Automotive
In pride of place on the stand will be the K200 Roadster micro car, manufactured by Super Light Cars (SLC), part of the Italian ATR Group, which specialises in the production of structural parts and components in carbon fibre advanced composites.  Hexcel’s collaboration with the ATR Group is based on the supply of a range of composite products including HexPly® M47, M48 and M49 prepregs, which provide a superior surface finish to automotive components.  The ATR Group is recognised as a leading supplier of structural parts in carbon fibre with quick production rates and high quality standards using different technologies.  The company works in cooperation with prestigious international customers including Ferrari, Maserati, Porsche, Bugatti and Lamborghini.

The K200 is made almost entirely of carbon fibre advanced composites, to provide the highest specific values of safety and rigidity, without limiting an aggressive and vivacious design. Weighing only 300Kg, it is the lightest two-seater car in the world, designed with technical solutions typical of performance cars and combining the experience of riding a sporting motorbike with the safety and comfort of a four-wheeled car.

The chassis is a carbon fibre sandwich monocoque design with a front carbon Kevlar® crash-box.  HexWeb® aramid paper honeycomb is the core material.  The body panels are made in carbon fibre composite. The K200 Roadster has a maximum speed of 110 km/h.

Aerospace
Hexcel initially developed its HexMC® carbon/epoxy moulding concept for industrial applications and it has enjoyed great success in replacing metal in sports equipment.  New HexMC® developments with key customers have focused on the requirements of the aerospace industry. Hexcel has succeeded in demonstrating that the technology is suitable for manufacturing aerospace-quality parts such as window frames and seat supports.  HexMC® is distinguished from other moulding compounds by the high compression strength that results from the multidirectional carbon fibres and epoxy matrix.  Mechanical performance is almost as high as with unidirectional prepregs.
 
HexMC® Aircraft Window Frame

Recreation
On this year’s stand at JEC Hexcel will be displaying Trek’s Madone SL 5.9, one of the bike models ridden by Lance Armstrong during the Tour de France 2004, on his way to a record sixth Tour de France victory.  Trek has progressively lowered the wheel and frame weight by reducing the weight of the individual prepreg plies -from 150gsm, to 120gsm, then 110gsm culminating in only 55gsm.  Hexcel has continually provided Trek with new products that reduce weight while pushing the performance edge.

Hexcel is launching HexPly® M52, a fast curing epoxy system, with long outlife, that is particularly suitable for compression moulding.  The new system provides an excellent surface finish and is therefore ideal for the high volume production of carbon composite components that need a good cosmetic appearance.  It is particularly suitable for the recreation sector, automotive and marine applications and other industrial markets. 

Hexcel customer, Blatchford, is helping amputees to participate in sports and leisure activities with greater freedom and comfort.  Central to Blatchford's product portfolio is the range of prosthetics known as the Endolite System. Using carbon fibre composite materials, elastomers and smart electronics; Endolite provides sophisticated but practical solutions to the needs of lower limb amputees. Products range from simple comfortable feet for low activity wearers to dynamic knees and feet for people who take part in sport or have highly active careers.
A new addition to the Endolite range is the Elite® all terrain foot, which will be displayed on Hexcel’s stand at JEC and SAMPE.  The Elite foot has an innovative twin-toe design which adapts and conforms to rough and smooth surfaces with optimised energy return.  It has a Tri-pod system providing effective propulsion and controlled stability on all terrain and an e-carbon heel providing active, responsive shock absorption and forward progression.  The high impact/high activity version of the Elite foot enables amputees to partake in activities that include rapid walking over uneven terrain, plus sports and work activities that may include high impact aerobics, running and lifting heavy objects.
Hexcel’s HexPly® 920 prepreg is used to manufacture the foot and the tube.  The foot is compression moulded and the tube is made using the bladder moulding technique.  The heel is manufactured with HexPly® 913 glass and HexPly® 920 carbon prepregs.  HexPly® 920 is the preferred prepreg because it provides the high level of toughness required.  Hexcel is proud to have been a supplier to Blatchford for over 25 years.

Wind Energy
For the Wind Energy market Hexcel has added a range of two-component epoxy resin systems to its product offering, in a strategic move to complement the company’s extensive range of prepregs, resin film infusion and resin transfer moulding products.  HexFlow® 200 is a range of two-part epoxy systems for resin infusion processes.  They are low viscosity systems for fast infusion and shorter production cycles.

Reinforcements
Hexcel has responded to the limited availability of lightweight 3K carbon reinforcements by developing an alternative line of 200 and 300 gsm fabrics based on 12K flat tows.  These products are available, at both weights, in twill and plain weave styles, at widths of 127cm (50").

In addition to these flat tow products, Hexcel is introducing a 200gsm biaxial (0°/90°) reinforcement based on NC2 technology, which allows light or heavy tows to be used, bringing a new solution to the marketplace.

Both reinforcement types will be promoted at JEC, along with the Texalium range of glass fabrics for cosmetic applications.  They will be ready for delivery in April and will be kept on stock.

Sampe Conference papers

Adhesives
Paul Webb, Hexcel Research Chemist, will be presenting a paper at the SAMPE conference on low temperature curing high performance epoxy paste adhesives.  Following on from the recent development of Redux® paste adhesives, Hexcel has now developed new high performance epoxy paste adhesives offering versatile curing options and high temperature performance.

Hexcel’s new two-component epoxy adhesives offer the end user different curing options - from ambient temperatures requiring lower cost tooling, to shortened cure cycles at elevated temperatures.  These structural paste adhesives are particularly suitable for composite bonding, with rheology and volumetric mix ratios optimised for automated dispensing equipment.  One particular adhesive recently developed is a room temperature curing liquid shim system with a formulation designed for maximum compressive performance combined with long working life.

Paul’s paper describes the design of these new epoxy paste adhesives, the range of curing options attainable, and demonstrates the mechanical performances achievable over the wide range of desired operating temperatures.

Resin Developments for Direct Processing
Hexcel has been investing much Resource and Technology capacity in the development of resins for direct processes such as Resin Transfer Moulding (RTM), Vacuum Assisted Resin Transfer Mouding (VaRTM) and Resin Film Infusion (RFI).  Hexcel will be presenting a paper at the SAMPE conference on Hexcel’s development of next generation resins for RTM and VaRTM.  The new resins exhibit higher modulus and greater toughness than current systems.

End

Hexcel Corporation is a leading advanced structural materials company.  It develops, manufactures and markets lightweight, high-performance reinforcement products, composite materials and composite structures for use in commercial aerospace, space and defense, electronics, and industrial applications.

Contact: Sophie Meyniel (France)
Tel : 33 4 72 25 26 33
Sophie.Meniel@hexcel.com

Contact : Rachel Atkinson (UK)
Tel : 44 (0)1223 838475
Rachel.Atkinson@hexcel.com