JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 13

transportation NEWS
From concept to launch:
efficient commercial vehicles
Gerret KalKoffen,
CEO
CarbonTT
Today, more than ever, we need to reduce our energy consumption - in conventional
and electric vehicles alike. CarbonTT's ultra-light carbon chassis addresses
today's most urgent urban logistics challenges: to make 3.5t vehicles more
sustainable. A proprietary pultrusion process guarantees a positive business
case for customers while improving the CO2
-footprint. And it all started at the
JEC Start-Up Booster.
W
"
hat's new about that? "
was the first question
jury member Dr. KarlHeinz
Füller, Mercedes-Benz
Group AG, asked when I quickpitched
our idea at the Startup
Booster Lounge in Hall 6 of the
JEC World trade show. " Hmm,
I've seen that before, it doesn't work.
Anyway, good luck, " he replied, before
we parted ways.
Moments later, I went on stage at
JEC's first Startup Booster and I
repeated my message: " We are
CarbonTT and we want to make
commercial vehicles more economical
and ecological - with carbon-fibre
composite light-weighting. "
This is a goal few people
oppose, but most with industry
knowledge are sceptical about its
achievability. Can CFRP be cost
competitive in the commercial
vehicles sector? Maybe Dr. Füller
was right...
Higher payload &
less emissions
After the presentation, I bumped
into Dr. Füller again. This time,
it was different - the tenor had
clearly changed. He asked me
about our multi-axial pultrusion;
he asked how we join our
components; and most of all,
he wanted to know why I was so
sure it would work.
We sat down and I described
our process, which allows high
operating speeds without wrinkles
in the non-crimped fabrics
- the first step to a high-quality
pultruded profile that we filed as
patent. I described a load-transfer
device with an adhesive injection
process that is easily quality controlled
and suited for high-volume
safety-critical assemblies
(our second patent). I told him
about our systematic approach
to take the lessons learned from
all the simulations, component
and vehicle testing we had done
and combine them into the current
design. " OK, that's not bad, "
he said. " But why should the customer
pay for it? "
We went through different customer
segments and how their
total cost of ownership is reduced
by increasing the payload
and decreasing energy consumption.
We also discussed
how difficult it was to find drivers
with commercial driving licences,
making the 3.5t segment
and higher payloads all the more
attractive. Lastly, Dr. Füller confirmed
that all OEMs are faced
with challenges regarding emissions
and the crash protection
of their batteries, forcing them to
rethink materials and body architectures.
Concept and application
seemed promising after all.
Close-up of CarbonTT's carbon chassis
Sprints and marathons
After JEC World, we met with
Mercedes-Benz Vans in Stuttgart
to discuss how and when a structural
CFRP component could
be introduced into the Sprinter
series. Unfortuntely, the new
Sprinter was just about to launch,
i.e., development was over. But
we found a solution in the form
of a Sprinter power cab and were
asked to develop a concept and
build a prototype vehicle... in
only 90 days! The race was on.
After the successful prototype,
our CFRP topic gained momentum.
We were asked to prepare
another concept that we later
presented in front of the board.
Despite the positive feedback we
received, organisational changes
in 2018 brought developments
to a halt. As a small startup with
an out-of -the-ordinary offering,
you are not always a top priority
for an OEM. 2019 went by
without us knowing whether we
could continue to build on our
early developments.
Fortunately, there are a lot of
good people in the world and
many at Mercedes. Thanks to
certain individuals, we found
a way to combine the processes
of a global OEM with an unconventional
startup. To manage
uncertainties, we were fortunate
to receive funding from LowerSaxony's
Economic Ministry
and entered a strategic partnership
with Rheinmetall. This way,
N°146 June - July 2022 / jec composites magazine
13

JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022

Cover
Edito
«Diversification opens up new perspectives in industry»
Contents
NEWS
In brief
Agenda
Achievement - Belgian-British aviator Zara Rutherford flies around the world in a Shark UL
Transportation - From concept to launch: efficient commercial vehicles
BUSINESS
Association - Lightweight technology opportunities: a B2B event for Indian and European stakeholders
Lightweighting - “The Lightweighting Initiative has long ceased to be a mere networking concept”
MANUFACTURING
AFP - Thermoplastic tape winding: reducing time to market
Filament winding - Filament winding process based on jet nozzle geometry for stealth aircaft
FEATURE SUSTAINABILITY: How is the composite materials industry assuming its responsibility ?
- Biocomposites: Sustainable, multifunctional hemp-based structural composites
- Fabrics: A new generation of sustainable bidirectional fabrics
- Wind: New glass for meeting new challenges
- Automotive: Competitive and sustainable thermoplastic composites for automotive applications
- Bio-resin - PUGreen: a new bio-resin concept for composites processing
- Self-healing material: Why healable composites are key to sustainability
- SMC/BMC: New bio-based composite successfully used
- Functionalization: Electrical functionalised composites by use of recycled carbon fibres
JEC WORLD 2022
- JEC World 2022 surpasses all expectations
- Review of North American Innovations
- JEC World 2022 witnessing a strong impact and an overall positive mood from the DACH region
- Business networking and growth for APAC
- JEC World 2022 Few European highlights
- JEC World 2022 – A natural fibre review
SOLUTION
- 3D printer - Bring your ideas to life
- Natural fibres - European flax and hemp fibres power a more sustainable automotive future
TECHNOLOGY
Additive manufacturing - PA and PETG forcontinuous fibre co-extrusion technology
rCF in additive manufacturing - How and where we found reclaimed Carbon Fibre - for Additive Manufacturing technologies
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Cover
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 2
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Edito
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - «Diversification opens up new perspectives in industry»
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 5
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Contents
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 7
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 8
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - In brief
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Agenda
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Achievement - Belgian-British aviator Zara Rutherford flies around the world in a Shark UL
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 12
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Ad1
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Ad2
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Transportation - From concept to launch: efficient commercial vehicles
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 14
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 15
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Association - Lightweight technology opportunities: a B2B event for Indian and European stakeholders
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 17
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 18
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Lightweighting - “The Lightweighting Initiative has long ceased to be a mere networking concept”
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 20
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 21
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 22
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - AFP - Thermoplastic tape winding: reducing time to market
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 24
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 25
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Filament winding - Filament winding process based on jet nozzle geometry for stealth aircaft
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 27
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 28
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 29
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Biocomposites: Sustainable, multifunctional hemp-based structural composites
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 31
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 32
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Fabrics: A new generation of sustainable bidirectional fabrics
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 34
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 35
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Wind: New glass for meeting new challenges
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 37
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 38
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 39
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 40
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 41
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Automotive: Competitive and sustainable thermoplastic composites for automotive applications
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 43
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 44
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 45
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Bio-resin - PUGreen: a new bio-resin concept for composites processing
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 47
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 48
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 49
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Self-healing material: Why healable composites are key to sustainability
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 51
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - SMC/BMC: New bio-based composite successfully used
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 53
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 54
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Functionalization: Electrical functionalised composites by use of recycled carbon fibres
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 56
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 57
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 58
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - JEC World 2022 surpasses all expectations
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 60
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Review of North American Innovations
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 62
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 63
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 64
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 65
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - JEC World 2022 witnessing a strong impact and an overall positive mood from the DACH region
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 67
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Business networking and growth for APAC
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 69
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - JEC World 2022 Few European highlights
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 71
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 72
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 73
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - JEC World 2022 – A natural fibre review
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 75
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 76
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 77
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 78
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 79
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 80
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - 3D printer - Bring your ideas to life
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 82
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 83
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - - Natural fibres - European flax and hemp fibres power a more sustainable automotive future
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 85
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Additive manufacturing - PA and PETG forcontinuous fibre co-extrusion technology
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 87
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 88
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 89
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 90
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - rCF in additive manufacturing - How and where we found reclaimed Carbon Fibre - for Additive Manufacturing technologies
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 92
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 93
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 95
JEC COMPOSITES MAGAZINE - Issue #146 - June/July 2022 - 96
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