick fiber-reinforced composite weighs just 2.7 kilograms. Aluminum 1.2 millimeters thick is also clearly heavier at 3.2 kilograms. This means using fiber-reinforced composites can reduce weight in sandwich facing by around 40 percent in comparison to steel and by around 15 percent when compared to aluminum.

Up to 92% of the fuselage of the A350 XWB aircraft will consist of composites made using the “Viper” machines.  These parts account for over 50% of the structure’s weight. 14 other MAG composites plants are also in use at Airbus and its European partners – four “Viper” and ten “Charger” ATL tape laying systems which are deployed to produce body parts, wing elements, jet engine casings, stabilisers and other structural components for the A320, A330, A340, A380 and A400M models.

MAG will be one of the exhibitors at the international Composites Europe (CE) trade fair, to be held from 14 to 16 September 2010 in Essen. Composite materials for the aerospace industry will play a major role here, with numerous companies servicing this segment.  Flugzeug-Union Süd GmbH (FUS) is one example; it supplies materials like vacuum films, separating foils, tear-off fabrics, liquid separating agents, sealing tapes and absorbent non-wovens to nearly all the major producers in the aviation industry. These are used to produce e.g. horizontal stabilisers and fins, wings, landing flaps, radomes, pressure bulkheads, interior fittings, doors, rotor blades and fuselage segments.

Tajima GmbH is presenting its machine technology for preform manufacture. Its TFP machines are distinguished by the fact that the fibres – be they CRP, GRP, or aramid – are arranged in the same way as later in the component itself. The size of the laying field, the number of heads and the fixing device for the carrier material can be individually adapted.  The Tajima machines are used to produce structural frame parts and also parts of the aircraft skin.

The Krempel group supplies prepreg materials with thermosetting and thermoplastic matrix systems, complex fibre-reinforced components, filament-winding tubes, extruded plastic profiles and plates to the aerospace industry. The composite materials have been fitted in different types of Airbuses for over 20 years now. The handles of the emergency exits in the Airbus A 320, for example, are made from Wacosit profiles manufactured by Krempel.

Roughly 100 customers in the aviation industry use adhesives, laminating resins and self-extinguishing materials in aircraft interiors supplied by Axson GmbH. Thanks to their self-extinguishing properties these materials are ideally suited for this purpose. A further company active in this field is Huntsman. The company has developed a new nano-hardened epoxy adhesive paste with good mechanical properties for joining and piecing together metal and composite aircraft structures.

For those who cannot wait until the technology show in Essen, an event will be held in just two months focusing on the latest developments in the aerospace industry. Aerospace Testing, Europe’s leading get-together for the aerospace industry, will be held from 18 to 20 May in Hamburg. The event brings together experienced developers and the leading trade suppliers: plenty of valuable technical information will be on offer.

A study carried out by the European Wind Energy Association (EWEA) shows that capacity increased by just under 20% to almost 65,000 megawatts in 2008. The possibility for growth is much greater in the UK than in Germany. In the offshore field in particular the UK has great potential. According to figures issued by the British Wind Energy Association (BWEA), 600 megawatts are currently in the construction phase, more than 1,200 megawatts already have approval and a further 6,600 megawatts are at the concrete planning stage.

One reason for the great interest in the UK is the comparatively generous remuneration. A British wind plant operator receives over ten cents per kilowatt hour. This total is made up of the energy certificate price, credit from tax exemption for renewable energies, a climate tax (climate change levy – roughly 0.50 cent per kilowatt hour) and the market price for electricity. A typical feature of the British wind industry is that the projects are planned and constructed primarily by large energy groups such as Scottish Power, Eon UK, RWE Npower or Scottish & Southern, both on water and on land.

RWE Innogy was recently awarded a contract by the British government to develop roughly 4,000 megawatts of offshore wind energy at Dogger Bank off the coast of Yorkshire in the east of England. The Little Cheyne Court wind park was officially opened last year in Kent. Delivering an installed output of roughly 60 megawatts, it is the largest onshore wind park in the south-east of England. The 26 wind turbines of the 2.3 megawatt class from Nordex supply renewable energy to over 33,000 households in the UK each year.

The case of Nordex shows how not only the power groups themselves but also the manufacturers of wind power equipment can benefit from the Brit-boom. The main prerequisite for producing the gigantic wind blades is fibre-reinforced plastics – as only they offer the necessary strength at the correspondingly low weight.

Gaugler & Lutz from Aalen, Germany are one example for showcasing innovations for the wind power sector at the COMPOSITES EUROPE 2010 . Material deliveries to the wind energy sector constitute a large proportion of its total sales. Its customers include all well-known German wind power equipment makers. The company is specialised in the manufacture and assembly of core materials for lightweight and sandwich construction. Besides different types of foam and balsa wood, the company also supplies reinforcing fibres and has its own production operation.  Roughly 4,000 rotor blades are manufactured each year using materials supplied by the company.