The two-day CU Innovation Day “Sustainable Production of Composites – Materials & Eco-Efficiency” at the Leibniz Institute for Composite Materials in Kaiserslautern brought together experts to discuss innovative approaches for the sustainable production of composites. The event offered exciting presentations, a factory tour and numerous opportunities for professional exchange.
On November 12 and 13, 2024, Composite United (CU) hosted the Innovation Day “Sustainable Production of Composites – Materials & Eco-Efficiency” in Kaiserslautern. The event was organized by the CU working group “Biocomposites” and the AVK working group “Natural Fiber Reinforced Plastics”, supported by the host, the Leibniz Institute for Composite Materials (IVW). The conference focused on the topics of sustainable production, bio-based materials and the further development of eco-efficiency, which are becoming increasingly important in view of stricter regulatory requirements for the carbon footprint. Prof. Dr. Ulf Breuer, Scientific Director of IVW, opened the event and provided insights into the research work of the institute, which employs 140 people along the entire value chain from material development to production. With around 40 participants, the event provided a platform for presentations, discussions, networking and practical insights into the work of IVW through a factory tour. “Composite materials are in competition with other materials. The conference topics of sustainable production, bio-based materials and the development of eco-efficiency are key to developing a sustainable competitive position against the backdrop of legislative requirements regarding carbon footprints,” said Dr. Heinz Kolz, Cluster Managing Director of CU West, in his welcoming address.
Keynote: Fiber-plastic composites – A key to sustainable lightweight solutions?
In the keynote speech, Prof. Dr.-Ing. Thomas Neumeyer and Dr. Barbara Güttler (both IVW) together with Prof. Dr.-Ing. Luisa Medina (Kaiserslautern University of Applied Sciences) highlighted key approaches to promoting sustainable lightweight construction concepts in line with the German government’s lightweight construction strategy. This focuses on recyclable design, innovative production methods and closed material cycles in order to achieve material and energy savings. A key point is the 9R strategy, which is aimed at smart product use and extending service life through repair. The focus is also on the development of resource-saving materials such as biopolymers, whose market is set to grow by 10-24% by 2030, and the recyclability of carbon fibers in order to make the energy-intensive manufacturing process more efficient. In addition, natural fibers were highlighted as a lightweight construction material, particularly for applications in the automotive and construction industries, with annual market growth of 5-7% forecast. These developments highlight the importance of innovative, sustainable composite materials for the future of lightweight construction.
Sustainable materials
The first session of the event was dedicated to the topic of “Sustainable materials” and presented pioneering approaches to the optimization of natural fibres and their use in composite materials. In his presentation “Quality assurance for domestic natural fibers for use in natural fiber-reinforced plastics”, Holger Fischer from the Faserinstitut Bremen shed light on the challenges and potential of uniform quality management for natural fibers. He underlined the need for international standards in order to make the processing and use of bast and leaf fibers more efficient. Luisa Medina from Kaiserslautern University of Applied Sciences presented the results of the EU project rLightBioCom in her lecture “New HPC components based on sustainable textile products and bio-resins”, in which natural fibres and basalt fibres were hybridized in order to develop composite materials with optimized properties. The final presentation was “MDTA4 testing: separation of cardable fibers and trash” by Dr. Ulrich Mörschel (Textechno Herbert Stein GmbH & Co. KG). He presented innovative testing technologies, such as the MDTA4, which is revolutionizing the analysis and cleaning of natural fibres with the help of modern AI systems. These developments illustrate the progress and potential of sustainable materials for the lightweight construction industry.
Eco-efficient production
The second session of the event, entitled “Eco-efficient production”, was dedicated to innovative strategies for promoting sustainable production methods. Hendrik Hahlbom from the Leibniz Institute for Composite Materials (IVW) presented the potential of polyhydroxyalkanoate (PHA) as a biodegradable plastic in his lecture “Processing and characterization of PHA films (Waste2BioComp)”. Obtained from organic waste through fermentation, PHA offers excellent barrier properties against water and oxygen and could represent a sustainable alternative to polyethylene and polypropylene.
Dr. Markus Schneider from Teijin Carbon Europe presented sustainable approaches for the production and use of carbon fibers (CF) in “Tenax Carbon Fibers deliver Sustainability”. He highlighted the benefits of CFRP in aviation and wind power and emphasized the importance of recycled carbon fibers and a zero-waste strategy that Teijin is pursuing. The company aims to become CO₂-neutral by 2023 through the use of renewable energy and optimized material flows. Finally, Dr. Markus Steeg from Automation Steeg und Hoffmeyer GmbH highlighted energy-efficient production technologies in his presentation “Technologies for sustainable FRP production”. Lightweight construction, miniaturized components and intelligent control systems significantly reduce energy requirements in production. In addition, the integration of renewable energies opens up new possibilities for the sustainable optimization of machine structures. These contributions underline the importance of eco-efficient production methods for the future of the lightweight construction industry.
Applications in sustainable lightweight construction
On the second day of the CU Innovation Day, Prof. Thomas Neumeyer opened the third session entitled “Applications in sustainable lightweight construction”. As a sustainable material, wood offers great potential for composite materials thanks to its natural properties and biotechnological modifications. Dr. Emanuel Akpan from the Leibniz Institute for Composite Materials showed in “High-performance composites made from wood fibres” how innovative processes such as in-situ lignin engineering can be used to develop high-performance, binder-free materials that promote the circular economy and resource conservation. In “Ecological sustainability assessment of composites components”, he explained M. Sc. Ul-rike Kirschnick from the Montanuniversität Leoben explained the importance of life cycle analysis (LCA) in the evaluation of composite materials. Mechanical recycling enables the reuse of glass fiber components (rGF), which reduces environmental impacts. The choice of suitable recyclates requires careful consideration of technical requirements and environmental benefits. Closed-loop recycling of production offcuts offers both economic and ecological benefits. In their presentation, Sabine Hummel and Theresa Pscherer from Rosenheim Technical University of Applied Sciences showed how mechanically recycled organic sheet offcuts can be returned to the production cycle. The results prove that recycled materials meet the technical requirements and at the same time reduce the environmental impact. Finally, Fabian Groh from Audi presented the “ECo2Floor – vehicle underfloors made from natural fibers and recycled polypropylene” project. The innovative material mix significantly reduced the carbon footprint of future electric vehicles and passed all tests for series production. With a CO₂ reduction of 40% in the vehicle underbody, the project demonstrates a successful combination of sustainability and technical requirements.
Laboratory visit at IVW: focus on future technologies
During the laboratory visit at IVW, the participants were given an insight into the laboratories and pilot plants at IVW, divided into the areas of materials analysis, component testing and processing technology. In materials analysis , material analysis methods from the EU project Waste2BioComp were presented, with a focus on the investigation of polyhydroxyalkanoates (PHA) with regard to crystallinity and thermal stability. In the area of component testing , systems for crash tests, coupled tension-compression-torsion tests as well as high-speed and fatigue tests, which can also be carried out under temperature-controlled conditions, were impressive. In processing technology , the focus was on the digitized production of CF-SMC, in which the fibre orientation of cut rovings is analysed using a polarization camera. In addition, innovative processes for winding and tape laying technology and a forming system with a clamping force of 2600 tons and an injection moulding unit were presented, which enable hybrid lightweight construction processes on an industrial scale.
Conclusion
Over two days, the Innovation Day provided a platform for knowledge transfer, discussions and networking on sustainable materials and processes in lightweight construction. The panel discussions focused on material availability, substitutability and the circular economy. It was emphasized that natural fibres such as flax and wood still offer untapped potential, while global markets and quality standards need to be systematically considered. The importance of suitable material flows for open and closed recycling loops was also emphasized. Challenges such as the provision of recycled content from specific waste streams and the inconsistent data basis for life cycle analyses (LCA) were critically discussed. Another topic was the role of plastics in the overall LCA of vehicles, which is minor compared to metals and batteries, but is becoming increasingly important due to regulatory requirements and rising costs. The discussion highlighted the need for closer cooperation between industry, research and legislators. The evening event in the Brauhaus provided an opportunity for in-depth discussions and networking in an informal atmosphere. At the farewell, Prof. Thomas Neumeyer thanked the speakers, participants and the IVW organization team and wished them a successful conclusion to the event. Dr Elmar Witten (AVK) underlined the relevance of the topics discussed and announced that they would be explored in greater depth at future events with Composites United, including the meeting of the AVK working group “Natural fibre-reinforced plastics” in May 2025 with a focus on “Standardization”.
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