Hexcel Corporation will mark its 75th anniversary by showcasing its latest developments for the aerospace and industrial markets at JEC World 2023 in Paris from 25-27. At Hall 5 - J41, the Stamford, Connecticut headquartered company will showcase its broad range of high-performance advanced lightweight composite material solutions for the aerospace, automotive, energy, sports and leisure, and marine industries as well as display its latest product innovations.

For the Aerospace sector, Hexcel will highlight a new, rapid-curing prepreg, developed for the high-rate production of semi-structural composite parts. HexPly M51 is designed for rapid hot-in/hot-out press curing and has a 40-minute cure cycle at 180˚C, reducing production times and costs compared with the use of standard autoclave-cured prepregs.

Using HexPly M51 also reduces the need for multiple sets of tooling and labour compared with conventional prepreg systems. The prepreg is fully compatible with automated tape laying (ATL), automated fibre placement (AFP) and pick-and-place processes, is REACH-compliant and demonstrates mechanical performance equivalent to other state-of-the-art 180°C cure prepregs.

Hexcel will also display a new demonstrator of an aircraft passenger door beam manufactured using a high-pressure resin-transfer moulding (HP-RTM) process, suitable for the high-rate manufacture of small-to-medium-sized parts. A dry carbon-fibre fabric preform is loaded into the 180˚C mould and is then injected with Hexcel’s latest generation resin HiFlow HF610F-2. With a total moulding time of 30 minutes, the process is more efficient by at least four times when compared to standard prepreg processes. Cleaning also is reduced to its minimum since there is no need to clean the mix head and no ancillaries are used. The scrap rate also is very low since the resin and curative are kept separately. Resins and reinforcements also do not need to be stored in freezers, minimising storage costs.

For the Marine market, Hexcel will exhibit a section of a Solid Sail mast made by Chantiers de l’Atlantique (CDA). Such masts are used for wind propulsion and, by harnessing the power of ocean winds, they reduce reliance on engines and cut fuel usage. The mast section is 2m x 1.6m x 1m in size and is made from carbon fibre laminates that are 40 mm in thickness. Other sections of the mast, manufactured using Bureau Veritas (BV)-approved HexPly M9.6 prepregs, are up to 70mm in thickness. CDA and its consortium won a 2023 JEC Innovation Award for their work on this project.

Also for Marine, Hexcel will show a section of a radar arch part from luxury motor yacht builder Sunseeker made using HexPly XF surfacing technology and HexPly SuperFIT semi-pregs. The part is lighter in weight and stiffer than versions made using resin-infusion processes and de-moulds with a pinhole-free surface that needs minimal preparation to be ready for paint. Sunseeker has recorded an overall reduction in process time and material costs of around 30% against traditional prepreg parts, using Hexcel advanced composite materials.

Hexcel innovations for Wind Energy on show will include HexPly XF surfacing technology as well as the Polyspeed range of pultruded laminates. HexPly XF lowers costs for blade manufacturers, providing a hard-wearing paint-ready surface directly from the mould, reducing finishing time and producing a lighter and more consistent surface than traditional gelcoats. Polyspeed materials are fibre-reinforced epoxy resin laminates that are supplied fully cured and in roll format. Options include grid-type products for optimized resin flow as well as unidirectional carbon fibre materials that provide consistently high mechanical properties for load-carrying elements of the blade.

As part of its portfolio of composite solutions for the Automotive industry, Hexcel also will present its prepreg and dry fabric material technologies as well as components including a sportscar wheel made in a fully industrialized high-volume production process.

For sustainable solutions, Hexcel will again feature a dedicated zone on its stand to showcase its latest development in sustainability. On display will be the HexPly Nature Range of prepreg materials, as well as an update on the prepreg waste recycling technology developed in partnership with Fairmat that was recently recognized with a Sustainability Award by Airbus Defence & Space.

Hexcel also will exhibit a detailed life-cycle analysis for a HexPly XF laminate section of a wind turbine blade shell. The laminate highlights that the XF infusion material can achieve 2.7 times greater coverage of high-quality, paint-ready surface finish, confirming its lower CO2 footprint versus traditional gelcoat.

Hexcel continues to develop its carbon fibre offering for future energy applications and is working to reduce overall hydrogen storage tank costs and improve performance by optimizing fibre usage and resin chemistry. With the investment and commissioning of a new towpreg line for high-pressure vessels in 2023, Hexcel underlines its strong commitment to this future technology.

“We are delighted to be celebrating our 75th anniversary with such a varied range of product launches and exhibits at JEC World 2023," said Thierry Merlot, Hexcel President – Aerospace for Europe, MEA/AP & Industrial. "Hexcel has been synonymous with innovation throughout its history. Our company remains a leader in delivering innovative advanced composite solutions to our customers, and we look forward to the next 75 years of continuing to create lightweight solutions that help create a better world for us all.”

www.hexcel.com