AIR’s eVTOL offerings now include an unmanned variation of AIR One for cargo and logistics use, featuring its agile design across different use cases.
Long-term supply agreements include KRD for windows, Latecoere for the aircraft’s doors, as well as Rallc and Alltec supplying composites expertise for fuselage development. Carbon Fiber Battery Brace
This is Archer’s second full-scale eVTOL aircraft to achieve this milestone, critical to being able to carry commercially viable passenger payloads.
Model includes new technologies produced at Performance Manufacturing Center (PMC) in Marysville, Ohio, which is part of Honda hydrogen business strategy that includes Class 8 trucks.
The composite eVTOL developer has now received two key operational certificates required from the FAA to begin operations when Midnight receives type certification.
Ragasco composite cylinders for LPG will become part of Worthington’s Building Products business, while Hexagon/Worthington Enterprises JV will target expanding storage and transport of CNG and hydrogen.
CAMX 2024: Fast and flexible AGX-V2 Series by Shimadzu provides more intelligent operability for testing tasks, supporting composites, plastics, metals and finished products.
Moldex3D users will now be able to conduct accurate 3D fiber orientation simulations using calibrated fiber parameters.
PolyMorphic Moulding technology uses 28,000 digitally controlled pins to create a shape from a 3D CAD shape in less than 20 minutes, achieving zero waste and enabling parts production 14 times faster than 3D printing.
CAMX 2024: Trilion Quality Systems is showcasing the Aramis optical strain gage, a material-independent measurement device with 3D-DIC capabilities.
An Aurora and Boeing team advances its high-speed, vertical lift concept to the preliminary design phase, which features three lift fans, a more refined composite exterior and an uncrewed cockpit.
Nesting, design, GUI and viewing features have been improved or added to the composites design software tool.
Avangrid recently donated 300 pounds of decommissioned wind turbine blades to test startup solution that recovers more than 90% of turbine blade material.
Powered by an 85% air/15% pure polyimide aerogel, Blueshift’s novel material system protects structures during transient thermal events from -200°C to beyond 2400°C for rockets, battery boxes and more.
Certification covers Tenax carbon fiber production at Heinsberg-Oberbruch, Germany, plant, adds to Teijin’s certifications for carbon fiber and PAN in Japan.
In an interview with one of Aptera’s co-founders, CW sheds light on the inspiration behind the crowd-funded solar electric vehicle, its body in carbon (BinC) and how composite materials are playing a role in its design.
Based on military feedback, Epsilon Composite developed an optimized, foldable stretcher that combines telescopic pull-wound carbon fiber tubes.
Equipment investment will enable the plastics processor to mass produce fiber-reinforced thermoplastic composites continuously, as well as adapt to specific needs.
CAMX 2024: Composite curing ovens by Wisconsin Oven provide a variety of features for comprehensive support, including temperature uniformity, energy efficiency, advanced controls and IoT, all backed by a dedicated team.
Additional financing is being secured to service automated fiber steering demand, build first RTS production facility in Gloucester.
Composite curing oven meets customer needs with ability to cure complex synthetic and composite parts.
In an interview with one of Aptera’s co-founders, CW sheds light on the inspiration behind the crowd-funded solar electric vehicle, its body in carbon (BinC) and how composite materials are playing a role in its design.
Based on military feedback, Epsilon Composite developed an optimized, foldable stretcher that combines telescopic pull-wound carbon fiber tubes.
CAMX 2024: Schmidt & Heinzmann customers are able to produce SMC or dry fiber fabric stacks more efficiently thanks to the AutoCut Pick&Place system.
Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.
CW explores key composite developments that have shaped how we see and think about the industry today.
Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.
Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.
With COVID in the past and passengers flying again, commercial aircraft production is ramping up. The aerocomposites supply chain is busy developing new M&P for an approaching next-generation aircraft program.
Electrification and a focus on sustainability lead to opportunities and innovations in composites, from battery enclosures to structural components and more.
This webinar will cover infusion technology for the manufacture of aerospace composite structures. Hexcel will give an overview of different infusion processes, types of reinforcement and resin products available along with some example applications. Agenda: Benefits of Infusion Overview of resin infusion processes Reinforcement types Resins Processing Example applications
In addition to its proven fire resistance as a pure foam and within a sandwich composite system, the new material offers efficient manufacturing of 3-dimensional geometries and opens new possibilities for direct function integration. Agenda: Manufacturing process of thermoplastic particle foams Sandwich composite component requirements of commercial aircraft interior structures (e.g. FST, Heat Release) Function integration into net shape molded foam parts (e.g. inserts) Potential use-cases in fire critical applications
Find out how outsourced, costly tooling can be produced in-house to overcome bottlenecks, reduce costs and protect IP. Agenda: Explore durable casting materials that can be 3D-printed in complex designs Discover industry-proven Sika materials now available for high-speed, additive tooling Explore the benefits of thermoset molds that ensure uniform expansion, optimum bonding with the end part, as well as high durability
Thermoplastic material systems have been used in aerospace for decades. Their use and adoption continues to grow and Trelleborg has been on the leading edge of development for many of these systems. In this webinar, Trelleborg will be presenting a range of topics from the use of in-situ, automated fiber placement of thermoplastics prepreg for structural and functional products to complex injection molding of thermoplastic interior pieces. It will explore some of the benefits these products provide and the potential for future growth and development. Agenda: Current state of thermoplastics in aerospace Thermoplastic composite use cases for high-performance electric motors and torque tubes Injection-molded thermoplastic interior pieces The future of potential for thermoplastic applications for aerospace
KraussMaffei will explain in-situ polyurethane (PUR) overmolding of injection-molded and composite parts and the development of this technology over the last decade. Waruna Seneviratne, director of the Advanced Technologies Lab for Aerospace Systems (ATLAS), will discuss how aerospace and advanced air mobility (AAM) markets can capitalize on this high-rate manufacturing solution. Agenda: What is ColorForm: process, equipment and tooling Pros and cons of the technology High technology solution examples: ColorForm automotive Market references in automotive Demand for future commercial aviation and both AAM and urban air mobility (UAM) What aerospace can learn from automotive for addressing demand for high-rate manufacturing Technological advances enabling material and process improvements for the future Role of ATLAS manufacturing innovation center for promoting advanced manufacturing and workforce development Road map for certification through manufacturing demonstrations
Discover the latest innovation in laser projection technology poised to increase accuracy, efficiency and reliability. LAP will unveil the features of its new CAD-PRO Xpert laser projection system and outline how various industries can benefit from the system's capabilities. Its cutting-edge technology platform empowers users with enhanced color range, speed and superior laser projection quality while increasing accuracy, efficiency and reliability. Explore how the advanced ergonomics of this system can reshape composite manufacturing processes across industries, ranging from aerospace and automotive to wind rotor blade production, yacht building and beyond. Agenda: Introduction of the features of the CAD-PRO Xpert Applications and advantages across industries Upgrading workplaces for enhanced digital worker guidance Modular system solutions based on the value-adding ecosystem
The International Composites Summit (ICS) is renowned as the only solely focused UK event for professionals involved in the composites industry. ICS promises to be a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business.
Join us at the ACCE 2023 event and learn about how the automotive and transportation industries are advancing with composites playing a key role in the development of electric vehicles and sustainability initiatives worldwide. Lightweight composites are ideal materials for improving vehicle performance, reducing mass, extending range and compensating for battery weight. Polymer composites are enabling lower emission vehicles, reducing the carbon footprint and saving energy to benefit the environment now and in the future. Thermoset and thermoplastic composites are the key to EV, Mobility and Sustainability.
The International Composites Summit (ICS), THE single place to do the most cost effective and sustainable composites business in the UK, is back for its highly anticipated 2023 edition, bringing together industry leaders, researchers, and innovators from across the composites sector. ICS promises to be a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business. The International Composites Summit is renowned as the only solely focused UK event for professionals involved in the composites industry.
CAMX is your best source for new solutions, technologies, and ideas you need for your current and future projects. CAMX makes it easy to watch live process demos, see materials and interactive displays on what may be possible in the future, and meet with hundreds of manufacturers, distributors, and suppliers.
Debuting in 2010, the Parts Cleaning Conference is the leading and most trusted manufacturing and industrial parts cleaning forum focused solely on delivering quality technical information in the specialized field of machined parts cleansing. Providing guidance and training to understand the recognized sets of standards for industrial cleaning, every year the Conference showcases industry experts who present educational sessions on the latest and most pressing topics affecting manufacturing facilities today. Discover all that the 2022 Parts Cleaning Conference has to offer!
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.
Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.
Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.
Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.
The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.
Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.
In an interview with one of Aptera’s co-founders, CW sheds light on the inspiration behind the crowd-funded solar electric vehicle, its body in carbon (BinC) and how composite materials are playing a role in its design.
Based on military feedback, Epsilon Composite developed an optimized, foldable stretcher that combines telescopic pull-wound carbon fiber tubes.
While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?
The total index reading backed down in May from its anticipated expansion, contracting again to land at 46.8.
Upon his one-year anniversary as editor-in-chief of CW, Scott Francis looks back at some of the brand’s changes and hints at where it might be heading next.
In 2018, Teijin broke ground on a facility that is reportedly the largest capacity carbon fiber line currently in existence. The line has been fully functional for nearly two years and has plenty of room for expansion.
PolyMorphic Moulding technology uses 28,000 digitally controlled pins to create a shape from a 3D CAD shape in less than 20 minutes, achieving zero waste and enabling parts production 14 times faster than 3D printing.
Proof-of-concept part used bio-based acrylontrile precursor with same performance as conventional CFRP but with significantly less CO2.
Recent conference in Denver, Colorado, emphasized the tools and knowledge composites manufacturers will need to meet customer and government sustainability goals.
Ultra-lightweight and made of recycled composites, the Eco Bracket cuts weight and cost in half and reduces CO2 emissions, in addition to providing high performance.
Brudeli’s patented plug-in Powerhybrid technology will use Hexagon Agility CNG/RNG fuel system with Type 4 tanks, enabling Class 7 and 8 trucks to meet ACT and ACF regulations.
Envalior 30% glass fiber-reinforced Akulon RePurposed material helps Ahrend achieve lighter task chair with closed-loop value chain and reduced emissions.
CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.
In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.
The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.
Closed mold processes have many advantages over open molding. In this knowledge center, learn the basics and vital tools needed to produce parts accurately.
CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.
Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.
Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
Explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.
This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.
This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.
This collection features recent CW stories that detail a range of tooling technologies, processes and materials.
As the number of battery and fuel cell electric vehicles (EVs) grows, so do the opportunities for composites in battery enclosures and components for fuel cells.
Source | (Top left, clockwise) Ceylon Graphene and The Graphene Council, Bramble Energy, Kautex Textron and EKPO fuel cells.
Batteries - Peel-and-stick thermal protection for aircraft batteries - New resins for lightweight fire and thermal protection - Underbody panel using bio-inspired Helicoid technology - Pentatonic thermoplastic composite-metal hybrid skip plate protector - Composites inside the battery - Graphene in batteries - OCSiAl scales graphene for battery applications Fuel Cells - Growing market - CW news stories, growth in fuel cell transport - Toray boosts carbon fiber production for fuel cells - Glass fiber PCBs to reduce fuel cell cost
Global electric car stock 2010-2022 (million units). Source | “IEA Global EV Outlook 2023”
According to the “IEA Global EV Outlook 2023,” electric car sales were up 55% in 2022 despite the fact that total car sales fell by 3% relative to 2021. In just five years, from 2017 to 2022, electric car sales grew from ≈1 million to >10 million. More than 2.3 million electric cars were sold in Q1 2023 and IEA projected an annual total of 14 million, a 35% increase over 2022. While the number of internal combustion engine (ICE) car models continues to decrease each year, the number of electric car models is increasing at a rate of 30% from 2016-2022.
In its “Electric Vehicle Outlook 2023,” Bloomberg NEF predicts that electric vehicle (EV) sales will rise from 10.5 million to 27 million between 2022 and 2026. The EV share of global new passenger vehicle sales will grow from 14% in 2022 to 30% in 2026.
Global passenger vehicle sales by drivetrain – Economic Transition Scenario (left) and “The Picture Today” (right). Source | Fig. 2, “Electric Vehicle Outlook 2023” by Bloomberg NEF and EVO Report 2023 summary page
Note, however, that batteries are also needed for the growing field of EVs in the air, referred to as electric vertical takeoff and landing (eVTOL) aircraft. In a March 2023 report, IBA Insight reported a total of 7,487 eVTOL orders with 4,050 on backlog. As explained in a 2022 article by Leeham News, the power for an eVTOL is supplied by its battery system, with modules that are highly complex and energy levels higher than a Tesla car. Protection is key as there is no quick exit to a sidewalk in the case of a fire or thermal runaway.
Battery pack modules from Electroflight, now EvoLito. Source | Leeham News and EvoLito
Another issue is that aircraft are even more weight-sensitive than cars. Thus, aircraft batteries need to be light and safe, says Gary Kendall, director of CDO2, in a 2023 article by Revolution.aero. CDO2 has developed new technology for imaging current flow in batteries. “If you’re going to put a lithium-ion battery in an airframe you need to put it into a fireproof box. The problem is that makes the battery heavy. What we have done is try to meet that regulation with as smaller weight overhead as possible by using composite boxes rather than metal, for example.”
The European Union Aviation Safety Agency (EASA) certified Pipistrel’s Velis Electro eVTOL in 2020 as a light sport aircraft (LSA) under SC-ELA.2015-01 (CRI F-101) and proposed the MOC-3 SC-VTOL battery regulations in 2023 (see Revolution.aero news). Meanwhile, the Federal Aviation Administration (FAA) is still trying to develop its battery regulations for eVTOLs.
Lilium will use Blueshift Materials’ AeroZero TPS films as thermal protection in its battery systems. Source | Blueshift Materials
Notably, eVTOL manufacturer Lilium (Munich, Germany) has selected Blueshift Materials (Spencer, Mass., U.S.) to supply thermal protection (TPS) for its initial series of eVTOL production aircraft. Blueshift’s AeroZero TPS will be used in Lilium’s carbon fiber composite battery design to help prevent burn through and mitigate the risk of thermal runaway propagation.
Based on polyimide aerogel, all of Blueshift Materials’ products are flame retardant, <1.5 millimeters thick and have a very low thermal conductivity/diffusivity. Able to operate up to 2400°C, AeroZero TPS products can be co-cured to a structure or made as a peel-and-stick film. “Blueshift’s thermal protection system is light, thin and easy to incorporate into our strict design requirements, while producing exceptional thermal results,” says Martin Schuebel, Lilium’s senior VP procurement.
“The automotive industry sees a need for new material solutions for battery components with superior flame retardancy compared to conventional thermoset prepregs and aluminum,” says Stefano Montani, transportation marketing manager at Syensqo (Heanor, U.K.), previously Solvay Composites. This performance allows passengers sufficient time to escape time in the event of a thermal runaway, he explains. “Structural battery housing solutions must also ensure reliable EMI [electromagnetic] shielding performance and enable efficient processing of large volumes at high production rates,” he adds. In October 2023, Syensqo launched SolvaLite 716 FR, a fast-curing epoxy prepreg designed for a wide range of structural parts and reinforcements in battery electric vehicles (BEVs). The new prepreg offers a rapid press cure time of 8 minutes at 150°C, designed to help converters achieve more efficient production, such as when using Solvay’s proprietary double diaphragm forming (DDF) technology.
Another 2023 launch is AOC’s (Collierville, Tenn., U.S.) Firepel R003 Resin Series for EV battery enclosures. It provides advanced mechanical and thermal performance compared to traditional polyester resins while also meeting the requirements of UL2596 for EV battery enclosure materials. Firepel R003 resins are designed for use in liquid molding processes such as vacuum infusion, resin transfer molding (RTM) and wet molding for the manufacture of high-performance composite parts.
In March 2024, Huntsman (Frankfurt, Germany) announced a portfolio of novel polyurethane- and epoxy-based resins for EV applications. These customizable, quick-cure, high-strength polyurethane resins include Vitrox and RimLine systems for underbody and upper cover battery protection applications up to 30% quicker than some existing technologies. The systems include products that can offer lower overall part weight and increased strength as well as improved structural performance. The RimLine RSM system is a glass fiber-reinforced polyurethane composite and is applied via reaction spray molding, which can be demolded quickly for an efficient production cycle. Huntsman also noted its range of intrinsic fire-retardant Araldite FST and unfilled mass production systems for WCM, RTM and HP-RTM processes that can enable short cycle times with low scrap rates.
Automated high-pressure resin transfer molding (HP-RTM)/liquid composites molding (LCM) demonstration line. Source | TPI Composites, Helicoid Industries
Announced in May 2023, TPI Composites Inc. (Scottsdale, Ariz., U.S.) and Helicoid Industries (Indio, Calif., U.S.) collaborated to produce a bio-inspired underbody protection panel using Helicoid technology. The composite structure leverages digital engineering, unconventional layup scenarios, biomimicry, advanced multiaxial intelligent weaving and automated manufacturing to protect high-voltage battery packs from road debris compared to current aluminum designs. Developed in a manufacturing cell at TPI’s Automotive Technology Center in Warren, Rhode Island, using the latest in automated ply cutting and robotic pick-and-place technologies, the process is said to be a seamless and cost-effective implementation of Helicoid architectures. A multiaxial noncrimp fabric (NCF) technology is used to strategically compose the full Helicoid stack in subunits. The stack layers are then robotically dosed and automatically placed and retrieved from a 2,500-ton press, resulting in high-performance precision parts.
Interest in using thermoplastic composites for battery components is growing as well. “From a materials perspective, the use of thermoplastic composites enables the structural components of batteries, when they reach the end of their service life, to have a higher recyclability percentage compared to conventional systems,” says Guillermo Ulldemolins, a researcher in sustainable and future mobility at Aimplas (Valencia, Spain). He notes this contributes to the circularity of the sector, making it more sustainable and environmentally conscious. In March 2024, Aimplas (Valecia, Spain) announced the launch of Lofith Composites, a new technology company focused on developing long fiber-reinforced thermoplastic (LFTP) composites. Aimplas is one partner in the multi-company MODALT project, which aims to generate knowledge to develop and manufacture more sustainable, lighter, safer and long-lasting batteries. “The storage module we are developing will contribute to unlocking high-performance electrified vehicle applications,” says program technical leader Danile Fons.
Even following exposure to particle bombardment and temperatures in tests as high as 1400°C, this Tepex test specimen did not undergo burn through. Source | Envalior
Envalior (Düsseldorf, Germany), a new company formed by DSM Engineering Materials (DEM) and Lanxess’ High Performance Materials (HPM) unit, is offering a new composite material under the Tepex brand that, even with low test specimen thicknesses, passes the standard thermal runaway tests for EV battery housings. Its high resistance to the extreme conditions of a battery cell fire can be attributed to its long and continuous non-flammable fibers that reinforce the material in a multilayer structure. “Above all, it’s thanks to the fibers that our structural material is capable of withstanding the extreme pressures, temperatures well in excess of 1000°C, and bombardment by abrasive hot particles that occur during the thermal runaway of battery cells,” says Dr. Dirk Bonefeld, head of Tepex product management. He notes the material is also ideal for components inside the battery such as the cell housing, holder and partitions.
In July 2023, SABIC (Riyadh, Saudi Arabia, and Houston, Texas, U.S.) launched its SABIC PP compound H1090 and Stamax 30YH611 resins. The 30% glass fiber-reinforced polypropylene resins are intumescent and flame-retardant (FR). Well-suited for compression and injection molding, they enable large, complex composite structural parts for EV battery pack components such as top covers, enclosures and module separators. Both grades offer optimized thermal barrier properties to help delay or contain thermal runaway propagation.
Solvay (Alpharetta, Ga., U.S.) also introduced a new family of long glass fiber (LGF) composites through its Xencor Xtreme LGF polyphthalamide (PPA) solutions for battery applications. Xencor XTreme PPA LGF materials are designed to offer resistance to direct flame exposure at 1000°C for more than 10 minutes and also to retain a high level of electrical insulation after exposure to flame, helping to mitigate thermal runaway. The materials also have a high glass transition temperature to maintain dimensional stability of parts under battery operating conditions.
Pentatonic battery system. Source | Kautex Textron GmbH & Co. KG
In February 2023, Kautex Textron GmbH & Co. KG (Kautex, Bonn, Germany) announced a first order from an automotive OEM for a fiber-reinforced thermoplastic composite underbody battery protection skid plate. The skid plate is part of the company’s new Pentatonic battery system product line supporting battery electric vehicle (BEV) production. The new skid plate design will be produced for on-and-off-road applications, Kautex says. It is designed to meet impact requirements and features more than a 50% weight reduction versus its steel counterpart.
Technology concept for the 3D continuous fiber printed, free-form, structure-supporting PRINTCAP supercaps. Source | RCCF at TU Dresden
The “Next Generation of 3D Printed Structural Supercapacitors” (PRINTCAP) research project (June 2022 to March 2025) aims to develop a new generation of supercapacitors (SC) for fast-charging, structural energy storage in automotive and aerospace EVs through the incorporation of 3D printing and multifunctional composites. Current energy storage systems are made of layers and stacking methods, which require shielding housings which often take up valuable installation space. Innovative structural supercapacitors (SSC), however, combine the energy storage function of SC with the high mechanical properties of lightweight composites — addressing weight reduction and opening up space. PRINTCAP aims to develop a near-neat shape SSC concept that combine weight- and space-optimized lightweight structures with the energy storage function. The developed concepts will also include initial solutions for recycling the materials used, as well as life cycle analysis (LCA) studies, in accordance with the cradle-to-cradle principle.
In January 2024, researchers at the Oak Ridge National Laboratory’s (ORNL, Oak Ridge, Tenn., U.S.) Department of Energy announced they developed a lighter, metal-free current collector made from carbon fiber-reinforced polymer (CFRP). A current collector is a component that often adds 10% to the weight of a battery cell without contributing energy. The aligned carbon fibers in ORNL’s new development work together with a thin film of carbon nanotubes (CNTs) to enhance directional and uniform current flow. Conventional current collectors include aluminum foil for cathode and copper foil for anode. Alternatively, development of current collectors made of assembled metal or carbon nanostructures such as metal, graphene, CNT or carbon fiber foams, and other similar structures, have shown potential, particularly carbon fiber and CNTs. “We are reducing 80% to 90% of the weight of the current collector,” says Jaswinder Sharma, ORNL researcher in this project. “This will help a lot in increasing the energy density of battery packs.” For more information, read the ORNL research paper, “A lightweight and metal-free current collector for battery anode applications.”
This section is taken from the report “Graphene for Battery Applications” developed for CW by the Graphene Council (New Bern, N.C., U.S.).
A nanomaterial that is made from pure carbon, graphene is often described as a two-dimensional (2D) material because it is only a few atoms thick and thus, almost entirely surface area. Because it comes in many forms and types, graphene can be considered a “family” of materials including graphene oxide, reduced graphene oxide, graphene sheets, graphene flakes and other versions.
Graphene can be used as an additive for lead-acid batteries and in the anodes, cathodes and electrolytes for the following battery chemistries:
Lead-acid batteries. Using graphene as an alternative to carbon black in lead-acid batteries has been very successful commercially to improve conductivity and reduce sulfation. By adding small amounts of reduced graphene oxide, lead-acid batteries have reached new performance levels:
In collaboration with what is said to be the largest battery manufacturer in Sri Lanka, Ceylon Graphene (Homogama, Sri Lanka) introduced the world’s first graphene-enhanced lead-acid battery in 2022, which reportedly provides 15-25% increased capacity, 30-35% increased charge and 50% lower water loss, enhancing performance and lifecycle.
Li-ion batteries. Graphene improves the chemistries of both the cathodes and anodes of Li-ion batteries so that they hold more charge and do so over more cycles. For anodes, graphene can be used as an additive in graphite or as a surface coating. For Li-ion batteries, graphene-enabled nanostructured-silicon anodes have been developed that enable silicon to survive more cycles and store more energy.
While graphene-enabled silicon (Si) anodes cost more per kilogram than those coated with spherical graphite, the boost to capacity potentially lowers the cost per kilowatt-hour (kWh). Graphene-based anodes are reportedly capable of enabling Li-ion batteries to achieve $80 per kWh. It has long been suggested that lithium nickel manganese cobalt (NCM) cathodes paired with Si-dominant anodes will increase energy density by up to 50%, reducing $/kWh cost by 30-40%.
Graphene can also be used in cathodes. When high battery performance is required, the electrical conductivity of the most common Li-ion batteries is fairly low, so electron conducting additives are frequently added. Graphene has been used in the matrix of a cathode material to significantly improve cathode electrochemical performance, and thus transmission and diffusion of electrons and ions. Graphene as a composite hybrid containing metallic material can also be used in a cathode. Graphene has been used as a support material in electrodes to keep metal ions in the required order to improve efficiency. When used as a composite in electrodes, graphene facilitates fast charging as a result of its high conductivity and well-ordered structure.
Talga (West Perth, Australia) is now marketing a Si-carbon composite (30-50% Si) for use as an energy-boosting additive to existing commercial battery anodes. The drop-in design uses Talga’s proprietary graphene, Si and graphite technology to enable low swelling and commercial production calendaring pressures in a lower cost and highly scalable manufacturing process. Meanwhile, Nanotech Energy (Chico, Calif., U.S.) is marketing a non-flammable Li-ion battery using graphene, limiting flame or explosion risk for a safer battery solution.
Li-S batteries. These batteries are low cost, less toxic and possess an energy density more than five times that of Li-ion batteries. They have a realistic potential to replace Li-ion batteries in commercial applications, especially in standalone energy storage systems. Because of these factors, Li-S batteries have received a lot of interest from industry and research institutes. Graphene materials have been widely explored for applications in sulfur cathodes, interlayers and Li anodes.
Graphene has been used for Li−S batteries as a cathode complement because its high electrical conductivity compensates for the insulating nature of sulfur, while its hardness and compliance provide resistance to mechanical stress from sulfur expansion during the discharge process. Graphene is being used in a large scale and highly capitalized commercial effort to enable the following features for Li-S batteries:
Lyten (San Jose, Calif., U.S.) is the pioneer of the Lyten 3D Graphene applications platform. The company’s decarbonization supermaterials are being tuned for a wide range of applications, including next-gen Li-S batteries for use in automotive, aerospace and defense market, among others.
Metal-air batteries. Metal–air batteries are based on the electrochemical coupling of a reactive anode to a cathode open to oxygen in the air as the cathode‐active material. In principle, this provides a battery with inexhaustible cathode reactant and, in some cases, a very high specific energy. Metal–air batteries show great potential to meet the growing energy demand for EVs and smart power grids. However, despite significant progress already achieved, challenges still remain in developing a practical metal–air battery with performance exceeding existing Li-ion batteries.
Graphene nanosheets (GNS) have been demonstrated as a desirable cathode material in Li–air batteries. Benefits include a high electrocatalytic activity superior to that of acetylene carbon black, ease of obtaining freestanding 2D or 3D films with high porosity for oxygen diffusion and very high surface area. Graphene Manufacturing Group (Richlands, Australia) has developed graphene aluminum-ion battery technology that has high energy densities and higher power densities versus current leading Li-ion battery technology, enabling up to three times longer battery life and up to 70 times faster charging.
Graphene nanotubes manufacturer OCSiAl (Luxembourg) will begin production in its new facility near Belgrade, Serbia in 2024. The nanotube synthesis plant will have an initial capacity of 60 tonnes/year, increasing to 120 tonnes/year by 2026. In addition to synthesizing nanotubes, the facility will manufacture nanotube suspensions for lithium-ion battery manufacturers in Europe, the U.S. and Asia — enough to enhance the performance of more than one million electric cars with an average battery capacity of 75 kWh per car. According to the company, its nanotubes create improve key battery characteristics, including cycle life, lower DCR, C-rate performance and cohesion between active battery material particles, making the battery electrodes more durable. Graphene nanotubes unlock new battery technologies, including high-silicon content anodes, thick LFP cathodes, fast-charging graphite anodes and can be applied in solid-state batteries.
Fuel cells use hydrogen (H2) as a fuel, combined with oxygen, to generate electricity through an electrochemical reaction, not combustion, producing only heat and water as outputs, and thus, are zero-emission power sources.
Components of a fuel cell and stack. Source |Slide 5, “Development of book of attributes for PEM fuel cell components” by Xiao-Zi (Riny) Yuan, workshop for NREL, May 5-6, 2021.
Fuel cells comprise a stack of cells sandwiched between end plates, which are typically metal. Within each cell are multiple components that can use carbon fiber, including bipolar plates, gas diffusion layers (GDL) and membrane electrode assemblies (MEA):
The number of unit cells in a fuel cell stack varies according to the power produced, application and technology used. For example, Nedstack (Arnhem, Netherlands) uses 48 cells to deliver 6.8 kilowatts of electrical power in its FCS 7-XXL PEM fuel cell, while Bosch SOFC (Stuttgart, Germany) uses 400 cells in its 120-kilowatt solid oxide fuel cell.
Fuel cell shipments by type 2018-2022 (1,000 units). Source | Fuel Cell Industry Review 2022 by ERM
There are multiple fuel cell types based on the six main electrolytes used: proton exchange membrane fuel cells (PEMFC), direct methanol fuel cells (DMFC), phosphoric acid fuel cells (PAFC), molten carbonate fuel cells (MCFC), solid oxide fuel cells (SOFC) and alkaline fuel cells (AFC). The two types that dominate both megawatts and units shipped are PEMFC, used mainly for transport applications, and SOFC used for portable and stationary applications.
Note: CW’s report from 2023 — “Composites end markets: Batteries and fuel cells (2023)” — provides additional information that may be helpful in understanding the landscape and key players for this market.
Fuel cell shipments (1,000 units) by application 2018-2022. Source | “Fuel Cell Industry Review 2022” by ERM
According to the “Fuel Cell Industry Review 2022” — the latest annual survey published by ERM (London, U.K.) in early 2024 — fuel cell shipments from 2021 to 2022 grew from 86,000 to 89,200 units and from ≈2.3 gigawatts (GW) to just under 2.5 GW, with a CAGR of around 25% since 2018.
Fuel cell shipments (MW) by application 2018-2022. Source | “Fuel Cell Industry Review 2022” by ERM
The most units were sold into stationary applications while 85% of megawatts (MW) were sold into transport, most of these for passenger cars (15,000 units) nearly all made by Hyundai and Toyota. China led in trucks and buses, shipping nearly 3,800 fuel cells, while fewer than 400 fuel cells for commercial vehicles went to Europe and North America combined. Shipments for fuel cell electric vehicles (FCEVs) are expected to continue in China as it pushes to meet its goal of 50,000 FCEVs in operation by 2025.
The 2.5 GW reported by the “Fuel Cell Industry Review” is only 17% of the 15 GW of global manufacturing capacity indicated by fuel cell OEMs as reported in the “Hydrogen Insights 2023” update (December 2023). That production capacity is housed mainly in South Korea, China and Japan. The “Fuel Cell Industry Review” reports that Asia is also the leading region for fuel cell adoption and use.
H2Motive range of compact, high-performance fuel cells for zero-emission H2 mobility. Source | Symbio
Symbio (Saint-Fons, France) is a zero-emission H2 mobility joint venture between Forvia, Michelin and Stellantis. In December 2023, the company inaugurated its SymphonHy gigafactory for fuel cells, ramping production from 16,000 to 50,000 units/year by 2026. Fuel cells supplied to Stellantis will extend its H2 FCEVs beyond already available mid-size vans in Europe to large-size vans, Ram pickups and heavy-duty trucks in North American. In February 2024, Symbio signed an MOU with Kawasaki Heavy Industries to apply fuel cell systems to construction equipment.
EKPO (Dettingen/Erms, Germany) is the joint venture between ElringKlinger and Plastic Omnium (now OPmobility) to produce fuel cells with an initial capacity of 10,000 units/year at its headquarters. The company has also formed a subsidiary in the city of Suzhou, west of Shanghai to supply the Chinese market. Announcements made in 2023 include supply to a European car OEM for a production vehicle, an NM12 Single PEMFC stack module with 359 cells for a single cruise ship operated by a global cruise line, a contract with H-TEC Systems for PEM electrolyzers and a contract with China FAW Group to deliver fuel cells for its premium brand Hongqi.
Accelera (Columbus, Ind., U.S.) is the zero-emission mobility business of engine manufacturer Cummins (Columbus, Ind., U.S.). In May 2023, it started electrolyzer production at its plant in Fridley, Minnesota, with annual production capacity of 500 MW scaling to 1 GW in the future. It also noted 300 MW of electrolyzer projects in North America including: 90 MW for Varennes Carbon Recycling in Quebec, 20 MW for Gevo/Zero6 Energy in North Dakota, 35 MW with Linde in New York, 20 MW with Atura Power in Ohio and a fleet of 1,000 electric school buses with Blue Bird in the U.S.
In January 2024, GM and Honda announced their joint venture Fuel Cell System Manufacturing LLC (FCSM) began production at the 70,000-square-foot facility in Brownstown, Mich., U.S. with plans to produce 2,000-3,000 fuel cells/year by 2025. Honda will reportedly take 2,000 modules — 25% of which will go into the Honda CR-V plug-in hybrid which replaces an internal-combustion engine with a fuel cell. Honda plans to generate demand for up to 60,000 fuel cell systems per year by 2030 for applications beyond cars.
News stories published by CW in 2023 also show the growing trend for use of H2 fuel cell systems in a range of transport applications: Aviation – GKN for H2 electric and combustion powered aviation – ZeroAvia flies Dash 8 Q400 and Dornier 228 H2 electric powered aircraft
Bus – Solaris H2 electric buses – New Flyer fuel cell electric transit bus
Cars – BMW iX5 H2 pilot fleet
Trucks – Daimler fuel cell truck – Nikola fuel cell trucks – Ford fuel cell trucks
Ships – H2 fuel cell pod for ships
Carbon fiber supplier Toray (Tokyo, Japan) announced that it is developing a range of materials for production, transport, storage and use of hydrogen (H2) as a fuel. These materials include CCM which traditionally has used a carbon fiber support for the catalyst layer due to its high strength and low weight. CCMs are also used in electrolyzers for green H2 production. The “Hydrogen Insights 2023” update reported electrolyzer manufacturing capacity has increased from 9 to 11 GW according to OEM statements.
Toray announced on March 17, 2023 that it would triple CCM production capacity at its subsidiary Greenerity (Alzenau, Bavaria, Germany), adding a third factory and expanding capacity at the second factory. Through Grennerity, Toray also produces MEA for fuel cells used in FCEVs including buses, trucks, commercial vehicles and passenger cars. At full capacity, Greenerity’s second plant will support annual production of more than 10,000 FCEVs. Toray says that it has positioned materials for H2 and fuel cell production and use as important for future growth and will extensively allocate resources to expand this business.
Bramble Energy (Crawley, U.K.) has developed technology to reduce cost by making its fuel cell stacks out of printed circuit boards (PCBs). As explained in a February 2024 The Engineer article and in Bramble’s white paper “System Architecture Advantages of the PCBFC,” this approach allows fuel cells to be made at any PCB factory worldwide, using the same materials and processes used for standard PCB manufacture — namely, machined FR4 glass fiber-reinforced epoxy resin laminate. The company’s model is to license its technology to PCB manufacturers who already supply most of the large automotive OEMs. By tapping into this huge, high-volume global manufacturing base, Bramble Energy believes its technology can cut cost to as little as $60/kW — more than 10 times cheaper than current technologies.
The market for pressure vessels used to store zero-emission fuels is rapidly growing, with ongoing developments and commercialization of Type 3, 4 and 5 tanks.
As the marine market corrects after the COVID-19 upswing, the emphasis is on decarbonization and sustainability, automation and new forms of mobility offering opportunity for composites.
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