[ MATERIAL ]
LIGHT. STRONG. FLEXIBLE.
THE BUILDING MATERIAL OF THE FUTURE
Cost effectiveness and freedom of geometry
A composite material combines two or more materials, such as strong fibres (carbon or glass) embedded in a resin, to create something stronger and lighter than either material on its own.
Weight saving foam
A composite sandwich places a lightweight core, such as foam or honeycomb, between two thin, strong fibre-reinforced skins, making the panel very stiff and strong while keeping its weight low, just as an I-beam gets its strength from material far from its centre.
Freedom of shape
The superior material properties enable aesthetically pleasing designs, e.g. slim constructions and seamless facades, which cannot be achieved with conventional materials. The surfaces can be very stylish and good looking.
High return on investment
Combined Composites can be tailored to your purpose through fibre orientation and material combination. The correct design of the properties results in a very cost effective product. Due to the low life cycle costs, the cost advantage can be enormous. High, directional strength (anisotropy) enables structures and properties that cannot be achieved with conventional materials.
Why we are using only Epoxy resin for marine applications
Epoxy resin bonds far better to the fibres, shrinks less when curing, and absorbs much less water than polyester or vinylester, so the laminate is stronger, tougher and lighter, and practically immune to osmosis.
High strength
Fibre reinforced composites outperform most metals in strength in absolute numbers as well as in weight to strength ratio.
Lightweight
Fiber-reinforced plastics are much lighter than metals yet can still achieve their rigidity. Experience shows that the use of composites can realise a weight saving of 20% to 400%. The specific weight of composites varies between 1.5 and 2.0 kg/L compared to 2.7 kg/L for aluminium and 7.8 for steel.
From stiffness to fexibility
With fiber composites, rigidity can be calculated and modified with the utmost precision from elastic to maximum rigidity. The stiffness to weight ratio of a high modulus carbon fibre construction is typically 5 times higher than steel or aluminium.
High resistance to fatigue
Fiber composites fatigue slowly and increase the life of highly stressed components and and can be defined in detail. The fatigue resistance of composites is much better than that of metals.
Low maintenance
Steel structures typically require periodic maintenance such as conservation and paint systems to prevent corrosion. Composites are not susceptible to corrosion, resulting in lower Life-cycle costs.
Chemical/Corrosion resistance
Perfect for rude conditions: Composite materials are resistant to salt and seawater, most solvents, oil, acids, hydroxides, etc. Extremely high resistance to corrosion gives a long service life in even the most aggressive environments.
Limited thermal expansion
The expansions of composite materials can be designed up to the zero expansion, depending on the fibre used. Fiber composites expand must less than metals.
Vibrations damping
Up to ten times more effectively than metals.
Insulation
Typical GRP lambda values are 1, compared to 50 for steel and 237 for aluminium, which results in excellent insulation properties.
Thermal conductivity
Carbon fibre used in a polymer matrix can be designed that is thermally conductive in the fibre direction with thermally insulating transverse to the fibre direction.
Sonar/Radar/X-ray transparency
High transparency to radar and excellent permeability to xrays.
Non-magnetic
Glassfibre reinforced composites have superiour non-magnetic properties.
PRE IMPREGNATED FIBERS
Our prepreg system´s low-temperature curing chemistry offers significant cost advantages and allowed us to switch from the infusion lamination process without developing expensive new high-temperature tooling.
The overall production cost is similar to or even lower than vacuum infusion due to cost savings in the shop during application and cleaning, less waste and lower health and safety costs.
• less weight than classic GRP (20-30%)
• less waste (<2%)
• almost zero production errors
• no harmful styrene or VOC emissions
• no human contact to chemicals
• no chemical mixing and vapour exposure
Our prepregs can be cured at temperatures as low as 70˚C, with the standard cure cycle being 12 hours at 70˚C, matching the typical cycle time for an infused part with a component Tg of 85˚C. These materials have a good outlife of 30 days at 20˚C and are available with unidirectional, multiaxial and woven reinforcements.
This magic potion is a potion not brewed by the druid Getafix, but it gives supernatural powers to yachts. And even better than the original which is brewed from various herbs, the AEOLOS potion gives supernatural powers for an unlimited time.
ENDLESS COMBINATIONS
Each material has its own characteristics. The fibres are embedded in the matrix. The stiffness can be drastically increased with light "spacer" materials.
Fibers
- carbon fiber (CFK)
- glass fiber (GRP)
- aramide fibers: Kevlar and Twaron (AFK)
- polyethylene fibers (Dyneema)
- polyester fibers
- basalt fibers
- ceramic fibers
- boron fibers
- natural fibers
The king of the fibers
Unidirectional carbon fibre is a real asset: because the fibre can be placed exactly in the direction of force, it offers enormous potential for increasing strength and durability while reducing weight. In addition, unidirectional fibre is again much stronger (typically twice as strong) than woven fibre because the tensile potential is much higher at only a fraction of the weight density. In woven materials the fibre makes curves, which means that it is more flexible. UD fibre does not bend when subjected to force - it lies flat. Flexibility is as important as strength. In unidirectional fibres, you can overlap them at different angles and orientations to maximise strength in different areas while keeping the fabric stiff and stable.
If aesthetics are an important part of the design, unidirectional fibres allow you to overlap the fabric with a variety of carbon fabrics to create a dynamic new look that is pleasing to the eye.
Matrix
- duroplastic (epoxy, vinylester, phenolic resin)
- thermoplastic matrix systems (PEEK, PP)
Spacers
- PU/PE-Foam
- wood (Balsa)
- Honeycomb (aluminium, aramid, paper)
THE BEAUTY OF COMPOSITE FABRIC
Composite materials have their own beauty. In recent years we have gained unsurpassed experience in applying great looking fabrics even to complex surfaces. These surfaces turn a carbon part into an iconic object.
Fabrics applied on 20cm width curved objects
FIRE RESISTANT SOLUTIONS ON COMPOSITE
Fire resistance is a particularly important factor in commercial shipping and architecture. In the past, composite materials have often been unable to comply with regulations, but we capable to create solutions to fit into the standards. Using fire resistant composites means again a huge weight reduction and/or increase in strength.
- special coatings (intumescent paint)
- protection with ceramic tiles
- architecture wall with Gypsum plaster, GPC or UHPC
- fire retardant resins and foams
- fire protection (rockwool, metal)
- construction methods
For Example:
In the UK the Building (Amendment) Regulations 2018 states that building work shall be carried out so that material which become part of an external wall are of European Classification “A2-s1, d0” or “A1”.
These classifications are taken from BS EN 13501-1:2007+A1:2009. The Building (Amendment) Regulations 2018, came into force on 21st December 2018 and will apply to all projects, as described above, that started on site after 21st February 2019.
In the Middle East, NFPA 285 is a standard for fire testing. We can design, produce and test panels and parts that meet the testing standards.
FIRE PROOFED PREPREGS
We work also with prepregs with outstanding fire performance of its’ specialist epoxy FR prepregs. We use prepreg materials (tested and certified to NFPA 285, ASTM E84 and EN13501-1), also available with the low temperature curing technology, combining additional processing options with market leading fire performance. Fire resistance is a particularly important factor. In the past, composite materials have often been unable to comply with regulations, but we capable to create solutions to fit into the standards.