JEC COMPOSITES MAGAZINE - Issue #119 - Supplement lnnovation report - 28

JEC WORLD 2018
Project Cedrus: advanced carbon hydrofoil for kite
Project Cedrus introduces the most advanced
manufacturing processes from aerospace,
automotive, and consumer products to the
world of sporting goods.
The first mass-produced hollow carbon hydrofoil for kite, windsurf, SUP, and surf offers
reduced weight and cost while improving safety and environmental impact of the activities
we love. Designed entirely using CAD and
finite element analysis, a single prototype and
set of molds was all that was needed for validation, dramatically reducing development
costs, schedule, and waste. The structural box
of the mast is produced in two pieces using
low cost open molding techniques, and bonded together using advanced adhesive application.
This eliminates the need for expensive bladder

Sports & Leisure

molds or high pressure tooling, and allows
optimization of the layup tailored to the rider's style and weight. Non-structural leading
and trailing edges extruded from soft thermoplastic polymers such as TPU or flexible
PVC are then adhesively bonded to the front
and rear spar, producing a hybrid structure
offering necessary strength and stiffness, with
reduced weight, cost, and improved safety
and durability. The design is material and process agnostic, and easily scaled for higher rate
manufacturing using stamping, CCM (continuous compression molding), or even HP
RTM. In addition to lower weight and cost,
the design and assembly process allows for the
integration of metallic fittings and adapters to
interface with any foil board for any sport. The
innovative technology will be available on foils

Finalist: Adherend Innovations, LLC (USA)
Partner: Composites Universal Group (USA)

produced for Bay Area Kiteboarding as the
launch customer, followed shortly by the surf
foil market. The technology is also available for
license, in the interest of improving the safety
and performance of equipment in all forms of
hydrofoil sports, and to reduce the environmental impact of these activities.

MAI hiras + handle: motorcycle rear swingarm
A complex shaped structural module, a motorcycle's rear swingarm, produced with a carbon fiber reinforced thermoplastic has been
realized and successfully tested. Between the
predicted results of the simulation and the
hardware test was a very good coherence.
One of the most important results is the extraordinary process concept which allows to
produce parts with various mechanical properties with one injection mold.
This modular construction system allows to
align the mechanical properties of the part
to the demand of the structure and this in
in accordance with different costs, only by

a modification of the endless carbon reinforced insert or by welding additional structural covers.
During the development of the part a lot of
detailed problems had to be solved, e.g. how
to place the tape on a curved surface and how
to achieve a good adhesion between tape and
metallic inserts.
Beside the automated injection molding process the production of inserts with and endless thermoplastics tapes has been realized in
a fully automated and controlled process.

Finalist: BMW Group (Germany)
Partners: EDAG Engineering GmbH
(Germany), KraussMaffei Technologies
GmbH (Germany), Chr. Karl Siebenwurst
GmbH & Co. KG (Germany), TUM-LCC
(Germany), Automation W+R GmbH
(Germany), FHG-IGCV (Germany)

with net shape pre-forming technologies developed by Group CTT, offer superior characteristics. These pre-forms are then processed
using Visceral Performance's proprietary processing technology to create hollow parts.
The end-result is a stick that offers superior
toughness, allowing for an advanced optimization of weight-to-stiffness properties, thus
producing unprecedented performance when
shooting a hockey puck. The thermoplastic
composites also offer superior surface finish
and is fully recyclable.

Finalist: Schappe Techniques (France)
Partners: Visceral Performance Inc
(Canada), Groupe CTT (Canada),
Compsult (Canada), Mat-Comp (Canada)

First-ever Carbon/PEI hockey stick
Current hockey sticks are relatively brittle,
leading to potential breakage and considerable
costs (for multiple replacements during a season). Visceral Performance's LETHAL hockey stick is the first Carbon/PEI Hockey stick.
It is made from Schappe Techniques' TPFL®
Carbon/PEI that allows for the making of porosity-free composites.
The TPFL® made of stretch-broken carbon
fibers also allows for perfect comformability
to the complex geometry of the tool that has
been developped. These features, combined

jec composites magazine / N° 119 supplement - Innovation Report

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #119 - Supplement lnnovation report