��AV introduces brand name for thermoplastic composites

Mon, 06 Aug 2018 00:00:00 +0200

��AV is pushing ahead with developing and marketing its continuous fiber-reinforced thermoplastic composites (CFRTP) by introducing Maezio™ as brand name.

These innovative materials are set to tap into the growing demand worldwide for strong and light materials that contribute to resource conservation and energy efficiency. From mobility and electronics industries to consumer goods and medical products, OEMs and part suppliers can benefit from the high performance capabilities of advanced composites while enjoying cost-effective and scalable manufacturing solutions offered by Maezio™.

“The brand gives us a clear and strong identity to further expand our expertise in thermoplastic composites,” says David Hartmann, Co-CEO of CFRTP, one of the two Co-CEOs for CFRTP composites alongside Dr. Michael Schmidt. “We believe the new brand can truly bring value to next-generation products across industries by delivering a combination of lightweight construction, specific strengths and finishes at a scale unreachable by advanced materials today.”

Material of tomorrow
The composite material of the future is based on continuous carbon or glass fibers impregnated with polycarbonate, thermoplastic polyurethane (TPU) or other thermoplastic resins. From these components, ��AV produces uni-directional reinforced tapes and sheets at the production site in Markt Bibart in south Germany for further processing by customers. Being strong, light, and aesthetic, these components can be combined into an unlimited number of products, giving designers completely new creative opportunities.

So far a further propagation of advanced composites was hampered by lack of cost-effective and scalable manufacturing processes. Besides that it is difficult to integrate them into high-volume products. All of this is about to change with Maezio™ composites.

Suitable for mass production
They can be thermoformed with existing thermoforming tools at high yield rates and low cycle times. This is vital when manufacturing scales can be in the range of millions of parts per year. Other production technologies such as hybrid injection molding, automated UD tape laying and automated fiber placement can be easily integrated.

As thermoplastic composites, Maezio™ products can be recycled at the end of their useful life, making them “a perfect example of what scalable and sustainable composite solutions look like in giving industries the material tools to push boundaries,” says Michael Schmidt.

Strong interest from many sectors
Maezio™ is attracting interest in such diverse segments as the electrical and electronics industry, the automotive business, household appliance manufacturers and furniture producers, medical technology, sports goods manufacturers, shoe producers and the luggage industry.

Haier, the world’s largest white goods brand, has launched a state-of-the-art air conditioner under its Casarte brand, which utilizes Maezio™ for the main housing of the product. In the world of footwear, the composites have helped Chinese athletic wear startup Bmai to develop even lighter and stronger marathon shoes which benefit athletes and leisure runners alike.

About ��AV:
With 2017 sales of EUR 14.1 billion, ��AV is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. ��AV has 30 production sites worldwide and employs approximately 16,200 people (calculated as full-time equivalents) at the end of 2017.

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Forward-looking statements
This news release may contain forward-looking statements based on current assumptions and forecasts made by ��AV. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in ��AV’s public reports which are available at . The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

The perfect travel companion

Thu, 08 Mar 2018 00:00:00 +0100

For many designers, ��AV’s new CFRTP composites (continuous fiber-reinforced thermoplastics) are a welcome relief from the burdensome limitations that have thus far been associated with the use of traditional carbon-fiber-reinforced, lightweight materials. Impact-resistant polycarbonate matrix, high-quality feel, stylish surface and above all extreme durability as a result of customized, automatically placed carbon tapes: Thanks to ��AV CFRTP, product designers can completely re-imagine numerous everyday objects. And develop products that require fewer compromises and are much closer to the designer’s original concept. The CFRTP suitcase demonstrates what all the buzz is about.

“When I first became interested in CFRTP, the ��AV engineers asked me: ‘What do you think: what could be made from this material?’,” says Aldin Sakic. “I answered: ‘What can’t be made from it?’,” jokes the young man.

In fact, many designers currently feel downright inspired by the possibilities of ��AV CFRTP composites. Aldin Sakic is one of them: 27 years old and already co-founder and CEO of his own design studio in Frankfurt, asdo design and research studios. Despite his young age, it is only by chance and just recently that he ended up in Frankfurt – he has spent a large portion of his working life in Shanghai, where he is still well-connected.

In 2016, just after he founded his studio, he was one of the first to discover the new composite at ��AV, the Leverkusen-based materials specialist. “Without materials you cannot design,” says Sakic. That is why industrial designers are always after new materials that they can use to stay ahead of the times – and shape the future. So without further ado, he also came knocking at ��AV.

Is it really plastic? Or metal after all?
When someone there handed him the first CFRTP tapes, the material immediately felt like a minor revolution to him. “You are not as limited as you are with other materials when you want to get the most out of it. It provides almost infinite freedom!” What should be made with it then? A camera? A lightweight drone? The sketchbook filled up with ideas. In the end, a suitcase was at the top of the list.

Because those who travel often, like Sakic, know that these travel essentials can never be light enough. It’s no wonder that in recent decades the travel industry has become a real Eldorado for the application of lighter, yet more stable plastics. Sakic thought that maybe a little more progress could be made here with ��AV CFRTP. Not only is the brand new polycarbonate composite based on versatile carbon fiber tapes ultra-light, but it also does away with the many disadvantages of previous plastic solutions.

So Sakic left with a set of material samples and disappeared for a while to a materials laboratory at the Offenbach University of Art and Design. There, the product designer was particularly impressed with the ultra-light CFRTP sheets – not only due to their outstanding stability and very low weight but also because of their look, which is reminiscent of slate, even without a coat of varnish. Sakic found it to be a “very elegant, natural-looking material!” Not to mention the almost bell-like sound the material makes when you tap on it. It is really plastic – or perhaps metal after all?

Following this, the telephone lines between asdo design and the ��AV technicians lit up. But not just to patiently answer material questions: the staff members in Leverkusen were also interested to see what happens when creative minds make use of the new material, which until then had primarily passed through the hands of researchers and engineers.

That a suitcase ultimately emerged as a project was not a surprise to David Hartmann, one of two Co-CEOs of ��AV CFRTP, together with Dr. Michael Schmidt. “These products are certainly an optimal way for the material to demonstrate its strengths. Despite its very low weight, our new composite is remarkably stable and durable.”

And he adds: “Of course, in addition to this application of our new composite there will probably emerge additional benefits because it can also be processed in classic plastic mass processing methods such as compression molding, thanks to its thermoplastic matrix made of the versatile and particularly impact-resistant plastic polycarbonate. It might even make the production of premium series products with ��AV CFRTP very profitable.”

Much closer to the original concept
The carbon fiber tapes from Leverkusen can be placed into the tape laying machine exactly where you need it in the product, in order to dissipate forces. That means design freedom! The less a designer has to worry about traditional material properties, the more flexibility he or she has.

“As a result, you can completely rethink classic products,” explains Aldin Sakic. The final product is closer to the designer’s original vision. Corners no longer have to be filed down, so that the product is still stable despite the model weight.

Space for power bank & co.
And the consumer benefits too. Thanks to CFRTP, the suitcases of tomorrow can become even lighter, and they will provide more space. Or they will remain at roughly the same weight as current products from the department store shelf, but then offer an added convenience: in the form of an integrated power bank, which can be used to quickly charge your cell phone.

Or even small, fold-out screens, on which you view your vacation photos during your layover in Singapore. From a technical standpoint, this has been possible for some time; the problem thus far has been the additional weight. But if the suitcase is put on an extra diet by way of ��AV CFRTP, why not turn the simple clothing container into a capable travel companion?

And then there are still the high-quality feel and the surface of the material, which can be seen even without time-consuming and expensive varnishing, say Sakic and his ��AV colleague David Hartmann. “People are used to seeing the standard carbon look,” explains the designer. “But this slate look, this is new.” And if you want, the surface can even look like brushed metal. “The material doesn’t have to hide – quite the contrary. Also, ��AV CFRTP feels especially valuable – in contrast to many customary lightweight materials,” adds David Hartmann. “You definitely have the feeling that you own something special.”

Much more in the pipeline
There are still other ideas in Sakin’s sketchbook. For him, the CFRTP suitcase is just the first of many more projects that are currently in various stages of implementation. The final design of the new model suitcase has not yet been determined: those who want to reinvent the suitcase are now standing at the doorway to a true universe of possibilities that must first be mapped out. “Of course we already have a prototype,” says Sakic, “but we are working on an even nicer one.”

And it has already been decided that this will not be the last CFRTP project to take shape at the hands of the asdo designers. Sakic, who has also worked for research institutes in the past, knows a great deal about technical challenges: “I am sure that we will be hearing a lot about this material.”

About ��AV:
With 2017 sales of EUR 14.1 billion, ��AV is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. ��AV has 30 production sites worldwide and employs approximately 16,200 people (calculated as full-time equivalents) at the end of 2017.

Find more information at and .
Follow us on Twitter:

Forward-looking statements
This news release may contain forward-looking statements based on current assumptions and forecasts made by ��AV. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in ��AV’s public reports which are available at . The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

����AV Press

����AV introduces brand name for thermoplastic composites

The perfect travel companion

��AV Press

��AV introduces brand name for thermoplastic composites