Ethernet Cable Showdown: Cat5e vs. Cat6 – Features, Benefits, and Recommendations

Cat5e vs Cat6: Unraveling the Ethernet Cable Conundrum for Modern Networks

<p dir="ltr" id="isPasted">The industrial applications of engineering thermoplastics like PC and high-performance thermoplastics like PEEK are growing. In 3D printable filament form, these materials offer a lightweight alternative to metals like steel and aluminum in industries like aerospace and energy.</p><p dir="ltr">Reinforcing these high-performance plastics with additives can further improve their performance. Chopped carbon fiber, for example, increases strength and stiffness and can be added to low- and mid-priced engineering plastics as well as high-performance plastics. As long as the 3D printer nozzle can handle abrasive materials, these composites can be printed in much the same way as ordinary thermoplastics.</p><p dir="ltr">The main drawback of high-performance composites like reinforced PEEK is the high cost of the required 3D printing hardware. Such materials require extremely high extrusion and chamber temperatures, and the price of suitable hardware — typically reaching six figures — often nullifies the general cost benefits of plastic 3D printing technology.</p><p dir="ltr">This article looks at <a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">carbon fiber reinforced PPS</a> as a means of achieving performance comparable to metal and PEEK but with lower temperature and cost demands.</p><h1 dir="ltr">What is PPS?</h1><p dir="ltr" id="isPasted">Polyphenylene sulfide (PPS) is a semi-crystalline thermoplastic that can be classified as a high-performance plastic alongside materials like PEEK and PEI.</p><p dir="ltr">Widely used in machining, molding, and additive manufacturing, PPS offers good mechanical properties, a high temperature resistance compared to standard and engineering thermoplastics, and flame retardancy. However, its most desirable characteristic is its excellent chemical resistance: PPS is resistant to many acids, alkalis, and solvents, as well as certain strong oxidants in certain conditions. For strong oxidants like chlorine dioxide, a coating or lining may be required.</p><p dir="ltr">Due to its desirable characteristics and favorable price compared to PEEK, PPS has a wide range of applications across industries. Its mechanical and chemical properties make it useful in automotive, energy, and chemical processing, while its flame retardancy and self-extinguishing nature have contributed to its status as a go-to material for electrical and electronic parts like SMT devices, motor housings, and transistor sealings.</p><p dir="ltr">Not only impressive from a thermoplastics standpoint, PPS is regularly used as a genuine alternative to metals like steel and aluminum. Its thermal stability and supreme chemical resistance make it usable in harsh chemical environments, while it is notably resistant to corrosion and the effects of automotive fluids.</p><h2 dir="ltr">PPS as a composite</h2><p dir="ltr" id="isPasted">For added strength and stiffness, PPS can be reinforced with additives like chopped carbon fiber or fiberglass, forming a composite material. In fact, PPS is more commonly sold as a “filled” material than an unfilled one.</p><p dir="ltr">According to researchers, the “addition of carbons can greatly improve the mechanical properties, tribological properties, post-fire structural integrity, and electrical/thermal conductivity of… PPS blends and composites.”</p><p dir="ltr">Carbon fiber reinforced PPS can be used for similar applications to unfilled PPS. However, the improved mechanical properties make it a suitable material for components like tooling, jigs, and fixtures. PPS composites are particularly suited to industrial FFF additive manufacturing, as these 3D printers cannot print materials like pure carbon fiber.</p><h1 dir="ltr">3D printing PPS</h1><p dir="ltr" id="isPasted">PPS, in both its unfilled and composite form, offers a fairly accessible route to the 3D printing of high-performance thermoplastic parts. This is thanks to its printing temperature of around 320 °C, which is high but not extremely so.</p><p dir="ltr">While a 320 °C extrusion temperature is beyond the capacity of most FFF 3D printers, it is significantly lower than the temperature required for 3D printing PEEK, which is around 400 °C. (PEEK also requires a very high chamber temperature.) Accordingly, PPS parts have a lower temperature resistance than PEEK parts, but they can still be used for demanding applications in which temperatures reach up to around 230 °C.</p><p dir="ltr">The type of 3D printer required for printing PPS is somewhere between an industrial-grade FFF printer and a specialist high-temperature FFF printer. Reliable production-level printers can cost around $10,000, while best-in-class high-temperature machines like the Stratasys Fortus 450mc cost around $150,000, which may be considered prohibitively expensive for small and midsize businesses.</p><p dir="ltr">When printing carbon fiber reinforced PPS, nozzle durability must be considered as well as temperature, as the chopped fibers are more abrasive than the thermoplastic base material and can therefore damage ordinary brass hardware.</p><p dir="ltr">A suitable build surface for PPS is PEI sheet, with the print bed heated to around 80 °C. For intricate 3D printed PPS parts printed on a dual-extrusion machine, the material is compatible with PVA support material.</p><p dir="ltr">3D printed PPS reinforced with carbon fiber is suitable for applications such as functional prototypes, tooling for molding and other processes, and manufacturing aids like jigs and fixtures. Industries using reinforced PPS filament include automotive, rail, and aerospace.&nbsp;<iframe id="664b352562706314cc391e64" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/ultimaker-factor-4?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></p><h2 dir="ltr">High performance, low cost</h2><p dir="ltr" id="isPasted">New additive manufacturing systems are making PPS 3D printing accessible to a wider range of users. For example, the <a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank">UltiMaker Factor 4</a>, which began shipping in May 2024, has a highly wear-resistant print core that enables printing temperatures up to 340 °C — adequate for printing carbon fiber reinforced PPS and many engineering thermoplastics.</p><p dir="ltr">What is unique about modern systems like the Factor 4 is their intermediate market positioning. Despite being able to print a genuine high-performance material like carbon fiber reinforced PPS, the Factor 4 is priced closer to an ordinary professional-grade desktop 3D printer than a high-temperature PEEK 3D printer.</p><p dir="ltr">To meet the needs of users in industries like electronics and automotive, UltiMaker has also developed its own composite material, UltiMaker PPS CF, tailored for use in the Factor 4. With consistent flow and desirable material properties, the material is formulated to offer high performance while being easy to print. The combination of printer and material also results in excellent dimensional accuracy, exhibiting minimal shrinkage compared to PEEK.</p><p dir="ltr">Like other carbon fiber PPS materials, UltiMaker PPS CF is highly recommended for functional prototypes and indirect manufacturing components, though its excellent chemical and heat resistance opens up a broad range of possible applications including end-use parts. The UltiMaker formulated PPS-CF is Flame retardant (V0-94) and guarantees low warpage also on large parts, setting it apart from alternative PPS CF filament providers.</p><h2 dir="ltr">Application examples</h2><h3 dir="ltr" id="isPasted">Air freight fastener</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNDMxMDg1Mjc0LXVsdGltYWtlci1wcHMtY2YtYWlyLWZyZWlnaHQtZmFzdGVuZXItM2QtcHJpbnQgKDEpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>This holder is used to securely fasten air freight or to safely stow components in the air freight packaging. Accordingly, it must be temperature-resistant, very strong and stable, and resistant to chemicals – application requirements that are all met with PPS CF. Another advantage of additive manufacturing is that the design can be adapted repeatedly, with all iterations meeting the necessary certifications thanks to the material used.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720444566254-Air+freight+fastener2.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h3>High-pressure pump valve</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNDMxNjU4ODMzLVB1bXBWYWx2ZTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted">This pump valve is installed in a train to conduct liquids or chemicals. But because it had become an obsolete component (it was no longer produced), the entire pump assembly would need to be replaced – costing approximately €5,000. Using PPS CF, it can now be 3D printed, so that it still meets the UL94 V0 standard for non-flammability and also for use with hot acids.</p><h3 dir="ltr" id="isPasted">Sensor Bracket</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNDMxMTYxMTgyLVNlbnNvciBCcmFja2V0IFBQUyBDRiAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p>This simple bracket is used in the production line and around the site to quickly mount sensors, cameras or other necessary extensions. Priority is given to ensure that the component can withstand extreme loads in outdoor use, including weather conditions, impact resistance or fire protection conditions.</p><h1 dir="ltr">New possibilities</h1><p dir="ltr" id="isPasted">Carbon fiber-reinforced PPS is a high-performance material suited to some of the most demanding industrial applications. Some additive manufacturing end-users might assume that they need the most expensive materials and hardware to achieve engineering-grade quality coupled with high levels of design freedom. However, the UltiMaker Factor 4 and its specially formulated PPS CF material show that this is no longer the case.</p><p dir="ltr">If you want to know more about the UltiMaker Factor 4 and the wide variety of engineering materials that can be printed on it, watch this<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank" rel="noopener noreferrer">&nbsp;video.</a></p>

High-performance thermoplastic composites can be used to replace metals. While PEEK is the benchmark for engineering performance, reinforced PPS is a genuine low-cost alternative.


Carbon Fiber Reinforced PPS as an alternative to PEEK and metal

<p id="isPasted">Jigs and fixtures are essential tools on any assembly floor, test lab, or machine shop. In this article, we will go over what they are and how you can supercharge your jigs and fixtures by 3D printing them using carbon fiber composites.</p><h2>What are jigs and fixtures?</h2><p>Before diving into the benefits of carbon fiber composite 3D printing, let&#39;s clarify what jigs and fixtures are and why they are critical aids that can make the manufacturing process more efficient, precise, and safe.</p><h3>Jigs</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693309586555-Picture_STline_jig.png" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">A jig is a custom-made tool that is employed to ensure precision and repeatability in manual processes like drilling, welding, and assembly. The primary purpose of a jig is to maintain consistency when producing duplicate parts and ensuring that each part aligns perfectly with the others. In simple terms, a jig acts as a template, guiding the tool to the correct position on a workpiece.</p><h3>Fixtures</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693309611422-trinckle_Fixture-Generator.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Unlike jigs, fixtures are used to hold a workpiece in place during operations. They ensure that the piece remains stationary, allowing tools or machines to function accurately. Fixtures are specifically designed to fit a particular part or shape, ensuring that the workpiece is held in the exact position and orientation required for the manufacturing process. An example of where this is essential is during milling or CNC machining.</p><h2>3D printing: a perfect match for jigs and fixtures</h2><p>Both jigs and fixtures are bespoke solutions with strict requirements that can be perfectly addressed by 3D printing. These are some of the areas where the advantages of 3D printing are most beneficial:</p><p><strong>Fast turnaround time</strong><br>Design iterations can be created quickly allowing for rapid prototyping when creating new jigs and fixtures or fine-tuning existing ones.</p><p><strong>High degree of customization</strong><br>When 3D printing parts, you have the design freedom to create custom jigs and fixtures that perfectly match the product and process you are optimizing for.</p><p><strong>Cost-efficient for low-volume production</strong><br>Traditional manufacturing methods can be costly when producing low volumes of specialized tools. Since 3D printing doesn&#39;t require new molds or dedicated machinery for each design, it can produce low quantities of jigs and fixtures at a fraction of the cost.</p><p><strong>Integrated and complex designs</strong><br>3D printing enables features like undercuts, internal channels, or intricate geometries that can be difficult or impossible to realize with traditional manufacturing. Allowing you to create jigs and fixtures that prioritize functionality without worrying about design constraints.</p><p><strong>On-demand production</strong><br>Rather than keeping a vast inventory of jigs and fixtures for various tasks, manufacturers can maintain a digital library. When a specific tool is needed, it can be printed on-demand, reducing storage space and associated costs.</p><h2>What are the advantages of carbon fiber composites for jigs and fixtures</h2><p>Carbon fiber composites are a class of material that include chopped-up carbon fibers embedded into a polymer, in a way that makes them easy to print while leveraging the advantages of each material. Alongside the usual benefits of 3D printing your jigs and fixtures, carbon fiber materials have some additional characteristics that make them well-suited to such demanding applications:</p><p><strong>High-performance properties</strong><br>Parts printed using carbon fiber composites have high strength, stiffness, and heat resistance, all essential properties for tools undergoing rigorous usage in a commercial setting.</p><p><strong>Weight advantages</strong><br>Carbon fiber is lightweight when compared to materials with similar performance characteristics. This leads to lighter tools and increased efficiency on the production floor.</p><p><strong>Durability and longevity</strong><br>The robustness of carbon fiber composites ensures that your jigs and fixtures can endure the stresses of the manufacturing process for a longer duration compared to those made from traditional materials.</p>

Jigs and fixtures are essential tools on any assembly floor, test lab, or machine shop. In this article, we will go over what they are and how you can supercharge your jigs and fixtures by 3D printing them using carbon fiber composites.

Enhancing your jigs and fixtures with carbon fiber composites

<p id="isPasted">Composites are a category of materials that encompass a large number of different properties and use cases. And even within carbon fiber composites, you can get vastly different results depending on the specific material you choose. In this article, we will take a look at the different UltiMaker carbon fiber composites available and help you decide which one is best for your needs. First, let&rsquo;s look at which characteristics all the UltiMaker carbon fiber materials share.</p><h2>The pros and cons of 3D printing with carbon fiber</h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692707046302-the-pros-and-cons-of-3d-printing-with-carbon-fiber-ultimaker.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Carbon fiber has long been a popular material due to its high strength-to-weight ratio. As a result, it is often used in high-performance (and high-cost) applications such as aerospace, automotive, and sports equipment. However, pure carbon fiber is a difficult material to work with and therefore expensive.</p><p>Enter carbon fiber-reinforced composites. Made by adding chopped-up carbon fibers to a polymer, you can maintain many of the benefits of carbon fiber, while also inheriting the beneficial properties of the material it is combined with. This process works similarly to combining two metals to make an alloy.</p><p>Carbon fiber composites as a category are useful for many reasons but the most notable is that it makes it possible to print carbon fiber parts using a standard desktop 3D printer such as those made by UltiMaker. As a result, UltiMaker offers four carbon fiber composite materials across our two professional 3D printer lines, alongside the many compatible third-party materials. Let&rsquo;s take a look at the properties they all share before diving into each one individually:</p><h3>High performance at an accessible cost</h3><p>The exact properties of a carbon fiber composite vary based on the polymer it is combined with but they almost all have high strength and/or stiffness characteristics. Especially when compared with its constituent polymer on its own. 3D printing makes carbon fiber parts more cost-effective than ever but the increased performance still comes at a cost. Carbon fiber composites are more expensive than entry-level 3D printing materials such as PLA or PETG. However, they are still cheaper than other more specialized materials, and UltiMaker carbon fiber materials, in particular, present an excellent price-to-performance offering.</p><p>Aside from the cost, the only other thing to be aware of when printing with carbon fiber is that the fibers themselves are abrasive, meaning a specialized nozzle is required. This is why the CC print core is required when printing on&nbsp;<a href="https://ultimaker.com/3d-printers/s-series/" target="_blank">S series printers</a> and the 1C extruder is needed on&nbsp;<a href="https://ultimaker.com/3d-printers/method-series/" target="_blank">Method series printers</a>.</p><h3>A beautiful matte finish</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692707075189-a-beautiful-matte-finish-achieved-with-carbon-fiber-3d-printing-materials-ultimaker.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">One of the less obvious benefits of carbon fiber composites is that your final part will have a clean-looking matte finish that gives them a pleasing visual identity and helps to counteract one of the aesthetic drawbacks of 3D printing, layer lines. Layer lines are significantly less noticeable on parts printed with any of the UltiMaker carbon fiber composites, making them a surprisingly good option for visual or proof-of-concept prototypes, as well as end-use parts.</p><h2>Which UltiMaker carbon fiber composite is best for you?</h2><p>Each of the carbon fiber composites offered by UltiMaker has its own strengths meaning that if you need a high-performance material, you should have no problem finding one that meets your needs.</p><h3>PET CF</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692707094705-pet-cf-ultimaker-3d-printing-composite-material.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">PET CF is the newest in UltiMaker&rsquo;s range of composites and the first available on S series printers. It offers the high strength, stiffness, and temperature resistance needed for performance applications, with the added benefit that all of those properties&nbsp;<a href="https://support.ultimaker.com/s/article/000002925" target="_blank">can be enhanced by annealing your printed part</a>. The annealing process will improve the temperature resistance of your parts from 80 &deg;C to a phenomenal 181 &deg;C, while also increasing their strength by 30% and stiffness by 10%.</p><p>PET CF also has low moisture sensitivity and high reliability, making it significantly easier to print than other third-party composites. Finally, this is the only composite that UltiMaker offers which comes in multiple colors. Alongside the usual black, you can also choose blue and gray options.</p><h3>ABS Carbon Fiber</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692707149947-abs-carbon-fiber-ultimaker-3d-printing-composite-material.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">ABS Carbon Fiber combines the reliability of ABS on the Method series with the performance of carbon fiber, meaning it&rsquo;s significantly easier to print than most third-party composites while still retaining many of the advantages. ABS Carbon Fiber is even easier to use because it&rsquo;s also the only composite on the Method series that is compatible with the&nbsp;<a href="https://ultimaker.com/materials/method-series-rapidrinse/" target="_blank">RapidRinse support material</a>, opening up limitless design flexibility with easy and convenient support removal. This makes it a great candidate for when multiple experimental design iterations need to be made over a short period of time. ABS Carbon Fiber stops you from worrying about failed prints and lets you focus on design innovation.</p><h3>Nylon Carbon Fiber (Nylon 6/66 blend)</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692707168102-nylon-carbon-fiber-ultimaker-3d-printing-material.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Nylon 6 carbon fiber has the high strength characteristics of other carbon fiber composites but the main thing that sets Nylon 6 Carbon Fiber apart is its insanely high heat deflection performance. It is capable of withstanding temperatures of up to 184 &deg;C, which is over 100 &deg;C higher than ABS and is even higher than that of PET CF parts&nbsp;<em>after they have been annealed.</em> That makes it the perfect material for any situation where heat resistance is important such as in automotive or industrial applications.</p><h3>Nylon 12 Carbon Fiber</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692707193554-nylon-12-carbon-fiber-ultimaker-3d-printing-material.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p>The major benefit of Nylon 12 Carbon Fiber is that it is resistant to moisture uptake, making it easier to print and giving the printed part a cleaner final appearance without the need for post-processing. The tradeoff for that increased ease of use is that it has a lower heat resistance than Nylon 6 Carbon Fiber, although still a higher thermal resistance than ABS Carbon Fiber or PET CF before it is annealed.</p>

Composites are a category of materials that encompass a large number of different properties and use cases. And even within carbon fiber composites, you can get vastly different results depending on the specific material you choose. In this article, we will take a look at the different UltiMaker carbon fiber composites available and help you decide which one is best for your needs. First, let’s look at which characteristics all the UltiMaker carbon fiber materials share.

How to choose the right carbon fiber composite for your needs

<p id="isPasted">Carbon fiber is one of the most powerful materials for anyone trying to get the most out of 3D printing. But when should you use it, and what applications can you use it for? Let&rsquo;s delve into these questions and discover why 3D printed carbon fiber composites are more accessible and versatile than ever before.</p><h2>Understanding carbon fiber composites</h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691403565354-3d-printing-carbon-fiber-ultimaker-detail.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Carbon fiber has a rich history, dating back to Thomas Edison&rsquo;s use of it as a filament in lightbulbs in the late 19th century. Recognizing the strength of carbon fiber, the Union Carbide Corporation further developed its processing techniques in the 1950s. Fast forward to the present, and carbon fiber is now commonly used in high-performance products like race cars and airplanes. With the advent of 3D printing technology and recent advancements in composite techniques, carbon fiber is now accessible for a whole range of new applications.</p><h2>The benefits of 3D printing with carbon fiber</h2><p>Traditional carbon fiber is known to be strong, lightweight, and to have a distinctive visual appeal with its graphite black cross weave pattern. However, traditional manufacturing processes can be labor-intensive and costly. This is where carbon fiber composite blends come into play.</p><p>By combining chopped carbon fiber with a base resin or polymer, the resulting composite is more manageable. This makes it suitable for various manufacturing techniques, including 3D printing. Furthermore, introducing different base polymers can add unique properties, enhancing the versatility of carbon fiber composites.</p><h3>The right time to use 3D printing</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691403627733-ultimaker-measuring-strength-carbon-fiber-3d-printed-parts.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Before you dive into&nbsp;<a href="https://ultimaker.com/learn/finding-the-perfect-carbon-fiber-3d-printing-application/" target="_blank">finding your perfect 3D printing application</a>, it&rsquo;s crucial to understand when it&rsquo;s most beneficial. Consider factors such as time savings, cost per volume, and the specific material properties required for your applications.</p><h4>Saving time with design iterations</h4><p>One of the most significant advantages of 3D printing is the ease and speed of setup. It allows direct transition from design to print job, significantly reducing the labor of creating individual parts. This benefit is further amplified when a part goes through multiple design iterations.</p><h4>Volume-base cost efficiency</h4><p>For high-volume production, traditional manufacturing methods like injection molding might be more cost-effective due to economies of scale. However, for low-volume requirements, such as prototypes, custom tools, or replacement parts, 3D printing often provides a more economical solution.</p><h4>Meeting material property requirements</h4><p>When selecting a material and manufacturing process, understanding the specific requirements of your application is paramount. You&rsquo;ll need to consider the stresses, strains, temperature thresholds, and exposure to moisture or chemicals your part will endure. Carbon fiber composites often meet or exceed the requirements of high-performance parts, making them a viable alternative to traditional metal components.</p><p>By harnessing the power of 3D printed carbon fiber composites, you can revolutionize your production process and create high-performance, custom parts with ease and efficiency.</p>

Carbon fiber is one of the most powerful materials for anyone trying to get the most out of 3D printing. But when should you use it, and what applications can you use it for? Let’s delve into these questions and discover why 3D printed carbon fiber composites are more accessible and versatile than ever before.

The advantages of 3D printing with carbon fiber

<h1 id="isPasted">Composite Engineering Challenge</h1><p>The Composite Engineering Challenge invited innovators, entrepreneurs, startups, and scaleups to submit projects that make use of fiber-reinforced composites.</p><p dir="ltr">The challenge received submissions from over 20 countries. The jury selected <a href="https://www.wevolver.com/article/the-composite-engineering-challenge-finalists" rel="noopener noreferrer" target="_blank">ten finalists</a> and three special recommendation projects.&nbsp;</p><p dir="ltr">The Wevolver Community voted to select their favorite finalist who will<span style="background-color: transparent;">&nbsp;be brought to the attention of senior management of MCG and the Venture group of MCG. The winner fo the 2023 Composite Engineering Challenge Wevovler Community Vote is&nbsp;</span>CarboScreen.&nbsp;</p><p dir="ltr">CarboScreen develops and produces a sensor-based monitoring system with AI-based software. It links sensor data to process know-how to optimize production and increase fiber quality. This has the potential to double production speed and reduce downtime, resulting in an increase in sales and enabling the use of CFs in mass markets.&nbsp;</p><p><span style="background-color: transparent;">Wevolver sat down with Felix Pohlkemper of CarboScreen to ask him about their tech, its impact, and what winning the community vote means to him and the team.</span></p><h3 dir="ltr">Wevolver: Talk us through the CarboScreen concept. What is the tech and how does it work?</h3><p dir="ltr"><strong>Pohlkemper:</strong> To understand why CarboScreen shines, it&#39;s important to first understand the current state of carbon fiber production.&nbsp;</p><p dir="ltr">Reinforcing fibers - such as carbon fibers - can only develop their full potential if they aren&#39;t damaged during production and processing. However, the current state-of-the-art optical monitoring of these processes is not good enough for most fiber production processes, such as detecting structural defects.&nbsp;</p><p><span style="background-color: transparent;">This deficit is particularly evident in the complex carbon fiber manufacturing process, where there currently aren&#39;t any sensor systems available for monitoring the quality of carbon fibers. This leads to reduced fiber quality and, in extreme cases, plant fires.&nbsp;</span></p><p dir="ltr">In order to be able to guarantee sufficient product quality, the maximum production speed of a carbon fiber line is limited to approximately 12-15 meters per minute. In other words, the production lines are only being used to 30-40% of their potential, due to process limitations. This restriction of production makes the final product more expensive. Averaging about &euro;20 per kilo - these fibers are well above the tolerable cost for mass applications.&nbsp;</p><h2 dir="ltr">How does CarboScreen stand out?</h2><p><span style="background-color: transparent;">The business model of CarboScreen includes the development, production and sale of a multimodal, sensor-based monitoring system to carbon fiber manufacturers. In addition to mechanical fiber damage, the system is also able to monitor relevant parameters, such as the degree of stabilization during the process.&nbsp;</span></p><p dir="ltr">The core competencies lie in the adaptation of various sensor systems to the carbon fiber manufacturing process and the development of an AI-based software platform.<span style="background-color: transparent;">&nbsp;</span></p><p dir="ltr">The software platform links the measured sensor data with process know-how and derives recommendations for action for the plant operator. The combination of sensor, fiber and process know-how to derive recommendations for the customer is the company&#39;s unique selling point.</p><h3 dir="ltr">Wevolver: How do you think CarboScreen&#39;s tech will impact carbon fiber production?</h3><p dir="ltr"><strong>Pohlkemper:&nbsp;</strong>The monitoring systems will enable an increase in the production speed of carbon fiber production. By doubling the production speed alone, it is possible to achieve an increase in sales of up to &euro;37.5 million per year per plant for users of the CarboScreen technology.&nbsp;</p><p dir="ltr">Long term, an increase in production volume per plant results in a significant reduction in the carbon fiber price. Industry experts are sure that this will enable the large-scale use of carbon fibers and their composites in mass markets such as the automotive sector.&nbsp;</p><p dir="ltr">The CarboScreen technology is paving the way for cost-effective, lightweight carbon fiber solutions in numerous industrial sectors such as e-mobility, civil aviation and renewable energies. CarboScreen also offers customers the possibility to monitor their produced fibers holistically and to market them certified to their end customers.&nbsp;</p><p dir="ltr">Carbon fiber production is the ideal entry market to develop and test this monitoring system due to its high added-value and sophisticated process control. However, we are planning to expand the portfolio to other markets, such as the glass fiber or man-made fiber industry.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1678780184846-Carbo+screen+1.jpg" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">CarboScreen monitoring system: Image credit: CarboScreen</span></span></span></p><p><span style='font-family: "PT Sans", serif; font-size: 26px; font-weight: 700; background-color: transparent; color: rgb(0, 0, 0);'>Wevolver: Do you see a potential partnership with the Mitsubishi Chemical Group venture team on the horizon? What do you hope this will look like?</span></p><p dir="ltr"><strong>Pohlkemper:</strong> We are focusing heavily on our positioning in the market and the development of further partnerships. For the continued development of the technology, cooperation with various subsidiaries of the Mitsubishi Group would be greatly welcomed.&nbsp;</p><p dir="ltr">Specifically, we are pursuing contacts who could be either potential customers (carbon fiber manufacturers/ processors), or potential partners (sensor manufacturers). For example, a partnership with the carbon fiber manufacturing department of Mitsubishi Chemicals would be useful for us. The partnership could go from a simple exchange to joint developments.&nbsp;</p><p dir="ltr">Furthermore, the use of the Line Scan Bar from Mitsubishi Electric for the detection of macroscopic defects would be advantageous. We have already developed a corresponding monitoring system with another camera system. If there is interest, we would be happy to present the topic again to the respective departments.&nbsp;</p><h3 dir="ltr">Wevolver: What does the future hold for CarboScreen? Where do you plan to take the tech in the next 6-12 months?</h3><p dir="ltr">Pohlkemper: CarboScreen&#39;s value proposition is to offer holistic monitoring and control of carbon fiber production for increased process reliability and productivity. For this purpose, CarboScreen develops and sells modular monitoring systems specially designed for carbon fiber production lines with AI-supported evaluation software.&nbsp;</p><p dir="ltr">In addition, consulting services on all aspects of carbon fiber production and the market are offered. The market entry will take place in cooperation with RWTH Aachen University and the Institut f&uuml;r Textiltechnik, respectively.</p><p dir="ltr">The monitoring systems will then be distributed via two different sales channels. On the one hand, Onejoon, the leading plant manufacturer for carbon fiber equipment, will offer the monitoring system as an upgrade for new or existing production plants. On the other hand, direct sales will be made to carbon fiber producers who want to upgrade their plants.&nbsp;</p><p dir="ltr">Interesting markets are located in particular in the growth countries China, Saudi Arabia and Turkey. Since the company founders have already worked with a large number of these companies (such as Saudi Aramco, Dow Aksa, SABIC), the chances of success for marketing are very good. Initial talks have already taken place.&nbsp;</p><p dir="ltr">By combining process and sensor know-how with good networking within the carbon fiber industry, CarboScreen can offer customer-specific overall solutions and act broadly on the market at an early stage.&nbsp;</p><p dir="ltr">Initially, the upscaling of the technology, the validation of the product and the marketing of the monitoring systems will be driven forward within the framework of the ongoing research project.&nbsp;</p><p><span style="background-color: transparent;">After the foundation of CarboScreen in 2023 and after completion of the research project, the production of the first monitoring systems for laboratory and pilot plants will begin in 2025.&nbsp;</span></p><p dir="ltr">In addition to offering consulting services such as workshops, studies or process design, and licensing the software, we plan for sensor system sales to be the main source of income. It is assumed that the first delivered systems will be designed for laboratory and pilot plants.&nbsp;</p><p dir="ltr">We project that by 2029, our &nbsp;total revenue will be around &euro;2.2 million.</p><h3 dir="ltr">Wevolver: What does winning the Wevovler community vote mean to you and the team?</h3><p><span style="background-color: transparent;"><strong>Pohlkemper:</strong> Winning the Wevolver community award is a great honor for us. As the award was chosen by the community, it shows once again the relevance of the topic at the moment. A widespread use of carbon fibers, also in low-cost areas, is only possible in the long term, among other things, if the carbon fiber price is reduced significantly. We are convinced that our technology will make a major contribution to this.&nbsp;</span></p><p dir="ltr">Furthermore, we are very pleased that we can further increase the visibility of our idea through the award. At this point in time, the most important thing for us is to position ourselves in the market in order to find out what customers want on the one hand and to build fruitful partnerships on the other. The Wevolver Community Award offers the ideal prerequisite for this. We have already received the first enquiries.&nbsp;</p><p dir="ltr">Finally, we hope that the presentation of our idea will lead to a long-term cooperation with Mitsubishi.</p><h2 id="isPasted"><em>About the sponsor:&nbsp;Mitsubishi Chemical Group Advanced Materials Division and Business Incubator Growth Garage</em></h2><p><em>MCG Advanced Materials Division</em><em>&nbsp;is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a wide variety of customer markets.&nbsp;</em></p><p><em>Growth Garage is the Business Incubator of the MCG Advanced Materials Division. Our mission is to support and grow new ideas using our technologies and advanced engineering materials to help tackle some of today&#39;s biggest engineering challenges. We are offering the opportunity for engineers and innovators to pitch us their ideas and receive manufacturing support and services.</em></p><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc4NDUxNjg3ODQxLWV5SmlkV05yWlhRaU9pSjNaWFp2YkhabGNpMXdjbTlxWldOMExXbHRZV2RsY3lJc0ltdGxlU0k2SW1aeWIyRnNZUzh4TmpZMk5UazRNakEyTlRnMExVMURSeUJzYjJkdklHSmhibTVsY2k1cWNHY2lMQ0psWkdsMGN5STZleUp5WlhOcGVtVWlPbnNpZDJsa2RHZ2lPamsxTUN3aVptbDBJam9pWTI5MlpYSWlmWDE5LndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></em><br></p>

The Composite Engineering Challenge, organized by the Mitsubishi Chemicals Group and Wevolver, invited innovators, entrepreneurs, startups, and scaleups to submit projects that make use of fiber-reinforced composites.


Composite Engineering Challenge Community Winner: Interview with Felix Pohlkemper of CarboScreen

<p id="isPasted">Carbon fiber has made its way into the design and manufacturing of many different products, and that&rsquo;s because of its impressive performance. One of its most recent cutting-edge applications is human exoskeletons. Imagine wearing a carbon fiber structure over your clothes to assist you at work.&nbsp;</p><p>There are already exoskeletons on the market to help humans perform better, work safer, and even monitor their health and strain through the Internet of Things (IoT). But there still remain challenges associated with the manufacture of carbon fiber parts for these to become mainstream items. In this article, we&rsquo;ll discuss what an exoskeleton is and why carbon fiber is an excellent material to use. We will also look at current trends for manufacturing carbon fiber composite parts, as well as the challenges and how we might be able to innovate to overcome those roadblocks with engineering ingenuity.</p><h1>What are exoskeletons?</h1><p>An exoskeleton, as the term implies, is when the skeleton is external on a living creature. Typically, exoskeletons are seen in nature on animals such as spiders, clams, and other insects. <sup>[1]</sup> But increasingly, the term exoskeleton is being used to describe a similar structure used to support humans. In this case, the exoskeleton is a piece of equipment a person wears externally that can assist them by providing increases in strength and stability.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjcwODQ5NTMxMTg2LWV4byAyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">An exoskeleton prototype. Image credit: Iberdrola.</span></span></span></p><p>Human exoskeletons can be purely mechanical, meaning the structure itself supports the worker through elements, such as the frame, hinges, and possibly springs. Exoskeletons can also be electrical and mechanical, incorporating the assistance of an electric motor. For example, the German Bionic exoskeleton in the image below supports a worker&rsquo;s lower back with two servo motors and a carbon fiber frame. The purpose of the exoskeleton is to prevent injuries when workers are performing repetitive operations, including lifting, carrying, and squatting.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjcwODQ5NTk0MjQ1LWV4byAzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">The German Bionic exoskeleton incudes two small motors: Image credit: German Bionic.&nbsp;</span></span></span></p><h1 id="isPasted">Why is carbon fiber an excellent choice for exoskeletons?</h1><p>Carbon fiber is being used in many engineering disciplines to replace structures previously constructed with steel or aluminum, because of its strength and stiffness. In order to compare the strength of materials we can examine the ultimate tensile strength. Carbon fiber has an ultimate tensile strength of ~3,500 MPa.<sup>[2]</sup> Aluminum has an ultimate tensile strength of 70 MPa and steel (ASTM-A36) has an ultimate tensile strength of ~400 MPa. [3]</p><p>To compare the stiffness of materials we can use Young&rsquo;s Modulus, which is also the ratio of stress over strain. Carbon fiber reinforced plastics (CFPR) have a Young&rsquo;s Modulus of ~150 GPa, while aluminum alloys are ~70 GPa and steel is ~200 GPa.<sup>[3]</sup> These are average figures, and the exact composition of the material will determine the precise Young&rsquo;s Modulus, but as you can see, carbon fiber composite materials have similar stiffness to traditional metals used in structures and machinery. These composites also have two important advantages over traditional metals when it comes to building an exoskeleton.</p><p>First, composites are much lighter than metals making it easier for workers to wear the exoskeleton and be assisted through repetitive tasks. Second, carbon fiber has the ability to be molded into a complex geometry fairly easily. In comparison, metals must be bought in a certain shape or must have a complicated die designed to form parts. But if you use carbon fiber, you create the part on a mold, using a precise lay-up. This means you can precisely maximize strength and stiffness for your design with minimal mass.&nbsp;</p><p>Depending on the specific carbon fiber composites you use, you &ldquo;lay up&rdquo; the sheets of fibers in a specific pattern to generate the material properties you require. Again, this is a benefit for the exoskeleton that can be manufactured to support the complex geometries of the human body and the variations in size and shape seen across the population.&nbsp;</p><h1>Current trends in carbon fiber composite manufacturing</h1><p>The most common carbon fiber manufacturing methods are still rather labour-intensive. The first method is wet lay-up, which is where the carbon fiber sheets are placed or &ldquo;laid up&rdquo; into the mold and the resin is applied by brush, brush<a href="#_msocom_1" id="_anchor_1" language="JavaScript" name="_msoanchor_1" target="_blank">[DI1]</a> , or spray gun. The second is preglamination, where the sheets of carbon fiber have already been infused with the resin, and after they are laid up in the mold, they are cured in an autoclave. The third is resin transfer molding (FRM), which lays up the fiber sheets into a special mold that will be sealed shut and resin is injected at high pressures. <sup>[4]</sup></p><p>To assist each of these methods, 3D printing has been applied at different stages of the process. The molds themselves are now being created using a 3D printer, which results in a more accurate product that requires less rework and surface geometry quality control than a hand-built or cut mold. In addition, there have been advancements in 3D printing the actual carbon fiber composites, using either a resin with chopped fibers embedded or by printing continuous fibers in the horizonal plane for strategic strength and reinforcement of the polymer. <sup>[4]</sup></p><h1>Challenges associated with carbon fiber composites</h1><p>Depending on the material requirements, budget, and available skilled labour, any of the methods we mentioned could be used to manufacture a carbon fiber exoskeleton. However, many of these methods are time-consuming, labor-intensive, and very precise, meaning human error in these processes happens quite often. And while some error or variation can be eliminated by using prepreg materials or RFM in order to standardize the amount of resin used, there can still be variation in lay up.&nbsp;</p><p>Large-scale manufacturing of carbon fiber composites for many different applications share common challenges. Finding, training, and retaining talent to manufacture molds, lay up fiber sheets, and perform quality control are roadblocks for many businesses. While the trends in using 3D printing in some aspects of manufacture could help alleviate the burden on the human labour required, these processes are still expensive and time-consuming. There is a real need in the market for solutions to overcome the challenges of manufacturing carbon fiber components.&nbsp;</p><h1>Overcoming manufacturing challenges using carbon fiber from Mitsubishi&nbsp;Composites Toolbox</h1><p>Mitsubishi Chemical Group has developed the Composites Toolbox, a combination of high-quality composite materials, experts, and manufacturing methods to rewrite what&rsquo;s possible in engineering. &nbsp;By replacing traditional materials with composite solutions that meet future performance, consumer, and sustainability requirements, more engineers can help optimize several applications.</p><p>The Composite toolbox includes a variety of materials; ranging from glass, carbon, or natural fiber reinforcements with a thermoset or thermoplastic matrix. A reduction of the environmental footprint can be obtained with low carbon footprint solutions, such as&rdquo; recycled carbon fiber (rCF), recycled thermoplastics, or biobased thermoset resins.</p><p>Are you using manual layup and think you need to compromise on freedom of design? The design freedom of some of these materials, such as <a href="" target="_blank">KyronTEX</a>, enables new designs at scale with high process efficiency due to the elimination of various intermediate process steps.</p><h2>Composite Engineering Challenge</h2><p id="isPasted">Mitsubishi Chemical Group is inviting innovators, entrepreneurs, and early adopters at universities, (pre-) startups, and scaleups that need <strong>fiber-reinforced composites</strong> to realize their prototype, part, product, or application.&nbsp;</p><p>We welcome projects, programs, and companies in the field of new mobility (EV, e-motor, battery casing, etc.), autonomous (delivery) vehicles, people movers, robotics, aerospace, space, bicycles, UAV, AAV, bionics (wheelchairs, exoskeletons, prosthetics), alternative energy (production, storage, transport), self-sensing or self-healing, sport &amp; leisure, alternative (low carbon footprint) fibers and more!</p><p><strong>The winning entry will be rewarded with a partnership with Growth Garage,&nbsp;</strong><strong>Business Incubator of the MCG Advanced Materials Division</strong><strong>.&nbsp;</strong></p><p><strong>This partnership package is valued at $25,000 and will be tailored to the winning team&rsquo;s needs according to their current business and product development stage.&nbsp;</strong></p><p><a class="button-main-action" href="https://wevlv.co/homepage-banner" target="_blank">Read more about the challenge here.</a></p><h2 id="isPasted"><strong>Key Dates</strong></h2><table><tbody><tr><td><strong>Composite Challenge Launch</strong>&nbsp;</td><td>Monday, October 24th, 2022</td></tr><tr><td><strong>Challenge Close</strong>&nbsp;</td><td>Sunday 22 January 2023&nbsp;</td></tr><tr><td><strong>Finalists Announced</strong>&nbsp;</td><td>Wednesday 1 February 2023&nbsp;</td></tr><tr><td><strong>Wevolver Community Vote</strong>&nbsp;</td><td>From 1-12 February 2023&nbsp;</td></tr><tr><td><strong>Winners announcement</strong>&nbsp;</td><td>Tuesday 21 February 2023&nbsp;</td></tr></tbody></table><h2 id="isPasted"><em>About Mitsubishi Chemical Group Advanced Materials Division and Business Incubator Growth Garage</em></h2><p><em>MCG Advanced Materials Division</em><em>&nbsp;is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a wide variety of customer markets.&nbsp;</em></p><p><em>Growth Garage is the Business Incubator of the MCG Advanced Materials Division. Our mission is to support and grow new ideas using our technologies and advanced engineering materials to help tackle some of today&#39;s biggest engineering challenges. We are offering the opportunity for engineers and innovators to pitch us their ideas and receive manufacturing support and services.</em></p><p><em>&nbsp;<img data-fr-image-pasted="true" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY2NTk4MjA2NTg0LU1DRyBsb2dvIGJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></em></p><p id="isPasted"><strong>References</strong></p><ol><li>Encyclopedia Britannica [Internet]. Exoskeleton c2017 Jan 31 [cited 9 Nov 2022]. Available from: <a href="https://www.britannica.com/science/exoskeleton-anatomy" target="_blank">https://www.britannica.com/science/exoskeleton-anatomy</a></li><li>Dragonplate.com [Internet]. What is carbon fiber? c2022 [cited 16 Nov 2022]. Available from <a href="https://dragonplate.com/what-is-carbon-fiber#:~:text=The%20stiffness%20of%20a%20material,500%20ksi%20(3.5%20Gpa)" target="_blank">https://dragonplate.com/what-is-carbon-fiber#:~:text=The%20stiffness%20of%20a%20material,500%20ksi%20(3.5%20Gpa)</a></li><li>The Engineering ToolBox [Internet]. Young&rsquo;s Modulus, tensile strength and yield strength values for some materials c2003 [cited 16 Nov 2022]. Available from <a href="https://www.engineeringtoolbox.com/young-modulus-d_417.html" target="_blank">https://www.engineeringtoolbox.com/young-modulus-d_417.html</a>&nbsp;</li><li>Formlabs.com [Internet]. How to manufacture carbon fiber parts c2022 [cited 16 Nov 2022]. Available from <a href="https://formlabs.com/blog/composite-materials-carbon-fiber-layup/" target="_blank">https://formlabs.com/blog/composite-materials-carbon-fiber-layup/</a>&nbsp;</li></ol><p><br></p>

Exoskeletons made with carbon fiber composites using cutting-edge manufacturing techniques can assist workers in performing repetitive tasks.

Could carbon fiber exoskeletons become common assistive wear for workers?

Reducing CO2 emissions from road transport presents a key challenge and opportunity for the automotive industry. 

Implementing carbon fiber composites in structural automotive components for reducing CO2

<p dir="ltr" id="isPasted">Mitsubishi Chemical Advanced Material&rsquo;s&nbsp;startup accelerator,&nbsp;Growth Garage&nbsp;concluded the&nbsp;High-Temperature Carbon-Fiber 3D printing challenge&nbsp;in December 2021. In this challenge, the participants were asked to incorporate the strength and properties of the KyronMax&reg; carbon-fiber 3D printing filament with the flexibility and sustainability of 3D printing in their design. The challenge focused on three main criteria: technical and commercial feasibility, scalability, and sustainability. We are composing a&nbsp;series of articles featuring the finalists and winners of the challenge so that the readers get a comprehensive view of their product, motivation and vision for the future.</p><h2 dir="ltr">Student Winners: Concordia University Team&rsquo;s Lunar Rover Arm</h2><p dir="ltr">In this article, we feature the&nbsp;Student Award Winners&nbsp;from Concordia University based in Montreal, Canada. The student project is currently being carried out by a group of seven undergraduate students who are developing a robotic arm which would be installed on a lunar rover for excavation and sample collection activities. The project is based on specifications provided by the Canadian Space Agency.</p><p dir="ltr">&quot;The parameters that we are dealing with are mainly extreme fluctuations in the ambient temperature on lunar surfaces. We must equip the lunar arm to not only operate in the extreme heat of the lunar day, but also during the extremely cold weather of the lunar night. Our task is to design and manufacture a preliminary prototype which can survive in these conditions,&quot; explained Aidan. Additionally, the lunar surfaces also tend to have significant levels of radioactivity. It is imperative to ensure that the lunar arm is protected against these conditions.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY5NTc0NjM4NTI0LWltYWdlMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner">The lunar arm, designed by the Concordia team.</span></span></span></p><p dir="ltr" id="isPasted">Typically, robotic arms employ motors housed within the arm to provide articulation at several joints. It isn&rsquo;t feasible to implement this mechanism in environments with extreme temperature fluctuations. In order to protect the electronic components, the actuators and electronics are enclosed inside the insulated and heated enclosure of the rover located below the arm. &quot;To address these problems, we have decided to implement a complete mechanical motion transmission, which allows us to enclose the electronic components such that they don&rsquo;t get exposed to the surroundings,&quot; explained the team lead,&nbsp;Aidan Mitchell.</p><h2 dir="ltr">Light, flexible and energy efficient</h2><p dir="ltr">The scope of activities that would be performed by the lunar arm are restricted to excavation and sample collection. The robot assembly uses a shaft and gear motion transmission, which ensures a smooth mechanical motion. &quot;The base of the assembly is equipped to have five degrees of freedom, which enables the arm to perform 360-degree motions. The second motor moves the top joint, enabling the excavation motion,&quot; said Aidan. The lunar arm must be light in order to ensure that the energy spent on its transportation is minimal. At the same time, it should have enough force and lift capacity to be able to collect soil samples.</p><h2 dir="ltr">KyronMax&reg; offers more design flexibility</h2><p dir="ltr">&quot;We are opting to use 3D printing, as we want to build prototypes with complex geometries, quickly and economically. When we were conducting the material research, we stumbled upon the 3D printing challenge. After researching more about the KyronMax&reg; material, the team realized that it is perfect for our project. The main value proposition of KyronMax&reg; is its high strength, which makes our task easier of creating a light and strong prototype,&rdquo; explains&nbsp;Mitchell.</p><h2 dir="ltr">Knowledge and Mentorship</h2><p dir="ltr">Being the winners of the student award, the lunar arm team would receive support and mentorship from MCAM and Growth garage for design optimization, material selection, and creation of business plans. &quot;As students, we are always looking for avenues and opportunities for gaining knowledge, and receiving guidance and support from experts in the field. We are really looking forward to working with the MCAM team to steer our project towards the path of success,&quot; concluded Aidan.</p><p dir="ltr">Follow <a href="https://www.linkedin.com/showcase/growth-garage-mcam/" target="_blank">Growth Garage</a>&#39;s&nbsp;LinkedIn page for more interesting stories about 3D printing entrepreneurs in various fields.</p><h2 id="isPasted"><strong>The Composite Engineering Challenge</strong></h2><p>We are inviting innovators, entrepreneurs, and early adopters at universities, (pre-) startups, and scaleups that need <strong>fiber-reinforced composites</strong> to realize their prototype, part, product, or application.&nbsp;</p><p>We welcome projects, programs, and companies in the field of new mobility (EV, e-motor, battery casing, etc.), autonomous (delivery) vehicles, people movers, robotics, aerospace, space, bicycles, UAV, AAV, bionics (wheelchairs, exoskeletons, prosthetics), alternative energy (production, storage, transport), self-sensing or self-healing, sport &amp; leisure, alternative (low carbon footprint) fibers and more!</p><p><strong>The winning entry will be rewarded with a partnership with Growth Garage,&nbsp;</strong><strong>Business Incubator of the MCG Advanced Materials Division</strong><strong>.&nbsp;</strong></p><p><strong>This partnership package is valued at $25,000 and will be tailored to the winning team&rsquo;s needs according to their current business and product development stage.&nbsp;</strong></p><p><a class="button-main-action" href="https://wevlv.co/homepage-banner" rel="nofollow" target="_blank">READ MORE ABOUT THE CHALLENGE HERE.</a></p><table cellpadding="0" cellspacing="0"><tbody><tr><td valign="top"><h2><strong>Key Dates</strong></h2><table><tbody><tr><td><strong>Composite Challenge Launch</strong>&nbsp;</td><td>Monday, October 24th, 2022</td></tr><tr><td><strong>Challenge Close</strong>&nbsp;</td><td>Sunday 22 January 2023&nbsp;<br></td></tr><tr><td><strong>Finalists Announced</strong>&nbsp;</td><td>Wednesday 1 February 2023&nbsp;<br></td></tr><tr><td><strong>Wevolver Community Vote</strong>&nbsp;</td><td>From 1-12 February 2023&nbsp;<br></td></tr><tr><td><strong>Winners announcement</strong>&nbsp;</td><td>Tuesday 21 February 2023&nbsp;</td></tr></tbody></table></td></tr></tbody></table><div align="left" dir="ltr"></div><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY5NTc0NzAxODE1LWV5SmlkV05yWlhRaU9pSjNaWFp2YkhabGNpMXdjbTlxWldOMExXbHRZV2RsY3lJc0ltdGxlU0k2SW1aeWIyRnNZUzh4TmpZMk5UazRNakEyTlRnMExVMURSeUJzYjJkdklHSmhibTVsY2k1cWNHY2lMQ0psWkdsMGN5STZleUp5WlhOcGVtVWlPbnNpZDJsa2RHZ2lPamsxTUN3aVptbDBJam9pWTI5MlpYSWlmWDE5LndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></p><p><br></p>

The student winners of the High-Temperature Carbon-Fiber 3D printing challenge have ambitions to build better rovers.


Lunar Rover Arm Brings Increased Functionality to space missions.

<p dir="ltr" id="isPasted">The High-Temperature Carbon-Fiber 3D Printing Challenge invited engineers and designers to submit ideas on how to leverage cutting-edge materials from Mitsubishi Chemical Advanced Materials. Participants in the challenge were asked to incorporate the strength and properties of the KyronMax&reg; carbon-fiber 3D printing filament with the flexibility and sustainability of 3D printing in their design.</p><p dir="ltr">We are composing a&nbsp;series of articles featuring the finalists and winners of the challenge.</p><p dir="ltr">In this article we showcase the work of <a href="https://www.linkedin.com/in/robinkocher/" target="_blank">Robin Kocher</a> from Human Earth Industries an upcoming player in the micro-engineered suits domain.</p><h2 dir="ltr">Suits for the future</h2><p dir="ltr">The specialized suits designed by Kocher, aims to protect against harsh weather conditions. The suits are primarily intended for providing support during disaster relief, extreme sports, and various outdoor activities. They have multiple layers which can be customized based on the activity.</p><p dir="ltr">&quot;We visualize the company in two parts. The primary focus behind Human Earth Industries is facilitating a change in society, imparting a sense of awareness in people regarding the 17 sustainable development goals, and spreading the word of change. The second part is the engineering aspect of it, where we aim to revolutionize the fashion technology industry,&quot; said Kocher. The idea for developing the suits was first conceptualized when Robin was still a student. As a gaming enthusiast, he wondered how the advanced suits in video games would be like in the real world. &quot;My interest in video games and science fiction helped me design the fabrics for the prototype. The ideas stemmed mainly from publicly available research,&quot; he added. &nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY5NTc0MzQxNDM4LWltYWdlMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner">The suit imagined by Human Earth Industries. Image credit: Human Earth Industries</span></span></span></p><h2 dir="ltr" id="isPasted">Sustainability is the top priority</h2><p dir="ltr">The suit has a customizable design where one can alter various functionalities. It would be possible to insert a layer that can measure the heart rate, blood oxygen, and ambient conditions. Additionally, another layer with a pathfinder module and smart ventilation (heating and cooling), primarily geared towards disaster relief activities would also be incorporated. &quot;The material that we use for the suits are not particularly environmentally friendly. I want to make products that can be used for a long time and the suits are designed to last a lifetime. I want people to pass on the suits to the next generations. This is one of my approaches to sustainability. The components would be made from bio-compostable products in the future,&quot; said Kocher.</p><h2 dir="ltr">Diversifying functionalities with carbon-fiber</h2><p dir="ltr">The early-stage startup wants to engineer their specialized suits for various operations. For instance, Robin has deep-dived into the topic and has identified the risks involved for horseback riders.</p><p dir="ltr">He is developing a prototype of a safety vest with a carbon fiber layer that protects the riders from potentially severe falls. This vest can also be purposed for other activities such as skiing and motorbiking.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY5NTc0MzkzODMxLWltYWdlMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></p><h2 dir="ltr" id="isPasted">MCAM&rsquo;s Growth Garage challenge pushed design ideation</h2><p dir="ltr">When we asked Robin, what the most challenging criteria of the submission was, he said: &quot;The criteria pertaining to the technical requirements was quite impressive, especially when we had to work with high-temperature requirements. When we started designing the product, we had to make sure that it satisfied the sustainability as well the high temperature criterion. It helped me visualize the incorporation of the carbon fiber layer in the specialized suits. The challenge was quite an enjoyable experience for me.&quot;</p><p dir="ltr">Kocher is impressed by Mitsubishi Chemical&rsquo;s focus on sustainability and conscientious practices. It was also one of the reasons that compelled him to enter the challenge. &quot;As a self-financed startup, it is always nice to receive support from organizations that can help us take our product to the next level, in terms of design, manufacturing and product upgrades. I would love to take part in the new challenges and create an awareness of thriving in the industry by consciously contributing back to the environment and society,&quot; he said.</p><p dir="ltr">Follow <a href="https://www.linkedin.com/showcase/growth-garage-mcam/" target="_blank">Growth Garage</a>&#39;s&nbsp;LinkedIn page for more interesting stories about 3D printing entrepreneurs in various fields.</p><h2 id="isPasted"><strong>The Composite Engineering Challenge</strong></h2><p>We are inviting innovators, entrepreneurs, and early adopters at universities, (pre-) startups, and scaleups that need <strong>fiber-reinforced composites</strong> to realize their prototype, part, product, or application.&nbsp;</p><p>We welcome projects, programs, and companies in the field of new mobility (EV, e-motor, battery casing, etc.), autonomous (delivery) vehicles, people movers, robotics, aerospace, space, bicycles, UAV, AAV, bionics (wheelchairs, exoskeletons, prosthetics), alternative energy (production, storage, transport), self-sensing or self-healing, sport &amp; leisure, alternative (low carbon footprint) fibers and more!</p><p><strong>The winning entry will be rewarded with a partnership with Growth Garage,&nbsp;</strong><strong>Business Incubator of the MCG Advanced Materials Division</strong><strong>.&nbsp;</strong></p><p><strong>This partnership package is valued at $25,000 and will be tailored to the winning team&rsquo;s needs according to their current business and product development stage.&nbsp;</strong></p><p><a class="button-main-action" href="https://wevlv.co/homepage-banner" rel="nofollow" target="_blank">READ MORE ABOUT THE CHALLENGE HERE.</a></p><table cellpadding="0" cellspacing="0"><tbody><tr><td valign="top"><h2><strong>Key Dates</strong></h2><table><tbody><tr><td><strong>Composite Challenge Launch</strong>&nbsp;</td><td>Monday, October 24th, 2022</td></tr><tr><td><strong>Challenge Close</strong>&nbsp;</td><td>Sunday 22 January 2023&nbsp;<br></td></tr><tr><td><strong>Finalists Announced</strong>&nbsp;</td><td>Wednesday 1 February 2023&nbsp;<br></td></tr><tr><td><strong>Wevolver Community Vote</strong>&nbsp;</td><td>From 1-12 February 2023&nbsp;<br></td></tr><tr><td><strong>Winners announcement</strong>&nbsp;</td><td>Tuesday 21 February 2023&nbsp;</td></tr></tbody></table></td></tr></tbody></table><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY5NTc0NDUyMDMzLWV5SmlkV05yWlhRaU9pSjNaWFp2YkhabGNpMXdjbTlxWldOMExXbHRZV2RsY3lJc0ltdGxlU0k2SW1aeWIyRnNZUzh4TmpZMk5UazRNakEyTlRnMExVMURSeUJzYjJkdklHSmhibTVsY2k1cWNHY2lMQ0psWkdsMGN5STZleUp5WlhOcGVtVWlPbnNpZDJsa2RHZ2lPamsxTUN3aVptbDBJam9pWTI5MlpYSWlmWDE5LndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></p><p><br></p>

Carbon fiber fashion aims to assist humans to endure extreme weather and activities. 


Augmenting human endurance with carbon fiber suits

An interview with the winner of the High-Temperature Carbon-fiber 3D Printing Challenge. 

Subterranean drone tackles food security

End-to-end recycling solutions deliver the benefits of carbon fiber composites with a more circular approach.

Carbon Fiber Recycling: Accelerating Aerospace Circularity

Lightweight composites deliver a clever combination of optimal mechanical performance with circularity. 

Discovering advanced composites: How a new generation of composite materials is revolutionizing engineering

<h1 id="isPasted">Composite Engineering Challenge</h1><p><strong><em>The challenge is now closed. The winners will be announced shortly.&nbsp;</em></strong></p><p dir="ltr" id="isPasted">The Composite Engineering Challenge invited innovators, entrepreneurs, startups, and scaleups to submit projects that make use of fiber-reinforced composites.</p><p dir="ltr">The challenge received submissions from over 20 countries. The jury has selected ten finalists and three special recommendation projects.&nbsp;</p><p dir="ltr">The final ten are now being reviewed by the jury, and the overall winner will be announced on February 21, 2023.&nbsp;</p><p dir="ltr">The Wevolver Community Vote is selected by the engineering community. The winner will receive an honorable mention at the awards ceremony and be brought to the attention of senior management of MCG and the Venture group of MCG. Further, the winner will be interviewed for an article published on Growth Garage and Wevolver. &nbsp;&nbsp;</p><p dir="ltr">Read about the ten finalists and then head to the&nbsp;<a href="https://www.wevolver.com/community-vote/circular-economy-challenge" rel="noopener noreferrer" target="_blank">voting page</a> to cast your choice.&nbsp;</p><p><a class="button-main-action" href="https://www.wevolver.com/community-vote/circular-economy-challenge" rel="noopener noreferrer" target="_blank">VOTE NOW</a></p><hr><p>The challenge will award innovative products / projects that make use of <strong id="isPasted">fiber-reinforced composites.</strong></p><p>The challenge is open for innovators, entrepreneurs, (pre-) startups and scaleups.</p><p>We welcome projects, programs, and companies in the field of new mobility (EV, e-motor, battery casing, etc.), autonomous vehicles, people movers, robotics, aerospace, space, bicycles, UAV, AAV, bionics (wheelchairs, exoskeletons, prosthetics), alternative energy, sport &amp; leisure, alternative (low carbon footprint) fibers and more!</p><p><a class="button-main-action" href="https://c8056756.sibforms.com/serve/MUIEAASlra81V1iZasKRZmA7U7n22-x7CxwVy_ehLPfJrr9Imp76jJPdpiZ1kuHbxnO80jW3anG-pE6KVVsOuwjTTXc3mf6IrOzBQX1BaoxGD0GF2Dmb5Ge1wEOKwm9kd1j8bpk13Mnf0S77OIPT2-rJiFelFwxjPYFFUKczFqqHgn4Yg4a41M65_hndhjcamu6m0HgutqfJEtLs" rel="noopener noreferrer" target="_blank">ASK ANY QUESTION REGARDING THE CHALLENGE</a><a href="#_msocom_3" id="_anchor_3" language="JavaScript" name="_msoanchor_3" target="_blank"></a><a href="#_msocom_4" id="_anchor_4" language="JavaScript" name="_msoanchor_4" target="_blank"></a></p><h1>Challenge Awards</h1><h3>Overall Jury Winner: Business, manufacturing, and design support package worth $25,000.</h3><p>The winner of the Composites Engineering Challenge is awarded a $25,000 partnership with Growth Garage, the Business Incubator of the MCG Advanced Materials<strong>&nbsp;</strong>Division, to develop their product or part in a way that enables them to scale their production.&nbsp;</p><p>This may be a combination of technical, design, business advice, prototype development, or other manufacturing assistance. The prize is designed with the winner to give them the resources and support they need at their specific production and business stage.&nbsp;</p><p>This includes but is not limited to:</p><p><strong>Hands-on Support</strong></p><ul><li>Support in material/technology selection.</li><li>Support to design for manufacturing.</li><li>Support in tool design.</li><li>Support to scale your production.&nbsp;</li><li>Support in providing a cost prognosis for medium to high-volume production and prototyping.</li></ul><p><strong>Access to resources</strong></p><ul><li>Access to MCG&#39;s latest carbon-reinforced composite materials (thermoset and thermoplastic-based) at scale.</li><li>Access to part production manufacturing technologies at scale (either at MCG or within the partner network).</li></ul><p><strong>Exposure to Wider Network&nbsp;</strong></p><ul><li>Opportunity for equity investment via MCG&#39;s CVC arm (Diamond Edge Ventures).</li><li>Exposure to potential customers.</li><li>Access to experts in community and jury.</li><li>Global exposure in various media outlets.</li></ul><p><strong>Innovations for a Circular Economy&nbsp;</strong></p><ul><li>Access to circularity and sustainability experts<a href="#_msocom_6" id="_anchor_6" language="JavaScript" name="_msoanchor_6" target="_blank"></a>.</li><li>Access to composites with a low carbon footprint by using recycled Carbon Fiber (rCF)<a href="#_msocom_7" id="_anchor_7" language="JavaScript" name="_msoanchor_7" target="_blank"></a>.</li><li>Access to the take-back program (production waste or end-of-live parts).</li></ul><p>The total value of this package is $25,000 and is developed together between the winning team, Growth Garage, and MCG Advanced Materials<strong id="isPasted">&nbsp;</strong>Division. Read about previous challenge winners and the support they received <a href="https://growthgarage-resources.mcam.com/articles" rel="noopener noreferrer" target="_blank">here</a><a href="#_msocom_8" id="_anchor_8" language="JavaScript" name="_msoanchor_8" target="_blank"></a>.</p><h3>Innovation Award: Business, manufacturing, and design support package worth support worth $10,000.&nbsp;</h3><p id="isPasted">The innovation award will be awarded to the most impactful, differentiated, innovative idea.&nbsp;</p><p>The Innovation Award Winner of the Composites Engineering Challenge will enter a partnership with<strong>&nbsp;</strong>Growth Garage, Business Incubator of the MCG Advanced Materials Division, to further develop their product or part to scale their project.&nbsp;</p><p>This may be a combination of technical, design, business advice, prototype development, or other manufacturing assistance. The total value of this package is $10,000 and is developed together between the winning team and Growth Garage.&nbsp;</p><h3>Wevolver Community Winner: Media package and Venture pitch. &nbsp;</h3><p>The winner will receive an honorable mention at the awards ceremony and be brought to the attention of senior management of MCG and the Venture group of MCG. Further, the winner will be interviewed for an article published on Growth Garage and Wevolver. &nbsp;&nbsp;</p><hr><h1 id="isPasted">Composite Engineering Challenge Introduction Webinar</h1><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable fr-active" contenteditable="false" draggable="true"><iframe src="https://www.youtube.com/embed/5yXgnnUxXsM?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-8="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" width="640" height="360" frameborder="0" data-gtm-yt-inspected-9="true" id="467181678" title="Introduction to the Composite Engineering Challenge"></iframe></span><br></p><p>In this recorded webinar, Tim Vorage, Global Growth Manager at (Growth Garage, Business Incubator of the MCG Advanced Materials Division). introduces the composite challenge, discusses the latest in carbon fiber technology, and provides insight into how to create a competitive advantage.</p><p><br></p><hr><h2><br></h2><h2>Challenge the status quo of composites&rsquo; scalability</h2><h3>Who can enter?</h3><p>The challenge is open to any business, research team, or project currently working on a product or part manufactured from or suitable for composites with the ambition to ramp up its production. &nbsp;The challenge is open to teams and companies around the world.</p><p>If you have the ambition to scale your production either now or in the future &ndash; this is the opportunity for you.</p><p><strong>Do you have the ambition to:</strong></p><ul id="isPasted"><li>Design, develop and produce a prototype based on fiber-reinforced composite materials</li><li>Replace metal with fiber-reinforced composite materials</li><li>Shift from a manual to an automated, medium/high volume production process</li><li>Reduce your products carbon footprint (light-weighting, rCF, alternative fibers)</li><li>Introducing smart composites for self-sensing or self-healing</li><li>Efficiently scale the (manual) production of your composite part and need the right material/design/manufacturing combination or investment.</li></ul><p>Mitsubishi Chemical Group and Growth Garage, Business Incubator of the MCG Advanced Materials Division will help you take you from where you are to the next level of production, assisting with design and business mentorship, material selection, and manufacturing. &nbsp;</p><p>If you are unsure if you qualify to enter, please contact the Business Incubator Growth Garage team directly at <a href="mailto:growthgarage@mcam.com" target="_blank">growthgarage@mcam.com</a>.&nbsp;</p><p><br></p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY1NTY1ODU4ODY4LTE2NjU1NjU4NTg4NjguanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii" width="602" border="0"></p><h1><br></h1><h1>The Judging Criteria</h1><p>The jury will reward projects that prioritize sustainability and push the boundaries of lightweighting while maintaining high feasibility and ingenuity.</p><p>We welcome submissions at all stages of growth and production.</p><p><a class="button-main-action" href="https://wevlv.co/launch-page-mcam" rel="noopener noreferrer" target="_blank"><strong>Register to submit here.&nbsp;<br></strong></a></p><h2>The 2022 Composite Engineering Challenge Jury</h2><p><a href="https://www.linkedin.com/in/timvorage/" rel="noopener noreferrer" target="_blank"><strong>Tim Vorage</strong></a><a href="#_msocom_16" id="_anchor_16" language="JavaScript" name="_msoanchor_16" target="_blank"></a> - Global Growth Manager at (Growth Garage, Business Incubator of the MCG Advanced Materials Division).</p><p><a href="https://www.linkedin.com/in/dr-lisa-weigand/" rel="noopener noreferrer" target="_blank"><strong>Dr. Lisa Weigand</strong></a> - Advisor Circular Economy at Mitsubishi Chemical Europe.</p><p><a href="https://www.linkedin.com/in/geenen/" rel="noopener noreferrer" target="_blank"><strong>Bram Geenen</strong></a> &ndash; Founder and CEO, Wevolver.</p><p><a href="https://www.linkedin.com/in/randy-white-412a7479/" rel="noopener noreferrer" target="_blank"><strong>Randy White</strong></a> - President -Engineered Solutions at MCG Advanced Materials Division</p><p><a href="https://www.linkedin.com/in/mgeljon/" rel="noopener noreferrer" target="_blank"><strong>Mark Geljon</strong></a> - Customer Experience leader, change-maker, and social entrepreneur.</p><p><a href="https://www.linkedin.com/in/jules-harings-67427a30/" rel="noopener noreferrer" target="_blank"><strong>Jules Harings</strong></a> - Associate Professor &amp; Group leader Macromolecular Physics &amp; Technology at AMIBM / Maastricht University.</p><p><a href="https://www.linkedin.com/in/peterwalde/" rel="noopener noreferrer" target="_blank"><strong>Dr. Peter Walde</strong></a> - Founder &amp; CEO at MAPEGY.</p><p><a href="https://www.linkedin.com/in/andy-rudd-a8a0317/" rel="noopener noreferrer" target="_blank"><strong>Andy Rudd</strong></a> - Global New Business Development Manager, Mitsubishi Chemical Methacrylates.</p><p><a href="http://Henning Bloech" rel="noopener noreferrer" target="_blank"><strong>Henning Bloech</strong></a>&nbsp; - Global Director Sustainable Solutions MCG Advanced Materials Division</p><p><a href="https://www.linkedin.com/in/will-chan-74ab3527/" rel="noopener noreferrer" target="_blank"><strong>Will Chan</strong></a><strong>&nbsp;-&nbsp;</strong>Composites Engineering Manager, Specialized Bicycle Components.</p><p><a href="https://www.linkedin.com/in/fumiko-uraki-73305b4/" rel="noopener noreferrer" target="_blank"><strong>Fumiko Uraki</strong></a> - Director of Venture Department at Mitsubishi Chemical Group Corporation.</p><p><a href="https://www.linkedin.com/in/jonas-grau-thomsen/" rel="noopener noreferrer" target="_blank"><strong>Jonas Grau Thomsen</strong></a> - CEO and Founder of Nordic Bionics / Thought leader/InfluencerNordic Bionics - Rehabilitation and Wearable Technology.</p><p><a href="https://www.linkedin.com/in/davidcleach/" rel="noopener noreferrer" target="_blank"><strong>David Leach</strong></a> - Director, Business Development ATC Manufacturing</p><p><a href="https://www.linkedin.com/in/stefan-schnippering-33b973103/" rel="noopener noreferrer" target="_blank"><strong>Stefan Schnippering</strong></a> - Venture Associate, Ph.D., Diamond Edge Ventures</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY1NTY1ODU4ODk1LTE2NjU1NjU4NTg4OTUuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="A person and person looking at each other

Description automatically generated with low confidence" class="fr-fic fr-dii" width="601" border="0"></p><p><br></p><h2><strong>Key Dates</strong></h2><table style="width: 100%;"><tbody><tr><td style="width: 50.0000%;"><strong id="isPasted">Composite Challenge Launch</strong>&nbsp;</td><td style="width: 50.0000%;">Monday, October 24th, 2022</td></tr><tr><td style="width: 50.0000%;"><strong id="isPasted">Composite Challenge Webinar. &nbsp;(Watch above)</strong></td><td>Thursday, November 17th, 17:00 - 18:00 CET.&nbsp;</td></tr><tr><td style="width: 50.0000%;"><strong id="isPasted">Early Bird Submission Closes</strong>&nbsp;</td><td style="width: 50.0000%;">Wednesday, November 30th, 2022</td></tr><tr><td style="width: 50.0000%;"><strong id="isPasted">Challenge Close</strong>&nbsp;</td><td style="width: 50%;">Sunday 22 January 2023</td></tr><tr><td style="width: 50.0000%;"><strong id="isPasted">Finalists Announced</strong>&nbsp;</td><td style="width: 50.0000%;">Wednesday 1 February 2023</td></tr><tr><td style="width: 50.0000%;"><strong id="isPasted">Wevolver Community Vote</strong>&nbsp;</td><td style="width: 50.0000%;">From 1-12 February 2023</td></tr><tr><td style="width: 50.0000%;"><strong id="isPasted">Winners announcement</strong>&nbsp;</td><td style="width: 50.0000%;">Tuesday 21 February 2023</td></tr></tbody></table><p><a class="button-main-action" href="https://wevlv.co/launch-page-mcam" rel="noopener noreferrer" target="_blank"><strong>Enter the Challenge here</strong></a></p><h2>Mitsubishi Composite Toolbox</h2><p>Mitsubishi Chemical Group has developed the Composites Toolbox, a combination of high-quality composite materials, experts, and manufacturing methods to rewrite what&rsquo;s possible in engineering. &nbsp;By replacing traditional materials with composite solutions that meet future performance, consumer, and sustainability requirements, more engineers can help enhance the world.</p><p>The Composite toolbox includes a variety of materials; ranging from glass, carbon, or natural fiber reinforcements with a thermoset or thermoplastic matrix. A reduction of the environmental footprint can be obtained with low carbon footprint solutions, such as&rdquo; recycled carbon fiber (rCF), recycled thermoplastics, or biobased thermoset resins.</p><p>Are you using a manual layup and think you need to compromise on freedom of design? The design freedom of some of these materials, such as <a href="http://KyronTEX," rel="noopener noreferrer" target="_blank">KyronTEX</a>, enables new designs at scale with high process efficiency due to the elimination of various intermediate process steps.</p><p>From a custom thermoplastic carbon composite organofleece into a part in 1 compression molding step, i.e. no intermediate lamination, placement, and consolidation steps required.</p><h3>Further reading and resources:</h3><ul><li><a href="https://growthgarage.mcam.com/" target="_blank">Growth Garage, Business Incubator of the MCG Advanced Materials Division</a></li><li><a href="https://composites.mcam.com/toolbox" target="_blank">MCG Composite Toolbox</a></li><li><a href="https://www.wevolver.com/article/discovering-advanced-composites-how-a-new-generation-of-composite-materials-is-revolutionizing-engineering/draft" rel="noopener noreferrer" target="_blank">Discovering Advanced Composites</a></li><li>Carbon Fiber Recycling: Accelerating Aerospace Circularity<a href="#_msocom_21" id="_anchor_21" language="JavaScript" name="_msoanchor_21" target="_blank"></a></li></ul><p>For more information get in touch with Wevolver Content Director, <a href="mailto:jessica@wevolver.com">Jessica Miley</a>.</p><h2><em>About the sponsor: Mitsubishi Chemical Advanced Materials &amp; Growth Garage</em></h2><p><em id="isPasted">MCG Advanced Materials Division</em><em>&nbsp;is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a wide variety of customer markets.&nbsp;</em></p><p><em>Growth Garage is the Business Incubator of the MCG Advanced Materials Division. Our mission is to support and grow new ideas using our technologies and advanced engineering materials to help tackle some of today&#39;s biggest engineering challenges. We are offering the opportunity for engineers and innovators to pitch us their ideas and receive manufacturing support and services.&nbsp;</em></p><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY2NTk4MjA2NTg0LU1DRyBsb2dvIGJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></em></p><p><br></p>

MCG Advanced Materials Division and Wevolver will award innovative products / projects that make use of fiber-reinforced composites. 

The Composite Engineering Challenge

<h3 dir="ltr" id="isPasted">Abbreviations</h3><p dir="ltr">DFM - Design For Manufacturing</p><p dir="ltr">&nbsp;</p><h2 dir="ltr">Challenges at the early stage</h2><p dir="ltr">As discussed in the previous blog, designers consider specific material, and fabrication limitations when creating designs. To know all about critical design parameters, material parameters, geometric constraints, etc. at an early stage is almost impossible. Thus, A lot of design decisions can not be made during the early stages as there are many unknowns, which leads to</p><ul><li dir="ltr"><p dir="ltr"><u>Challenge 1</u>: &nbsp;The threat of making too many critical design decisions in production in the early stages of design without considering the manufacturing process. As design maturity increases, it becomes increasingly difficult to implement design changes without affecting component performance or cost.</p></li></ul><p dir="ltr">&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjYxMTU2NzUzNzY5LTE2NjExNTY3NTM3NjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="574" class="fr-fic fr-dii" style="width: 756px; height: 289.747px;"></p><p dir="ltr">&nbsp;</p><ul><li dir="ltr"><p dir="ltr"><u>Challenge 2</u>: Reliance on isotropic material-based digital design tools constrained by certain geometrical shapes, limiting the design optimization domain to material thickness and geometries. This approach does not consider the different manufacturing process key advantages and limitations, resulting in material/defects probabilities, and shape limitations due to continuous fiber involved in the process. In short the black metal design approach (<a href="https://www.ansys.com/zh-cn/blog/switching-to-composite-materials-requires-a-new-product-design-black-metal" target="_blank">explained here</a>)&nbsp;</p></li></ul><p><br></p><p dir="ltr">There are numerous reasons why engineers pursue the black metal design approach. For one, the established guidelines make the design process straightforward. The challenge is that assessing the strength of a composite structure is more complex than assessing the strength of a metal structure. This is because the layered composites are made out of multiple plies, each with different spatial extents and angles.</p><p dir="ltr">&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjYxMTU4MzIzNDAwLTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></p><p dir="ltr">&nbsp;</p><ul><li dir="ltr"><p dir="ltr"><u>Challenge 3</u>: Current methods and tools used by designers are either geared toward metal manufacturing processes or do not adequately consider composite manufacturing, rendering them a misleading solution. As a result, existing tools are either too component-specific or too general in their approach.</p></li></ul><p dir="ltr">&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 758px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjYxMTU2NzUyOTI2LTE2NjExNTY3NTI5MjYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" class="fr-fic fr-dii" style="width: 756px; height: 237.329px;"><span class="fr-inner" spellcheck="false">Figure 3.&nbsp;</span></span></span></p><p dir="ltr"><a href="https://sci-hub.hkvisa.net/10.1007/s10443-017-9611-y" target="_blank">Differences between composite and metal construction in all life cycle phases [Source]</a></p><p dir="ltr">&nbsp;</p><h2 dir="ltr">Challenges due to DFM tools</h2><p dir="ltr">The DFM process requires manufacturing constraints to be known at the time of design creation, which leads to two challenges for composites&nbsp;</p><ul><li dir="ltr"><p dir="ltr">Challenge 1: Designing for novel manufacturing processes: If the design is using a novel manufacturing material/process, and the manufacturing constraints are not fully understood,</p></li><li dir="ltr"><p dir="ltr">Challenge 2: &nbsp;Digital tools&#39; Best practices: If the digital tools used to create the design are derived for use with a different material or process. A strategy for using digital design tools in the context of DFM is required.</p></li></ul><p dir="ltr">Understanding the above-specified challenges provides a good grounding for the problem at hand. In the upcoming blogs, we will dig deeper into the state-of-the-art solution available to such challenges.</p><h3 dir="ltr">&nbsp;</h3><h2 dir="ltr">Key Takeaways</h2><ul><li dir="ltr"><p dir="ltr">The primary challenge of limited knowledge at the early stage of the design</p></li><li dir="ltr"><p dir="ltr">The heavy reliance of designers&#39; training on metal (isotropic) design, limits their ability to see the composites design from a new approach</p></li><li dir="ltr"><p dir="ltr">Composites design requires heavy consideration of manufacturing parameters in design, as each process for the same given material will generate different properties</p></li><li dir="ltr"><p dir="ltr">The Design For manufacturing adds another layer of complexity as composites manufacturing is not a set domain and offers almost endless possibilities to combine and produce the part</p></li><li dir="ltr"><p dir="ltr">A good shop floor experience with a well-known digital process is a must and goes a long way for DFM in composites design</p></li></ul>

The article will highlight the challenges in designing composites suitable for automated manufacturing with Design for manufacturing (DFM) considerations.

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