Spirit will utilise the funds to build tooling, fabricate composite parts and machine complex metallic parts at its Wichita, Kan., facility. Spirit designs and manufactures both composite and metallic structures for commercial and defence customers.

With long-standing machining capabilities, Spirit produces more than 3 million parts annually for equipment manufacturers at peak production. The 5-axis centre in Wichita focuses on large, complex, soft metal parts for fuselage, pylon and wing structures, all built on high-tech, high-speed, latest-generation equipment and is part of 12M sqft of manufacturing space.

Our growing work on defence programs has provided a measure of stability for the company, and helped us as we shift capacity to serve other needs, particularly in the defence market

Duane Hawkins, Senior Vice President; President, Defense and Fabrication, Spirit AeroSystems

The company supports a number of military programs, including programs for the U.S. Air Force, the U.S. Navy, the U.S. Marine Corps and the U.S. Army.

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Materials made of composites are suited for battery enclosures for different reasons: Besides their lightweight, which enhances the electric vehicle’s range, fibre-reinforced plastics offer high stiffness. In addition, they meet high requirements for water and gas tightness and feature excellent fire protection properties. Composite materials can also help to achieve improved structural stiffness of the underbody, e.g. to protect against penetration, as well as optimised thermal management. Carbon fibres are ideal for especially stressed structures or load-bearing elements, such as the underbody panels and side frames. For components subjected to less stress, such as battery box covers, glass fibres or a fibre mix may suffice.

In addition to the new application for the hybrid model battery enclosure, SGL Carbon will continue producing the usual components made of carbon-fibre-reinforced plastic for the BMW i3 and delivering materials for the Carbon Core body of the BMW 7 series and has been nominated as the supplier for all carbon materials – fibres, textiles, stacks – for the BMW iNEXT, set to be launched in 2021.

Over the years SGL has supplied a number of automotive manufacturers with carbon materials and composite components, from sports car parts to large-scale deliveries of leaf springs and structural components.

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Saertex supplies Bombardier in Belfast with textile reinforcement materials and carbon fibre non-crimp-fabrics to produce wing skins for the A220 aircraft using its resin transfer infusion (RTI) manufacturing process. Bombardier’s carbon-fibre wings are currently the largest and most complex composite structures designed, manufactured and assembled, using this infusion technology.

Saertex’s carbon-fibre, non-crimp-fabrics was developed especially for Bombardier’s Resin Transfer Infusion manufacturing technology. The resulting significant weight savings help the A220 deliver unbeatable fuel efficiency in a single-aisle aircraft.

The wings of the A220 are built by Bombardier at the company’s Belfast plant in Northern Ireland. Spirit AeroSystems has entered into an agreement with Bombardier to acquire its aerostructures and aftermarket activities in Belfast, Casablanca and Dallas. The transaction is expected to complete in the first half of 2020 and remains subject to regulatory approvals and customary closing conditions.

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To optimise the range of the taxis, every single gram counts. Measuring about two metres in length and 1.5 meters in width, the ultra-light landing skid will weigh less than three kilograms, making it about 15 per cent lighter than a similar component made from aluminium. This increases the potential flight time capacity of the air taxi which is a key differentiator for the air taxi operator.

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The serial production of the components will start at the end of 2020. The carbon fibres and fabrics, as well as the assembled components, come from SGL Carbon. On top of this order, there is the potential for more significant extensions with further substantial volumes for the shared platform business of the manufacturer.

In addition, SGL Carbon has won a smaller volume contract from a European sports car manufacturer to serially produce bottom layers made of composites as of mid-2020. The company is additionally in talks with further automakers to develop and manufacture battery enclosure solutions for its e-car platforms.

Driven by the increasing need for e-cars worldwide and thus for new flexible chassis platforms, our composite battery enclosures are a very promising new application in our product portfolio. Sebastian Grasser, Head of Automotive Segment at the business unit Composites

A key part of any e-car chassis platform is the enclosure of the battery which usually occupies most of the space in the underfloor of the chassis and has various very specific requirements far beyond low weight. The battery cases also need to be very stiff to support driving dynamics. In addition, the material has to protect the underbody against impact, enable optimised thermal management and offer excellent fire protection as well as complete water and gas impermeability. All these requirements are met by composites much better than by any other material. With these advantages, composite battery enclosures perfectly fit e-car-specific and highly flexible chassis variants, so-called “skateboard” platforms, to be used as a basis for a great variety of different e-car models.

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The long-term agreement provides now for a substantial ramp-up of current production and delivery volumes of gas diffusion layers for the NEXO fuel-cell car to support Hyundai’s objectives in the area of fuel cell drives. The investment required to fulfil this contract will not increase the overall capital expenditure budget of SGL Carbon in the next two years, as the company has reprioritised its investment projects.

In the medium-term, SGL Carbon plans to more than quintuple its business with fuel cell components to annual sales of approximately 100 million euro. The company supplies around 200 customers around the world with gas diffusion layers for use in fuel cells. As a result of the growing demand, the company has gradually stepped up production capacity at its plant in Meitingen. Thanks to its technological expertise and experience, SGL Carbon is in a position to manufacture high-quality components for fuel cells on an industrial scale. To further advance the accelerated commercialisation, the business with gas diffusion layers (GDL) will be transferred from the central R&D department Central Innovation to the business unit Graphite Materials & Systems (GMS) already in the fourth quarter 2019.

The extension of the partnership with Hyundai is perfectly aligned to our strategic direction. Intelligent solutions in the area of sustainable energy are one of the key growth drivers for our company. Whether used in a drive system in vehicles or as a stationary power supply, the fuel cell is one of the greenest energy technologies around. The market for fuel cells thus offers enormous potential for us. Dr. Michael Majerus, Spokesman of the Board of Management of SGL Carbon

Powered by hydrogen, the fuel cell is one of the cleanest technologies of the future. Hydrogen can be produced in a climate-neutral way using surplus energy from renewable sources. The only waste product after the reaction is water, which can be discharged in the form of water vapour. In the transport sector, the fuel cell offers a greater range and a shorter refuelling time than battery-powered drive systems. According to market estimates, up to 20 per cent of all-electric vehicles in the world will be powered by fuel cells by 2030. In addition to the automotive sector, there are also huge opportunities arising from the stationary use of fuel cells, e.g. as a power supply.

SGL Carbon has been carrying out research and development into components for fuel cells since the 1990s. The gas diffusion layers regulate the flow of gas within the fuel cell and carry water and heat away. They have a significant impact on the power density and the efficiency of the fuel cell. SIGRACET® gas diffusion layers from SGL Carbon were first used as a standard in the Hyundai iX35 in 2012.

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The contract will see A C Marine & Composites build the 10m composite blades for both of the O2’s twin rotors (four blades in total) giving the machine a swept area of over 600 square meters, the largest ever on a tidal turbine.

The Orbital O2 is a 72m long floating superstructure, supporting two 1 MW turbines at either side capable of generating over 2MW from tidal stream resources. It will become the world’s most powerful tidal turbine when it enters operation in 2020 as part of a long term project at the European Marine Energy Centre, Orkney. Improvements in Orbital’s platform design have allowed for a rotor diameter increase of 4m on the company’s previous, record-breaking, 2MW SR2000 turbine, with the O2 capable of producing electricity for over 1,700 UK homes.

Orbital Marine Power based in Orkney and Edinburgh is focused on the development of a tidal energy turbine technology capable of producing a step-change reduction in the cost of energy from tidal currents. The company’s floating technology offers a low-cost solution for simplified and safe manufacture, installation, access and maintenance along with the ability to use low cost, small workboats for all offshore operations.

We are extremely proud to have been awarded this contract by Orbital Marine; becoming part of the wider UK supply chain for the O2 project. Our structured production philosophy and in-house resin infusion technology will no doubt add value to this commercial tidal stream project. This is also a great opportunity for A C Marine & Composites to work on a project that will have a positive impact on the environment, whilst reaffirming the UK’s commitment to renewables. Alex Newton, Director, A C Marine & Composites

Orbital’s contract with ACMC follows recent contract awards as part of the overall build programme for the O2; these include the O2 platform manufacturing contract to TEXO Group in Dundee and an anchors contract to FAUN Trackway in Anglesey.

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With new manufacturing processes driving down the costs of producing carbon composite parts, manufacturers are starting to specify them even more on mid ranged sports cars. Prodrive will supply a range of composite components to 3 different UK-based car manufacturers.

Components being manufactured for each sports car include carbon aero packs with rear wings, diffusers and front splitters, along with further exterior trim parts such as bonnet vents and sills. Several of these components will be made using Prodrive’s patented TPP injection process which was introduced in 2014.

Dominic Cartwright, Prodrive Composites managing director said;

Carbon composites used to only be the domain of exotic super cars, but new manufacturing processes are bringing down their cost and we are increasingly being asked to quote for parts on sports cars and mid-priced luxury cars.

Prodrive Composites is already manufacturing the composite bodywork and interior for a British super car as part of an ongoing £20 million contract, as well as a number of projects in the marine, aerospace and space industries. These contracts have seen the company increase its workforce from 70 to nearly 180 in just the last 18 months.

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Kaman has announced its been awarded an extension to its current contract with Bell Helicopter to manufacture skin components for the Bell UH–1Y and AH–1Z helicopters. This five-year follow on contract has an expected value in excess of $25 million. The components will continue to be manufactured at the Kaman Composite Structures facility in Bloomfield, Connecticut.

Kaman started supplying Bell Helicopters back in 2011 and is a major supplier of integrated aerostructures, including metallic and composite structural assemblies and metallic parts for aerospace companies engaged in commercial and military aircraft and aeroengine programs.

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The composite struts help distribute load from the wings and fuselage into the centre wing box providing structural support for the airframe. Using a patented manufacturing technology called STaR (Struts, Tubes and Rods) that was licensed by Exelis from Bodair S.A the unique strut design provides a high strength-to-weight ratio alternative to metallic struts and, according to the company has greater weight savings when compared with rival composite production methods.

Mike Blair, vice president and general manager of Exelis Aerostructures said;

With significant weight savings and reduced maintenance costs, composite structures and components continue to replace traditional metallic structures on next-generation aircraft, and the Airbus A350 XWB is a prime example. We are positioned to meet the growing market demands and provide our customer with significant value through our Exelis StaR product line, delivering innovative, cost-effective solutions at a high rate of production.

The Airbus A350–1000 is the longest fuselage version of the Airbus wide-body jetliners, as with the other A350 XWB family members, the A350–1000 combines the latest in aerodynamics, design and advanced technologies to realise a 25% saving in fuel compared to its current aluminium long-range competitor.

Deliveries of the new parts are scheduled to begin in 2016 and will continue through 2020.

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