Composites have replaced traditional materials such as wood and metal for the same reasons that they have penetrated many other markets. The weight-savings have been a major driver, combined with design optimisation and performance improvements that enable sporting enthusiasts to compete at a higher level for less effort. So tennis players and golfers can hit the ball faster and further – and can place it more accurately. Cyclists and rowers can accelerate and maintain speeds for less physical exertion.

Fishing rod manufacturers were quick to recognise the improvements that composites could bring to the sport. Early composite rods had a glass/polyester prepreg construction, which then evolved into glass/epoxy prepreg with the quest for higher performance and a cleaner manufacturing environment. However, when cost pressures drove the glass/epoxy business to the Far East in the late 1970’s, Hexcel remained successful by developing higher performance carbon/epoxy solutions for market leaders including Daiwa, House of Hardy, Garbolino and many other Italian manufacturers. Carbon fibre prepreg enables manufacturers to fine-tune the rod performance. Carbon fibre rods have the strength to lift heavy fish from the water and to cast long distances, whilst retaining the sensitivity for the angler to feel the slightest touch on the end of the line. The development of extremely high modulus prepreg tape allowed significant breakthroughs in the design of competition roach poles. The damping characteristics of the composite enable the rods to flex deeply without oscillating. They provide the ideal combination of power and sensitivity, lightweight and durability.

Hexcel began supplying tennis racket manufacturers with composite materials in the late 1970’s. The Dunlop Maxply Fort was one of the early rackets to increase the power potential by blending glass fibre and carbon fibre composites with wood. Today’s all-carbon and carbon/titanium rackets are powerful and lightweight, with a sweet spot area over 50% larger than with wood rackets. The carbon fibre also dampens vibration on impact with the ball to provide excellent manoeuvrability and ball control. Hexcel is the major supplier of carbon fibre prepreg tape to HEAD, with an epoxy system that cures in only 11 minutes at 140°C.

Composite golf clubs are a more recent innovation that have had no less an impact on the sport. Carbon fibre shafts enable golfers to hit the ball further and more consistently, and the wide range of shafts available enables a player to select the most suitable golf club for his game. Steel shafts weigh typically 90-120 grams, whilst ultra light carbon shafts are less than 40 grams. The player’s ability to control a ball’s trajectory is affected by shaft torque, and whilst the torque of steel shafts is fixed at around 3.0, the torque of carbon shafts can vary between 2.0 and 12.0. A recent development is the bubble shaft concept that was pioneered by Salomon Group and is very successful for Taylor Made. The bubble shaft is manufactured using the bladder moulding process, in which the prepreg is placed in a single mould cavity around a flexible membrane (pressure bag). The pressure bag is filled with compressed air during the moulding process to produce a single controlled surface. The use of a fast curing epoxy system provides high production rates and has made bladder moulding a very efficient technique. The Hexcel epoxy system developed for this market also provides an excellent surface finish.

Composite bikes account for 14% of Hexcel’s sales to the recreation industry. Over 20 years, the increasing use of composites and Hexcel’s continuous product development, has been driven by the constant wish to increase cycling speed. Hexcel has been a long-term supplier to Corima, France, whose bikes continue to win races and break time trial records. Corima favours carbon fibre prepregs for the weight-savings and high rigidity that they can target in a specific areas of the frame and wheels for maximum response when starting up and accelerating. Hexcel has been assisting Corima with the technology change in bike wheels. When moving from a solid disk design to a 4-spoke concept the customer has selected high performance 180°C curing prepreg rather than the previously used 120° C system, to withstand the high temperatures experienced when brakes are in contact with composite parts. Tour de France winning bike manufacturers, Trek, use HexPly® prepreg tape because its unidirectional properties mean that engineers are able to ‘spot tune’ performance characteristics of the bike for the perfect ride, adding extra rigidity in some parts and shock damping flex in others. All of this allows for faster pedalling and more accurate cornering. Trek has also selected Hexcel’s new HexMC® carbon fibre/epoxy moulding compound to manufacture small component parts, such as the rear links of the cross-country full suspension Trek Fuel 100. HexMC® enables Trek to save more than 50 grams per bike, while the HexMC® link is twice as strong as its aluminium predecessor. HexMC® enables detailed 3D shapes, that can’t easily be made from high performance composites, to be manufactured in series production.

Competition rowing boats have also benefited from Hexcel’s composites technology. Market leaders such as Empacher in Germany have used honeycomb for many years for weight-savings and stiffness. Long time customers of engineered fabrics and core materials have also moved from wet lamination to prepreg technology. Trends in this market are for higher performance, lighter boats where the resin content is precisely controlled and with carbon replacing aramid for extra strength. Looking forward, Hexcel will continue to anticipate and respond to customer requirements. Three years ago the company developed Texalium®, the aluminium powder coated prepreg that is being used by leading ski manufacturers including Blizzard and Atomic to produce eye-catching skis with high performance. HexMC® carbon fibre/epoxy moulding compound has already been used by Benetton to manufacture in-line skates and is undergoing trials with other sports goods manufacturers who appreciate its rapid moulding capability combined with light weight and strength. Hockey stick manufacturers are increasingly turning to prepreg, with Hexcel now a major supplier to Easton for their 100% composite sticks.