<![CDATA[AV Press]]> /press/ en Thu, 01 May 2025 01:30:34 +0200 Wed, 19 Mar 2025 23:18:30 +0100 <![CDATA[AV Press]]> https://content.presspage.com/clients/150_2529.png /press/ 144 AV introduces brand name for thermoplastic composites /press/covestro-introduces-brand-name-for-thermoplastic-composites/ /press/covestro-introduces-brand-name-for-thermoplastic-composites/385726AV 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.

]]> Mon, 06 Aug 2018 00:00:00 +0200 https://content.presspage.com/uploads/2529/500_2018-094-4-462240.jpg?10000 https://content.presspage.com/uploads/2529/2018-094-4-462240.jpg?10000 AV joins Composite Application Center in Singapore /press/covestro-joins-composite-application-center-in-singapore/ /press/covestro-joins-composite-application-center-in-singapore/385831Significant market potential for fiber-reinforced thermoplastic composites

]]>AV has joined forces with an international group of companies to launch the Composite Application Center (CAC) in Singapore. Its aim is to drive the development of advanced composites by delivering industry- and application-focused services to specific regional and global markets. At the Germany-Singapore Business Forum at Hanover Fair, the group of currently ten companies and two research entities signed a Memorandum of Understanding (MoU) for the launch of CAC. The group is spearheaded by Composite Cluster Singapore.

“With this initiative we are responding to the request of the composites industry to bring together partners of all stages of the composites value chain,” said Dr. Florian Doetzer, Managing Director of Composite Cluster Singapore. “Through this integration the Composite Application Center will be able to develop end-to-end solutions. 

Florian Doetzer added, “They include suppliers of materials, software, equipment and process technologies, as well as manufacturing companies. AV has a strong know-how in advanced composites especially in thermoplastics, and provides a high value contribution to CAC.” CAC will officially start its operation ‪on May 1, 2018,‬ and will ramp-up activities and capabilities throughout this year. Additional companies are expected to join in later.‬‬‬‬‬‬‬‬

Increasing demand for composite materials
“Advanced composites, particularly thermoplastic materials, will play an important role in satisfying the growing demand for strong and light materials,” says David Hartmann, Co-CEO of the Continuous Fiber-Reinforced Thermoplastic Composites (CFRTP) business at AV. “For this purpose partnerships need to be formed within the industry, to deploy solutions that can help get those next-generation products into consumers’ hands. CAC offers a unique platform for partnerships to grow, and that’s an invitation we would like to extend to everybody in the composites and adjacent industries.” 

The new center will provide a platform focusing on customer trials, prototyping, pilot manufacturing, training and support services. Product companies can leverage on CAC’s combined expertise and facilities to reduce initial investments and risk for composite related product design and manufacturing. The center will also collaborate closely with international leaders in composite research, as well as regional education and training centers to allow the industry to tap into latest technologies and create a sustainable talent pool.

Global interest from many sectors
“Our polycarbonates have already proven themselves in many applications that require strength, low weight and beauty”, says Dr. Michael Schmidt, the other Co-CEO of CFRTPs at AV. “However, the electronics industry and other industries want even stronger and lighter materials that can be used to produce thinner parts and integrated functionality.” 

Besides the electrical and electronics industries, CFRTPs are attracting interest in such diverse segments as the automotive business, household appliance manufacturers and furniture producers, medical technology, and manufacturers of sports goods and shoes.

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.

]]> Tue, 24 Apr 2018 00:00:00 +0200 https://content.presspage.com/uploads/2529/500_fallback-image.png?10000 https://content.presspage.com/uploads/2529/fallback-image.png?10000 Designer-look air conditioning systems /press/designer-look-air-conditioning-systems/ /press/designer-look-air-conditioning-systems/385745Lightweight construction materials must above all be light and stable. If they also look good: all the better. However, while many people had enough of the typical "carbon fibre fabric look", AV CFRTP composites (continuous fiber-reinforced thermoplastics) provide the market with a completely new look – as can be seen by looking at air conditioners of the Chinese appliance manufacturer Haier. 

The material was actually developed to produce extremely light-weight components that can withstand enormous forces thanks to ultra-thin, endlessly long carbon fibers and are nevertheless as easy to process as thermoplastic polymers. But unlike the now aged racing material, designers are already interested in the new look of AV's new composites. After all, new materials that are both practical and "design-suitable" are in high demand – as the example of a brand-new air-conditioning system from the Casarte brand of the Chinese household appliances company Haier shows.

"The low weight of CFRTPs was actually not so important to us," says Shao Qingru from Haier's design team. Wait a minute: did I hear that correctly? Thanks to unidirectional carbon fiber tapes, the latest ultra-lightweight material from AV is breaking new records in terms of weight reduction combined with very high strength. So why does the designer use it if the lightweight construction potential of the new composite material is not really that important to her? 

The Haier Group reports that it holds the world's largest market share in the appliance sector and produces a very large number of air conditioning systems, washing machines, microwave ovens and refrigerators for demanding customers. Such a global player selects its materials very carefully. So why CFRTP, Mrs. Qingru? And why for a new air conditioning system for the Casarte brand of the group, which has acquired its reputation through luxury goods made of glass and steel, the products of which are sold as celebrated design objects with a nearly artistic appeal?

Customers love good looking products
And this is exactly the key to the riddle. "The decisive factor was the surface quality," says Qingru. "When I saw the material for the first time, I was very impressed by its aesthetic quality. So naturally, we were immediately interested in this new premium material when AV introduced it to us at a Haier Innovation Day." 

There is a simple reason why Casarte employees have focused mainly on metals and glass up to now. Their goal is a unique design that electrifies customers. In the fiercely contested appliance market, manufacturers must stand out from the crowd if they want to fascinate and retain customers. Good design always determines the success of a product, according to Qingru, but ugly things quickly disappear. It is not for nothing that Casarte employs around 300 product designers in twelve countries around the globe, who give their creations the most unique look possible. And steel, aluminum and glass attract attention.

Aesthetic material wanted
The catch: "It is not easy to find new materials that we can work with," says Shao Qingru. In the meantime, she and her colleagues spend most of their time working on proven materials in such a way that they differ from the familiar appearance and help to give their products a new face. And to make them even more appealing for customers. "But in this sense, we are reaching more and more of our limits." 

For example, in order to make aluminum suitable for use in living rooms, it requires some combination of finishing processes like sandblasting, brushing and anodizing. I.e. it is equipped with a more robust surface electrically before it can shine in the product. And this elaborate processes cost time and money. "CFRTP, on the other hand, is a beautiful material", the designer says. Beautiful even without make-up, so to speak.

A plastic is the better metal
The first new product in the Casarte product range, which is allowed to be encased in the new AV material, is an air-conditioning system: Two slender columns with a luxurious metal effect that does not require any metal at all thanks to CFRTP and an otherwise restrained, transparent paint finish: In their brilliant polycarbonate matrix, the endless carbon fibers of the new lightweight construction material, which lie parallel to each other, are reminiscent of brushed aluminum, even without the need for the time-consuming finishing process. 

Even the sound fits: Anyone who knocks against the case will hear the typical metal-like "Dong", which is another good reason for many designers to take a closer look at the material. "Sound is also part of our design language", explains Qingru, "it contributes to the unique user experience. Customers want to touch, feel and hear the product. The metallic sound makes you feel like you have a stable and reliable product." 

The keyword "reliable" is much more than just that: Since CFRTP, thanks to established plastic production techniques such as compression molding, requires fewer processing steps from the raw material to the end product than, for example, aluminum or even traditional carbon fiber-reinforced plastics, which require several hours in post-processing, the CFRTP inventor in Leverkusen clearly expects that the overall part quality is reproducibly higher. The result: reject rates decrease because the material has to be processed less elaborately after demolding. This, of course – like the short cycle times of the forming process – is likely to have a positive effect on production costs.

"AV made a breakthrough here"
The high performance of the material has already convinced Haier in such a way, that the other strengths of the new lightweight construction material at Haier take a back seat. For example, the low weight and the targeted design of the tape layers to divert induced forces: for the chic design piece, these properties are also not completely unimportant, and a pleasant bonus for the user who wants to carry the product home – but the inspiring appearance is what really counts. Beauty counts!

In any case, Shao Qingru is proud to have discovered this material for the new air conditioning system of the Haier brand Casarte. "New materials are not easy to find. And the effort required to successfully bring them to the end product is high. I believe that AV and Haier have made a real breakthrough here." At Haier, with whom AV has been working for a long time and has recently entered into a strategic partnership, further projects are already being considered.

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.

]]> Wed, 28 Mar 2018 00:00:00 +0200 https://content.presspage.com/uploads/2529/500_fallback-image.png?10000 https://content.presspage.com/uploads/2529/fallback-image.png?10000 Premium material for designer appliances /press/premium-material-for-designer-appliances/ /press/premium-material-for-designer-appliances/385829Haier, a world-leading brand of major household appliances, has launched a state-of-the-art air conditioner under it's Casarte brand, utilizing AV’s novel continuous fiber-reinforced thermoplastic (CFRTP) composites. These composites are used to house the air conditioning units, which are artistically designed in the form of two standalone cylinders, providing structure and the premium aesthetic qualities known for the brand.

“As an award-winning high-end consumer appliance brand owned by Haier Group, Casarte is known for it's high quality design and materials,” says Xiongwei Li, Head of Marketing of Casarte, Haier Group. “In this context, it is only natural that an innovative material with premium qualities like CFRTP becomes the ideal choice for this premium air conditioner.”

A plastic with a metallic effect
CFRTP composites are made from ultrathin, unidirectional (UD) tapes that are laminated together at specific angles to form sheets that can be customized to specific performance criteria. The long strands of fiber are oriented and provide strength in the lengthwise direction of the fibers. The resulting thin, stiff, and lightweight yet very strong sheets look and sound like metal, but have the flexibility of a thermoplastic material. Thanks to it's unidirectional carbon texture, CFRTP lends the air conditioner a luxurious metallic effect with a sleek and beautiful surface. The overall design is modeled with Casarte’s core values by placing an emphasis on design artistry.

“Not only does this mark a pivotal step into consumer home appliances for CFRTP composites, but it brings a new premium material and exciting new design opportunities within the reach of designers,” says David Hartmann, one of the co-CEOs of AV CFRTP, together with Michael Schmidt.

A new premium material for designers
Traditionally composites have been known to be prohibitively costly and often difficult to work with. CFRTP changes all of this, offering a modern, cost effective and easy to form thermoplastic composite material that opens the path to completely new applications and user experience.

For the Casarte design team, it means that for the first time it has been possible to specify a high-performance composite material with unique aesthetics in their range of premium air conditioners. “Up until now, we have been quite limited in terms of material selection, typically relying on metal to provide the performance and aesthetics that we require,” says Shao Qingru, one of the CMF designers in the Casarte design team.

Attractive surface
In describing the depth and richness that Qingru sees in the surface texture of AV CFRTP, she points at a very tangible benefit of the material. “CFRTP is a very attractive material for us in that it has a natural, unidirectional surface pattern right from the start, unlike metals such as aluminum that requires some combination of finishing processes like sandblasting, brushing and anodizing before it is ready to go into the product. For CFRTP, the finish is all natural and has a beauty to itself.”

“Based on thermoplastics, CFRTP composites can be thermoformed with existing thermoforming tools at high yield rates and short cycle times. They are compatible with a wide range of coatings and decoration processes for designing unique surfaces, logos and other signature details. Laser-etched patterns transfer easily from steel molds,” says Michael Schmidt.

Smart air conditioning system
The Casarte air conditioner features intelligent recognition and air zoning. It comes with sensors that can detect the location of people in a room and perceive temperatures in humans so it can intelligently control the air flow and temperature in different zones based on the needs of people.

Strategic partnership
This is not the first time for AV’s innovative material solutions to be used in Haier products. The partnership was already forged at Haier’s foundation in 1984, when AV (at that time Bayer) began supplying raw materials to Haier for the thermal insulation of refrigerators. In October 2017, AV and Haier signed a global strategic cooperation agreement on the expansion of their decade-long partnership to a global scale, by constantly developing advanced products featuring the latest material solutions to address the market demands of the global home appliances industry.

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.

]]> Mon, 12 Mar 2018 00:00:00 +0100 https://content.presspage.com/uploads/2529/500_2018-024-887926.jpg?10000 https://content.presspage.com/uploads/2529/2018-024-887926.jpg?10000 Going through hell to get to heaven /press/going-through-hell-to-get-to-heaven/ /press/going-through-hell-to-get-to-heaven/385637Lightweight, highly resilient and ideally also attractive to look at: These are the demands that enthusiastic cyclists make on the components of their bikes today. The challenge: the synthetic resin-carbon fiber composites that are in great demand in this scene may be light and chic – but the risk of breakage is always present. With its brand-new, lightweight CFRTP composites (continuous fiber-reinforced thermoplastic), AV opens up a new chapter: they can be processed in a novel process in just one step.

Previous restrictions on synthetic resin composites, such as the mass production capability and intrinsic brittleness of the material, could soon be a thing of the past thanks to CFRTPs. The impact-resistant matrix material polycarbonate further increases safety – and the popular carbon look is also included. Last but not least, CFRTP composites also increase the cost-effectiveness of production. Time for a change of guard in the bicycle sector!

Tours with adrenaline factor
When are mountain bike tours most beautiful? Of course: on the ups and downs! It goes without saying that not only all the driver's senses are challenged as much as possible: The material also has to withstand enormous forces and shocks when shooting over roots and rocks, in tight hairpin curves and in hard landings after a jump.

This is reason enough for experienced developers such as Dr. Niccolo Pini, founder and managing director of next composites GmbH in Otelfingen, Switzerland (a company of Ensinger GmbH), to keep up with the latest materials that the market offers in order to achieve the best there is for the bikers. His latest highlight: a pedal crank made of CFRTP, the new high-performance composites in AV's portfolio. The part is not only extremely light and robust, but also looks great due to the coveted carbon fiber optic. Thanks to the new manufacturing possibilities of next composites, it can be reproducibly and automatically produced – with all the advantages for component quality. 

True engineering work
Get on your bike, get out of the exhaust fumes of city traffic, head down fast downhill over winding paths: For engineers, some mountain bike tours mean that the rider is in the sky while the material goes through hell. Of course, no one needs a breakdown when shooting at 50 km/h, for example due to broken handlebars, frames or cranks. 

"The development of components for mountain bikes is true engineering work," explains Niccolo Pini of next composites. He is also a passionate cyclist who has been thrown out of the saddle several times while pursuing his hobby. A man who knows his way around – from several perspectives.

Genuine engineering work for shooting over rough and rocky surfaces
Material failure often has a very simple reason for Pini: poor workmanship due to manual labor. "Even for simple components such as a crank, you need sixty to seventy carbon fiber blanks in classic synthetic resin processing, which have to be aligned manually in the correct order and position. This is exhausting work that requires a lot of concentration. No wonder there are quality problems." From the outside you can hardly see the black carbon part. But when it comes down to it, the break is there – and the driver goes over the handlebars.

The solution for Dr. Pini is AV CFRTPs – continuous carbon fibers impregnated with the high-performance plastic polycarbonate. This new composite material offers enormous strengths thanks to the fiber reinforcement, but thanks to its thermoplastic matrix, it can be processed mechanically and significantly faster than epoxy-based systems. "Machines make mistakes less often," says Pini. This means that problems with incorrectly laid carbon fiber sheets, which can lead to fractures later on, are remedied from the very beginning. 

“In fact, the great strength of our CFRTP tapes is that they are not only able to absorb high forces thanks to the continuous carbon fibers," adds Dr. Michael Schmidt, who is one of two Co-CEOs of AV CFRTP, together with David Hartmann, "but that with their help, several conventional steps in the processing of previous carbon fiber thermoset composites can be combined in a single, fast process.” The tapes are automatically cut at precisely the required angle according to the mechanical requirements. They are then placed into a tool before the preform manufactured in this process is pressed in the next step.

High impact strength protects against fractures
In addition, there are considerable economic advantages in terms of post-treatment: traditionally manufactured composites made of synthetic resin and carbon fiber usually have to be laboriously treated with fillers, reground and polished in order to satisfy the aesthetic demands of the customers. 

According to Pini, a "classic" carbon frame passes through up to 70 pairs of hands in the course of its manufacture. Approximately 120 working hours are required to bring the component so that it can be hung on the wall in the shop – and half of this time is needed for rework. With AV CFRTP, on the other hand, the component with a high-quality surface finish comes out of the machine practically ready for sale. And with a weight of 150 grams, the new crank is still incredibly light despite its load-bearing capacity – this is an important argument for the new material, according to Niccolo Pini, especially when it comes to moving parts in bicycle construction.

The matrix material polycarbonate also offers clear advantages. "Thanks to its high fracture toughness, this plastic is ideal for such applications," says Dr. Pini. According to the composite expert, thermoset materials such as those often used in the manufacture of carbon fiber composites, on the other hand, tend to break brittle quickly in the event of blows – this is just not enough for the stresses and strains that mountain bikes are subject to in the fields and forests. Polycarbonate, on the other hand, is also able to withstand violent blows.

CFRTPs from AV are "Composites 2.0"
Another advantage: The toughness of the plastic material means that metal inlays, which are commonplace with synthetic resin composites, can be largely dispensed with when processing AV's CFRTP tapes. Dr. Pini and his colleagues simply cut their threads into the molded crank – ready. At present, they only need a single inlay – and that too should soon be a thing of the past. "We are gradually approaching the goal of doing without aluminum inlays altogether," says the manager, "in order to make the crank even lighter at the end."

CFRTP is a new material whose maximum performance potential has yet to be explored by the engineers. In this way, Pini also takes the wind out of the sails of critics who did not have the best experiences with thermoplastic materials in bicycle construction in the 1990s: "With CFRTP, AV has practically reinvented carbon fiber composites!” The specialists of the plastics company are happy to pass on their knowledge: "We have received a competent answer to every question," says the Swiss engineer. 

AV is also proud of the project. "This was one of our first orders and the best opportunity for us to bring our unidirectional CFRTP tapes into a fascinating application," says Dr. Michael Schmidt.

"AV is also a very reliable consulting partner – and I have been working in this industry for 15 years," says Dr. Pini. No wonder that the committed bike fan is already thinking about further projects with the new material from the high-end materials factory in Leverkusen. AV also sees a whole range of new opportunities for CFRTP tapes – in addition to the sports sector, there are also opportunities in the automotive sector, electronics, medical technology and other sectors. The chances are good, because the demand for lightweight yet stable, cost-effective plastic components is growing worldwide.

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.

]]> Thu, 08 Mar 2018 00:00:00 +0100 https://content.presspage.com/uploads/2529/500_fallback-image.png?10000 https://content.presspage.com/uploads/2529/fallback-image.png?10000 The perfect travel companion /press/the-perfect-travel-companion/ /press/the-perfect-travel-companion/385845For 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.

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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.
 

]]> Thu, 08 Mar 2018 00:00:00 +0100 https://content.presspage.com/uploads/2529/500_fallback-image.png?10000 https://content.presspage.com/uploads/2529/fallback-image.png?10000 Making the design world resonate /press/making-the-design-world-resonate/ /press/making-the-design-world-resonate/385862A design office in the Cologne area is inspired by innovative materials

]]>Furniture designers are always on the lookout for new materials that put a breath of fresh air into offices, conference rooms and living rooms. So the continuous fiber-reinforced thermoplastic composites (CFRTP) made by AV fell on very fertile ground in this industry: they inspire the product designers not only with their extraordinary stability at the lowest-possible weight, but also with their unusual, novel aesthetics. 

“An exciting, authentic material that looks very organic” is the opinion of Thorsten Frackenpohl, for example, who heads a successful design office south of Cologne. CFRTP materials could give completely new impetuses to furniture design. And with the economically efficient processing methods long established with thermoplastic plastics, they can also be efficiently produced.

Thorsten Frackenpohl pulls a heavy shelf out of the wall. It contains several handy, black containers that are brimful with things you could also find in a hobby cellar: plastic samples in all imaginable colors, sponges, cartons, wood, colorfully printed cartons. But this is no hobby workshop; its one of the hottest design offices in the Cologne area: the Noto GmbH in Hürth. The cabinet is standing in a brightly lit conference room, only separated by a glass wall from the young Noto employees workstations on whose screens some of the ultimate must-haves of tomorrow are just starting to evolve. 

And Thorsten Frackenpohl, dressed in jeans, a gray sweater and a loosely-tied scarf is one of the company’s CEOs. Next he pulls out a box labeled “AV”. It has rolls with black tape, thin black plates the size of a letter envelope, a laptop cover with the logo of the plastics-experts from the Rhineland. “That is our materials achieve,” the designer explains, “and these are sheets made of CFRTP, a completely new material with which we are experimenting right now.”

An aesthetic material
“For us it is very important to be able to touch things,” Thorsten Frackenpohl explains. “What does a material feel like, does it seem cold or warm? That is important. And listen to this,” he says as he knocks his wedding ring against a thin disc. 

“We designers like to try new things. New materials open up doors to new innovations for us. And AV CFRTP entails some truly magnificent properties. It seems to be almost organic, making it exciting, unusual, novel. It sounds like metal but has an appearance completely different from the carbon-fiber reinforced plastics available up to now and that look gives the product a completely new optical direction. ” 

In fact, nowadays if you think about parts made from conventional CFRP non-woven fabrics you would probably think of Formula One or aerospace – and you have probably had your fill. “In contrast, the fibers in the CFRTP sheets have an effect almost like wood grain – but only almost. The material is authentic; it doesn't pretend to be something it is not. It’s packed with a huge number of possibilities.” 

From consumer electronics to furniture design
Some of those are furniture, chairs, or perhaps a table? Actually, the Noto designers in their stylish work loft have acquired their merits rather with products from the consumer electronics sector – in company handouts printed on thick paper you can find speaker cabinets, routers, sound systems and even snowboard boots all of which exude a chic and yet discreet charm. 

The walls of the seminar rooms in the basement where the 3D printers and workplace desks are located are decorated with product ideas in various development stages. But furniture – so far, furniture has rather been ignored, and many other designers are already playing around in the field. And the first idea after the first reach for the CFRTP samples from AV was for something completely different anyway: drums.

Paper-thin and yet extremely stable
Since Frackenpohl has been dealing with the brand-new sheets for quite a while he quickly realized: they are far too good for just a drum set. After all, not only does the material have a surprising sound: the nearly paper-thin CFRTP sheets are most notably extremely light and nevertheless incredibly solid. “I was attracted by the idea of turning it into something where at first sight you say: that just can’t be!” 

A table, for instance, that you wouldn’t trust to support everything you could put on it. That in principle you could balance on one hand – but which still surprises with a metallic sound if you put a glass on it. Or a chair that seems so delicate that at first you can’t believe what it can withstand. “As an example, it’s hardly possible to make cell phones any thinner. And they don’t need to be since they are already handy enough. But there is still plenty of design freedom for furniture.” 

Furniture in carbon appearance
Frackenpohl is especially fascinated by the “formal-aesthetic appearance” of the new continuous carbon-fiber material: “There are already many simulated surfaces on the market.” On top of that, AV CFRTP is opening up new business doors. You can already get “carbon-look” furniture, explains Frackenpohl, but that is usually just individual projects: the fact is that classic carbon-fiber processing is very expensive. 

But furniture made of CFRTP should be significantly less expensive to manufacture since a combination of the classic processing methods with injection molding and thermoforming can be drawn on; methods which are long established in the industry and which can be run with great economic efficiency. In particular, the cycle times for CFRTP are considerably shorter than when producing “classic” carbon-fiber components, which in part is still run manually and which require a lot of rework. “It might even be possible to convert on-going projects to CFRTP” says Frackenpohl: that is nearly already a “democratization” of the carbon fiber.

“The material will take off!”
But at the moment this is only tables and chairs. For the latter, Noto even already has concrete models on the starting line – Frackenpohl places some of them on the conference room table, hand-sized, with legs made of furniture-making wire and, in the basement in a corner next to the 3D printer and table saw, you can already marvel at some appropriately formed CFRTP sheets: thin like the wall of a milk carton, but already clearly recognizable as a seat.

Frackenpohl stands up and puts the AV sample box back in the storage room. There will probably be a lot of discussions in front of the beamer screen at the conference table on the final shape of the chair in the near future – and the table has not come much further along than the many ideas on the movable walls in the cellar seminar rooms that, covered with stickers in various colors, are waiting for their realization – at least tentatively. “In industrial design, at the end only one out of a hundred ideas is actually achieved; the rest stay in the draft stage. But AV CFRTP is already letting the design world resonate. As soon as the first parts go into production, things will take off,” says the materials expert from Hürth with certainty. 

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.

]]> Thu, 08 Mar 2018 00:00:00 +0100 https://content.presspage.com/uploads/2529/500_fallback-image.png?10000 https://content.presspage.com/uploads/2529/fallback-image.png?10000 Composites for economical lightweight construction /press/composites-for-economical-lightweight-construction/ /press/composites-for-economical-lightweight-construction/385679AV presents new material solutions at the JEC World 2018 trade fair

]]>Fiber-reinforced composites are becoming increasingly important worldwide. This actually comes as no surprise, as the demand for lightweight materials with high strength is increasing in more and more industries. The number of new composite applications is correspondingly large, also as a replacement for conventional materials such as metal or wood. New properties also add to the range of possible applications.

AV has been involved in the development of material solutions for composite materials for many years. Be it miniaturized electronic products, thermally insulated facades or wind power plants: energy and resource-saving composites, together with efficient manufacturing technologies, are among the core components of AV's sustainability concept.

At the composite industry's international performance show, the JEC World 2018 from March 6 to 8 in Paris, the company will be presenting lightweight, rigid and aesthetic materials and efficient processes for their production at Stand C28 in Hall 5.

New high-tech material

AV has developed a completely new composite technology for the efficient production of particularly thin, lightweight, high-strength yet aesthetic parts. It is based on continuous fiber-reinforced thermoplastic composites (CFRTP) made of polycarbonate. AV produces tapes and sheets for further processing by customers and has now significantly expanded its production capacity at Markt Bibart to supply the world from there.

Especially in the electronics industry, the trend is towards thinner and thinner housings, e. g. for laptops and smartphones. Laptop lids can be manufactured from CFRTP plates in a single-stage process, enabling shorter cycle times and significant cost savings. Compared to magnesium alloys, they are around 15 percent lighter and can be equipped with aesthetic surface structures.

Wind power rotor blade nearly 60 meters long

The expansion of renewable energy sources such as wind energy continues to progress. Even more intensive use requires a more cost-efficient production of wind turbines.

AV has developed a special polyurethane infusion resin for rotor blades. In combination with reinforcing glass fibers and an efficient vacuum manufacturing process, it enables shorter cycle times and thus cost advantages. The resin developed in China has been awarded DNV-GL certification - a prerequisite for entering the Chinese wind power industry.

In China, a new prototype of a rotor blade with a blade length of 59.5 meters has now been produced. AV wants to produce more blades with even longer blade lengths in order to enable an even more efficient use of wind energy.

Composite material for facade insulation

In the BeNeLux region, strict specifications apply with regard to the thermal efficiency of the building envelope. Curtain-type ventilated facades are widespread, especially in office and industrial buildings there. With today's material solutions, the ever-increasing requirements can only be met with thicker insulation material or not at all.

For the regional situation, FISCO composite solutions company in Zusmarshausen, Germany, together with further partners, has now developed a new wall bracket that meets the requirements and which significantly facilitates the assembly process. The mounting system is part of the substructure for curtain-type ventilated facades and consists of two different elements: a core made of glass-fiber reinforced plastic (GFRP) which carries the load of dead weight and wind from the facade into the masonry, and a cylindrical insulation board which encloses the GFRP core and improves the insulating effect.

Fire-resistant polyurethane material

Due to its outstanding fire protection and good mechanical properties, FISCO composite solutions uses the Desmocomp® material from AV as matrix material for the GFRP core. The aliphatic polyurethane resin was developed primarily for outdoor applications, as it has very good weather resistance. The single-component system can be easily processed using the pultrusion process.

Waterborne polyurethane dispersions from the Baybond® line are used as film formers in glass and carbon fiber sizings for thermoplastic composite materials. The dispersions boast very good film formation, elasticity, adhesion and yellowing stability and ensure good mechanical stability of the composite. What’s more, some Baybond® products are also approved for contact with foods. AV is also working on new products for thermosetting applications.

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.

]]> Mon, 05 Mar 2018 00:00:00 +0100 https://content.presspage.com/uploads/2529/500_fallback-image.png?10000 https://content.presspage.com/uploads/2529/fallback-image.png?10000 Innovative materials for future lightweight construction /press/innovative-materials-for-future-lightweight-construction/ /press/innovative-materials-for-future-lightweight-construction/385767Recipient of the European Plastics Innovation Award

]]>Lightweight materials are in greater demand than ever – and not just in the automotive industry. Manufacturers of electronic devices such as laptops, tablets and smartphones also want to slim down their products. The advantages are obvious: while consumers appreciate light, thin devices, manufacturers also benefit from lower shipping costs while reducing their logistics-related ecological footprint. 

AV has developed a sophisticated composite technology that opens the door to a sustainable future for lightweight products. It is based on continuous fiber-reinforced thermoplastics (CFRTP) in combination with a highly efficient production method. The company recently received this year's European Plastics Innovation Award for its composite “A-Cover” for next-generation laptops. The development took second place in the category “Best Lightweight Innovation.” 

Pushing the boundaries
“Winning this prize confirms that we have truly pushed the boundaries with our CFRTPs, in order to meet the needs of tomorrow,” says Dr. Michael Schmidt, who, together with David Hartmann, heads the Thermoplastic Composites department at AV. “These composites are ideally suited for producing thinner, lighter and yet more robust parts for IT devices.” 

David Hartmann particularly highlights the major weight advantage: “Compared to a conventional magnesium-aluminum alloy, we achieve weight reductions of approximately 15 percent. And the A-Cover composite exhibits the same good bending and torsional rigidity as the metallic material.” Moreover, CFRTPs meet Underwriters Laboratories' flammability standard of V-0. 

Contemporary design
The composites give product designers an unprecedented degree of design freedom. For example, various combinations of resin and carbon or glass fibers can be used for optical effects. Textures can also be created, for example within the mold or by sandblasting, CNC milling and laser cutting. 

The A-Cover composites come close to achieving the quality of a Class-A surface. An environmentally friendly water-based two-component finish with optimal adhesion to polycarbonate substrates provides the visual upgrade and permits individual design.

Fast and efficient production
By utilizing a “single mold manufacturing” concept, AV is able to combine the three conventional steps of preheating, thermoforming and functional integration into a single process. The results are twofold: substantially lower costs and shorter cycle times. 

The European Plastics Innovation Award was instituted by the pan-European trade association PlasticsEurope and the Society of Plastics Engineers, SPE. The awards honor companies that use plastics to develop new ideas, methods, products or technologies that meet the needs of society while respecting the demands of sustainability.


About AV:
With 2016 sales of EUR 11.9 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 around the globe and employs approximately 15,600 people (full-time equivalents) as of the end of 2016.


Find more information at and . 


Forward-Looking Statements
This 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 on the AV website at . The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

]]> Mon, 16 Oct 2017 00:00:00 +0200 https://content.presspage.com/uploads/2529/500_2017-101-2-912466.jpg?10000 https://content.presspage.com/uploads/2529/2017-101-2-912466.jpg?10000