Download the flyer with a short description  “Energy Efficiency and Renovation in Buildings & Infrastructure”
	Download the flyer with detailed information “Energy Efficiency and Renovation in Buildings & Infrastructure”

If you are interested and would like to receive more information, please get in touch with:

Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de

	Download the flyer with a short description  “Trends and Design Factors for Hydrogen Pressure Vessels”
	Download the flyer with detailed information “Trends and Design Factors for Hydrogen Pressure Vessels”

If you are interested and would like to receive more information, please get in touch with:

Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de

	Download the flyer with a short description  “Composites in Aircraft”
	Download the flyer with detailed information “Composites in Aircraft”

If you are interested and would like to receive more information, please get in touch with:

Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de

	Download the flyer with a short description  “Utilty & Cargo Bikes”
	Download the flyer with detailed information “Utilty & Cargo Bikes”

If you are interested and would like to receive more information, please get in touch with:

Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de

Download the flyer with the key facts on the Joint Partner Project “Cell-to-Pack Battery Casings”

If you are interested and would like to receive more information, please get in touch with:

Alexander Knauff
Manager Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 16
Mobile: +49 177 283 5184
Email: alexander.knauff@azl-aachen-gmbh.de

Download the flyer with the key facts on the Joint Partner Project “Lightweight Tailgate”

If you are interested and would like to receive more information, please get in touch with:

Alexander Knauff
Manager Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 16
Mobile: +49 177 283 5184
Email: alexander.knauff@azl-aachen-gmbh.de

The purpose of this project was to develop a simple drop tower set up for oblique foreign object penetration impact testing. Different materials, monolithic and sandwiches and material combinations, are compared on equal safety level and suitability for battery casing.

Results:

• An application relevant test method for penetration damage to bottom materials for battery casings.
• Relative safety performance of different material options, such as solid laminates, sandwiches, different thicknesses and layups, in comparison with aluminum reference material.
• For each material it will give guidance what minimum amount is needed to prevent penetration or unacceptable damage.

Download the flyer with the key facts on the Follow-up Project “Bottom Impact Protection”

This project is closed, for more information regarding questions please contact us directly:

Philipp Fröhlig
Senior Project Manager | AZL Aachen GmbH
Phone: +49 241 475735 14
Email: philipp.froehlig@azl-aachen-gmbh.de

The purpose of this project was to develop a fire testing procedure for materials and material forms, enabling the evaluation of suitability for the EV battery casing.

Results:

• A standard test method enabling suitability of various materials for fire safe application in a battery casing.
• Comparison of relative performance of various materials and/or protection layers.
• Guidance to minimum material needs to survive battery fire testing.

Download the flyer with the key facts on the Follow-up Project “Fire Protection”

This project is closed, for more information regarding questions please contact us directly:

Philipp Fröhlig
Senior Project Manager | AZL Aachen GmbH
Phone: +49 241 475735 14
Email: philipp.froehlig@azl-aachen-gmbh.de

Based on the frequently addressed requirements from the industry AZL was kicking-off a fourth phase to follow up on the developments of the AZL Joint Partner Project Cost- and Energy-Efficient Double Belt Press System” (project phase III) on August 30th, 2021.

In November 2020, the Joint Partner Project to improve the AZL “Cost- and Energy-Efficient Double Belt Press System” has been successfully accomplished. As result of the project, the isobaric double belt press system now accomplishes max. temperatures up to 300°C and is equipped with a closed-loop temperature control, optimized control system and HMI and with a belt cleaning system. The machine concept has been validated by extensive material and processing studies for the demonstration of wide applicability of the novel machine concept. Impregnation studies on thermoset as well as on thermoplastic material have been accomplished.

In order to investigate the full potential of this double belt press technology, further system upgrades, process trials, and optimizations for different materials and tasks were planned for the 12- week follow-up project.

The process temperature for the processing of high-performance polymers was raised >300°C with the aim to achieve up to 400 °C.
The press was expanded to include isochoric functionality so that, for example, foam or honeycomb cores can be processed.
This isochoric functionality was combined with the existing isobaric functionality.

Also included in the project were vouchers for bilateral testing on the double-belt-press. The newly patented machine has already been used by many industrial partners bilaterally.

This project is closed, for more information regarding questions please contact us directly.

Alexander Knauff
Manager Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 16
Mobile: +49 177 283 5184
Email: alexander.knauff@azl-aachen-gmbh.de

In a third stage of AZL’s project of the machine-development of 5-seconds fully consolidated multi-layer composite laminate production, additional heating elements were investigated and subsequently added.

The “Ultra-Fast Consolidator Machine” for the production of tailormade laser-assisted in-situ consolidated TP-FRP laminates within cycle times of less than 5 seconds was build up from white paper by AZL in close cooperation with industrial partners.

The third stage of the project the improvement of the thermal management is focused in order to exploit the high potential of the system and to further enhance the resulting laminate properties.

As requested by industrial partners a technical and economical comparison of laser and infrared heating systems were conducted.

In the previous phase II, the tape placement machine was expanded to create a highly productive, fully automated close-to-series production system. Extensive system tests, process investigations and laminate qualifications were successfully carried out.

Four companies have joined the 12-week project: Easicomp GmbH, Laserline GmbH, Maru Hachi Corporation and Mitsui Chemicals Europe GmbH

The project offered the additional benefits of cost-sharing, co-design of the content of the development and individual trials as well as the exchange within the consortium.

The machine system was also available for bilateral testing to all companies.

This project is closed, for more information regarding questions please contact us directly.

Alexander Knauff
Manager Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 16
Mobile: +49 177 283 5184
Email: alexander.knauff@azl-aachen-gmbh.de

The future of automotive drive systems is electric. In the foreseeable future, the number of electrically driven vehicles will outweigh the number of combustion engines. A key issue in the direct comparison of the technologies is the range in connection with energy storage and the integration of batteries in the various vehicle concepts through light and robust battery casings.

Multi-material concepts based on composites offer high potential to meet the various requirements for functionality and performance. Compared to “conventional” battery boxes for electric cars, which are mainly made of aluminum and steel, composite solutions offer, among other things, lower weight with higher stiffness. Corrosion resistance as well as impermeability to various fluids are also among the decisive advantages.

The project aims to give an overview about existing solutions, applications, supply chains and their players as well as market potential. The advantages of a multi-material approach are evaluated. In the end an exemplary multi-material battery casing were developed and a production concept was derived. After this project a follow-up project addresses the realisation of this developed concept by manufacture of the multi-material battery housing which are used as a demonstrator product in the future.

This project is closed, for more information regarding questions please contact us directly.

Download the flyer with the key facts to the project

Within the Joint Partner Project “New Designs for Low-Cost and Energy-Efficient Double-Belt Presses” and the Follow-Up Project which was successfully accomplished in May 2019, a prototype machine of an Inductive Double Belt Press was developed, designed and built. The general machine concept has been validated.

This third project with the focus on process evaluations comprises an upgrade and optimization of the system for advanced material and processing studies and includes extensive material and processing studies for demonstration of wide applicability of a novel machine concept to identify which materials can be processed at which speeds, which requirements do exist using the material and which reproducibility can be achieved in impregnation and consolidation. It is also examined how thermal process parameters influence the product quality and how the different pressure profiles enable different laminate types.

This project is closed, for more information regarding questions please contact us directly.

Download the flyer with the key facts on the Follow-up Project “Inductive Double Belt Press”

By implementing the prototype machine, the initial Joint Partner Project is completed. The partners decided already to continue the joint research with a follow-up project which comprises the prototype upgrade and optimization for advanced material and processing studies as well as extensive material and processing studies for demonstration of wide applicability of the novel machine concept in the industry.

This project is closed, for more information regarding questions please contact us directly.

A follow-up project started at the end of 2016 to progress on the developed double-belt press system with the aim to build an industry-scaled machine according to the pursued concepts. The final design phase of the novel double belt press machine system has already been reached. The optimization of the inductor homogeneity is currently in progress, so is the procurement of induction heating equipment. AZL is preparing a scale-up estimation regarding cost and energy consumption of the system.

Large-scale production of composite sheets can be achieved by a continuous production process using double-belt presses. Current machine designs however suffer from low energy efficiency as well as strong limitations concerning the product geometry flexibility.
In the first project phase, the AZL, together with six partner companies, developed a prototype for proof-of-principle of a novel cost and energy-efficient double-belt press system for the continuous production of composite sheets. A follow-up project will start at the end of 2016 to progress on the developed double-belt press system with the aim to build an industry-scaled machine according to the pursued concepts.

To increase resource-efficiency in the production of continuous fiber-reinforced plastics, the processing of scrap-optimized blanks with defined fiber alignment (“tailored composite blanks”) on basis of unidirectional semi-finished products (thermoplastic tapes, tow-pregs or dry-fibres) offers high potential compared to textile-based pre-products. Nonetheless, today’s production systems for the manufacturing of tailored composite blanks are limited in throughput per system.
The 18-month Joint Partner Project involves 12 Partner Companies from seven countries to develop a machine prototype for proving the feasibility of a novel manufacturing principle to produce tailored composite blanks in seconds at medium investment cost.

The biopolymer market is expected to grow from USD 10.5 billion in 2020 to USD 27.9 billion by 2025. Market trends like focus on sustainable production or availability of cost-effective bio-based raw materials are driving forces. Thus, bio-based polymers are already established in the packaging industry, the further potential in industrial applications, especially in composites remains to be discovered.

The project aims to evaluate the potential for future applications of bio-based composites. It provides a comprehensive investigation and documentation on the current and future markets, an overview about technical challenges and requirements and analyses most promising applications within business cases.

Project Start: 22th October 2020

Project Duration: 5 months

Download the flyer with the key facts to the project

The study “Next Generation Mobility Solutions” addressed the possibilities of implementing new mobility solutions and the connection to composites. Within the study the AZL provided a market segmentation and analysis to discuss the most promising markets and applications.

The study also provided a comprehensive investigation and documentation on the key trends and state-of-the-art solutions, applications, materials and technologies in the mobility market. Furthermore, it reflected the technical requirements of these products.

In the project a technology matching was carried out with the aim to present composite based production processes and materials that fit existing and upcoming mobility technologies and driving forces of the focused markets segments.

The study is closed, for more information regarding questions and a final report please contact us directly.

Project Start: October, 2019
Project Duration: 6 months

Download the flyer with the key facts to the project.

Click to read Johns Manville’s Statement to their participation in the study.

Composites offer a broad possibility to be used in furniture parts and structures. AZL addressed these potentials with a short-term study identifying potentials and USPs of composites in growing furniture market, including a furniture market segmentation, elaboration of technical requirements as well as identification of high-potential applications. The aim was to understand the material selection process of furniture designers to increase the use of composites in furniture parts.

The study answered questions such as: 

• • What are the key trends in design & technology and what is driving this market?

• • How does the future of furniture look like?

• • How can the market be segmented?

• • What are today’s and upcoming technical requirements of furniture products?

• • How do today’s value chains and state-of-the-art processes & materials look like?

• • Where do composites fit in to these trends and driving forces?

• • Where can composites add value in design & manufacturing?

• Where have composites already been applied successfully?

The Procedure:

The study was structured in four short-term phases completed in 4.5 months and provided a brief and comprehensive insight into the market potential and technological requirements.

Download the flyer with the key facts to the project.

Thermoplastic tapes enable new and innovative designs and improved properties for injection molded parts: As local reinforcements, tapes allow for increased stiffening, cost savings, higher surface hardness or enhanced optics. Small and medium-sized injection molders in particular can achive great advantages from tapes. Yet the high number of injection molding companies in Germany and other countries makes rare use of thermoplastic tapes and their potential.

The study is addressing this need to increase the use of tapes in injection molding. With a systematic identification of suitable applications and background on development and manufacturing processes, the study is supporting SME injection molders to make use of the potential of thermoplastic tapes. Tape manufacturers and machine and tool builders on the other hand will get in contact to potentially new customers and will get insights in their requirements and pitfalls in using thermoplastic tapes in their processes.

Keyfacts of the study:

• • Reaching out and understanding the SME injection molders base

• • Systematic identification of potentials for thermoplastic tapes in injection molding

• Provide an extensive documentation of the state of the art methologies and technologies for the development and the production of parts

Systematic Procedure in 6 Months

The 6-months study started with an overview on the status at typical injection molders evaluating their know-how in thermoplastic composites, barriers, chances and risks as well as their typical innovation process. These insights were derived from expert interviews as well as visits. In a second phase, the technology experts identified application potentials in a systematic procedure: Advantages and challenges of hybrid thermoplastic composites compared to conventional plastics were identified and applications were clustered and benchmarked. The study concluded with recommendations for actions: Business cases for hybrid thermoplastic parts gave concrete examples for parts. Recommendations for action to overcome technical and organizational barriers were given together with a practical guide including guidelines for project initiation, design, manufacturing and planning.

In mobilizing the injection molding and composite community the AZL and IKV draw on their strong networks of more than 370 companies in total covering the entire value chain from material suppliers and system and tool manufactures, over molders to OEMs. The AZL and IKV both have a strong background in developing a market overview and a profound technological insight into composite processes, materials and applications. Being one of the largest plastics institutes, the Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University is an innovation driver and research partner having many years of experience in all areas of plastics technology. The Aachen Center for Integrative Lightweight Production (AZL) of RWTH Aachen University is specialized in research on integrated and combined process chains for multi-material systems.

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The Joint Market and Technology Study on “Energy Storage Systems” is motivated by the strong market growth which is apparent for energy storage systems. The market volume in Germany is expected to grow from about 2.5 billion euro in 2011 to approximately 14 billion euro in 2025 (Source: www.statista.com, 2015). The globally unstoppable transmission of energy supply by renewable energy will only be accomplished with efficient energy storage systems.

With a strong focus on the technological analysis of established, emerging and still developing systems and technologies, the study will offer a broad decision basis for the business development of companies. The results are relevant for suppliers of materials, of processing technologies as well as of systems and machinery who want to evaluate the potential of their products, their production technologies as well as their know-how in the field of energy storage systems.

Starting with a detailed market segmentation including an assessment of the economic and technological potential, the technology readiness level as well as important key players will be analyzed. All the important technologies in the field of energy storage, chemical energy storage as well as thermal energy storage are considered. The team of experts will identify use cases in the field of energy supply, of operating energy grids as well as of mobile and permanent decentralized applications. Different system configurations, materials and components will be analyzed with the aim to identify technological enablers. The study will additionally reflect supply chains (supplier of systems, materials and technologies) and business models with future technological potential and requirements.

Key facts:

• Addressed market segment: Energy storage systems
• Duration: 8 months
• Start: January 2018
• Status: Completed
• Addressed participants: Companies seeking new business opportunities in the field of energy storage systems

Our partners/supported by:

• RWTH Aachen University
• CONBILITY GmbH
• Bundesverband Energiespeicher (BVES) [German Energy Storage Association]

Download the flyer with the key facts to the project.

Read more on the Kick-Off meeting on January 30th, 2018.

The Joint Market and Technology Study on High-Performance SMC of AZL and IKV aims at broadening the understanding of interdependencies by providing in-depth knowledge on SMC applications and technologies, key challenges, and technological solutions for establishing High-Performance SMC. This will serve as basis for the elaboration of design guidelines, a target-oriented development and to open up new business opportunities.

Scope and content of the study have been developed in close collaboration with the industrial AZL Workgroup which was established in an initial workshop in 2016 with more than 60 participants from the industry, including several automotive OEMs such as Audi, BMW, Ford, Hyundai, MAN, Toyota and Volkswagen. During several meetings, the industrial workgroup defined different joint research and development initiatives to build a toolbox for HP-SMC, one of them being the Joint Market and Technology Study on High-Performance SMC.

The 12-months study is designed as a joint study involving players along the entire value chain. This approach allows participants to benefit from the knowledge of all study partners and experts who are involved in the project. Study participants will be a direct part of the study and will be able to influence the progress according to their specific demands.

Key facts:

• Addressed market segment: Automotive, Electronics, Buildings and Construction
• Duration: 12 months
• Start: September 2017
• Status: Completed
• Addressed participants: all composite players as well as material suppliers, equipment and mold suppliers, part manufacturers, OEMs or engineering suppliers and part developers

Download the flyer with the key facts to the project.

Copyright: Fraunhofer Institute for Production Technology IPT

The Joint Partner Study “Assessment of Existing Standards for FRP Pipes and Vessel towards Development and Qualification” will start end of July 2017 with a duration of 4 months and is open for AZL Partner Companies to join.

Pipes and vessels represent an ideal application for fiber reinforced plastics (FRP). Therefore FRP are of growing interest for fluid transportation and storage in industries like oil, water or gas, but also for the transportation and automotive sector. Lightweight for low handling and transportation cost, non-corrosiveness for long service life are some drivers behind that interest. In return, the processing of traditional materials, such as steel and aluminium, is well established and consequently, development and qualification efforts are often lower than for FRP.

FRP pipes and vessels need standardization to compete with metal-based vessels.

Within the AZL Pipes and Vessels Workgroup a market study on FRP pipes and vessels was alreadyconducted to gain a current market overview about relevant industrial applications. The results was presented during the last workgroup meeting. In addition the “Assessment of existing standards for FRP pipes and vessel towards development and qualification“ will be conducted in this Joint Partner Project. The study will include investigations and analyses of relevant applications for FRP pipes and vessels in different market segments, such as oil and gas, water and automotive Industry. A detailed overview on requirements, existing standards (material and product related) as well as test and measurement methods for materials, pipes and vessels qualification will be given. The results will be presented exclusively to the project participants.

Key facts:

• Addressed market segments: oil, water or gas, transportation and automotive
• Duration: 4 months
• Status: Completed
• Addressed participants: all AZL partner companies

AZL Partner Companies find further information at the AZL Partner Section.

Please contact us for information on the results >

Buildings & Infrastructure – comparable to the transportation sector – are markets with enormous and growing potential for lightweight materials and related technologies. The new construction but also the rehabilitation and the renovation of existing Buildings & Infrastructure components will play a decisive role.

Within this Joint Market and Technology Study new potentials for composite technologies in Buildings & Infrastructure will be identified. Drawing on technical expertise, but also a well-grounded knowledge of market specific information, AZL is determining where and with which products, materials and production technologies new business opportunities will open. Therefore, AZL is creating and rating new scenarios for high potential applications and will provide necessary information to support product and service development of participating companies.

In two prioritization workshops, AZL together with the study partners determine the key segments as well as ten technologies/applications with the highest market potential which will be investigated in detail. The study will comprise application analyses of 12 market segments, investigation of 100 applications, technology analyses of 25 highlight components and 10 detailed business cases. Besides requirement analyses for materials and production technologies, new concepts for efficient profitable production technologies are developed including cost engineering analysis.

The study is open for all companies along the value chain of the composites as well as buildings & infrastructure market. AZL and AVK partner companies can participate at a reduced fee.

Get an overview on all AZL activities related to Buildings & Infrastructure here.

Key facts:

• Addressed market segment: Buildings and Infrastructure
• Duration: 6 months
• Expected start: November 2016
• Status: Completed
• Addressed participants: all composite players as well as companies from the buildings & infrastructure market such as architects, designers, structural engineers or general contractors

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The first AZL Market and Technology Study in 2013/2014 addressed the overall lightweight market to provide a systematic and structured market overview of current lightweight applications, parts and materials, production technologies as well as material and system suppliers.

450 applications were investigated from which 50 highlight components were chosen and analyzed in detail resulting in technology demonstrators. 12 business cases were developed giving application-related insight into large-scale lightweight production scenarios.

Key facts:

• Addressed market segments: Transportation, Oil/ Water/ Gas, Building and Construction, Renewable Energy, Consumer/ Sports/ Leisure
• Involved partners: 34 companies of the whole value chain (material supplier, molder, manufacturing equipment supplier, Tier 1 and 2, OEM)
• Duration: One year, 2013-2014