Large-Scale Production of Carbon Fiber Reinforced Plastics

MAI Projects

The MAI Carbon cluster in the German city triangle Munich, Augsburg and Ingolstadt persues the objective to lead CFRP technology to series capacity by 2020. In order to achieve this goal, quantum leap innovations are required along the complete component-part life cycle, i.e. starting from the fiber and matrix material, through the manufacture of the component parts and product systems, to the stage of conclusive recycling concepts.

Various partners are bundled in the cluster to increase their knowledge in order to realize technical leadership with the employment of CFRP component parts in mass production, and to make Germany the global leader in the area of fibercomposite technology. The intensive cooperation of German large-scale companies of repute and technology leaders from the application sectors involving automobile manufacture, aerospace travel, mechanical and plant engineering, as well as fiber and semi-finished product manufacturers, make the MAI Carbon Leading-Edge Cluster unique.

MAI Form

Improve the predictive capability for forming processes of composite materials with thermo-viscous properties in high volume automotive applications.

Project volume: 2.5 MEUR
Project term: Nov. 1, 2014 – Oct. 31, 2017

Project partners:

Automation W+R GmbH
BMW AG
Dassault Systèmes Deutschland GmbH
SGL Carbon GmbH
Technical University of Munich
Voith Composites GmbH & Co. KG

Project objective:
The overarching objective of the MAI Form Project is to improve the predictive capability for forming processes of composite materials with thermo-viscous properties in high volume automotive applications. Improving the predictive capacity of manufacturing processes can help reduce production and development costs and develop robust manufacturing processes. The MAI Form Project aims to achieve this objective by developing enhanced characterization, simulation and validation methods..

www.carbon-composites.eu/mai-form

MAI Tank

Investigate and develop new types of pressure tanks made from carbon fiber reinforced plastics with focus on an efficient manufacturing process with fiber-thermoplastic composites.

Project volume: 1.3 MEUR
Project term: Oct. 1, 2014 – Mar. 31, 2017

Project partners:

Apparatebau Gauting GmbH
Technical University of Munich, Department for Carbon Composites
Voith Composites GmbH & Co. KG

Project objective:
The MAI Tank research project will investigate and develop new types of pressure tanks made from carbon fiber reinforced plastics. The focus will be on an efficient manufacturing process with fiber-thermoplastic composites. This project will partly address and refine the sequential construction mode approach for pressure tanks that was already investigated in the StorHy (hydrogen storage) project. One new feature in particular is the use of a centrifugal casting process for a type 5 tank. Compared with the pressure tanks available on the market to date, the manufacturing process can be made more efficient and the application range can be extended due to the modular structure of the vessel. Another advantage of the new manufacturing process is the connection of the necessary sealing layer with the cylinder tube laminate in a single step.

www.carbon-composites.eu/mai-tank

MAI Autopreg

Systematically refine the CPP (carbon pre-impregnated press-forming) process to create the necessary technical maturity for industrialization.

Project volume: 1.5 MEUR
Project term: Nov. 1, 2014 – Apr. 30, 2016

Project partners:

BMW AG
C-CON GmbH
Voith Composites GmbH & Co. KG

Project objective:
The aim of the MAI AutoPreg project is to systematically refine the CPP (carbon pre-impregnated press-forming) process and adapt the materials and technologies used to one another to create the necessary technical maturity for industrialization. The focus of the work will be on developing an impregnation unit adapted to the winding process, a new matrix material, integrated machine technology including adapted automation technology, as well as a suitable "handling system". The technical feasibility will be tested through implementation in real-life conditions. Additionally, other advantages in respect of formability and waste reduction will be investigated.

www.carbon-composites.eu/mai-autopreg

MAI Last

Development of simple and cost-effective load introduction areas.

Project volume: 2.8 MEUR
Project term: Feb. 1, 2013 – Jan. 31, 2016

Project partners:

Airbus Group Innovations
Audi AG
BMW AG
Voith Composites GmbH & Co. KG
Munich University of the Federal Armed Forces

Project objective:
Development of load introduction areas that are simple and cost-effective to produce and that are functionally equivalent to more elaborate versions. To be able to design load introduction areas more effectively, there first needs to be a better understanding of the mechanisms acting on the load transfer area. This will be done by means of tests and calculations.

www.carbon-composites.eu/mai-last

MAI Pop

New kind of preform technology using innovative approaches to allow fast production of preforms directly from the base material with minimal waste.

Project volume: 3.5 MEUR
Project term: Jan. 1, 2013 – Dec. 31, 2015

Project partners:

Voith Composites GmbH & Co. KG
Audi AG
Krauss-Maffei Technologies GmbH
Siemens AG

Project objective:
The project aim is to develop a new kind of preform technology using innovative approaches to allow fast production of preforms directly from the base material with minimal waste. Customizing the process technology to the component should also substantially improve efficiency and drastically reduce costs.

www.carbon-composites.eu/mai-pop

MAI Design

Structured along the entire design and production process chain for CFRP components it aims to develop an understanding of the composite material and structure geared towards optimal use of the material.

Project volume: 5.2 MEUR
Project term: Jul. 1, 2012 – Jun. 30, 2015

Project partners:

Technical University of Munich, Department for Carbon Composites
Airbus Group Innovations
Aerostruktur Faserverbundtechnik GmbH
Audi AG
Automation W+R GmbH
BMW AG
CADCON Ingenieurgesellschaft mbH & Co. KG
Airbus Helicopters Deutschland GmbH
ESI Engineering System International GmbH
KSB AG
Premium Aerotec GmbH
Roding Automobile GmbH
Voith Composites GmbH & Co. KG
Deutsches Zentrum für Luft- und Raumfahrt (German Aerospace Center)
University of Applied Sciences Augsburg
Fraunhofer ICT Project Group Functional Integration in Lightweight Components
Munich University of the Federal Armed Forces
Technical University of Munich, Department for Carbon Composites

Project objective
The MAI Design project is structured along the entire design and production process chain for CFRP components. It aims to develop an understanding of the composite material and structure geared towards optimal use of the material. The research will be jointly conducted on a broad scale by partners from the automotive, aerospace and mechanical engineering sectors as well as from engineering firms, software companies and research institutions. The results will be permanently grounded through the establishment of an engineering center to offer training and professional development, workshops, seminars and summer school programs in the MAI region.

www.carbon-composites.eu/mai-design

MAI Plast

Develop an integrated process chain for the production of fiber reinforced plastic with thermoplastic matrix material that is suitable for high volume production applications.

Project volume: 9.6 MEUR
Project term: Jul. 1, 2012 – Jun. 30, 2015

Project partners:

Audi AG
BASF SE
BMW AG
Siemens AG
SGL Carbon GmbH
Airbus Group Innovations
Thermoplast Composite GmbH
Airbus Helicopters Deutschland GmbH
Premium Aerotec GmbH
KUKA Systems GmbH
Voith Composites GmbH & Co. KG
University of Augsburg
Technical University of Munich, Department for Carbon Composites
Fraunhofer ICT Project Group Functional Integration in Lightweight Components
Fraunhofer Institute for Machine Tools and Forming Technology
Deutsches Zentrum für Luft- und Raumfahrt (German Aerospace Center)
TEC-KNIT CreativCenter für technische Textilien GmbH
Krauss-Maffei Technologies GmbH

Project objective:
The aim of the MAI Plast project is to develop an integrated process chain for the production of FRP with thermoplastic matrix material that is suitable for high volume production applications. To this end it will identify suitable composites and composite combinations and develop efficient manufacturing processes. Based on end-user requirements, appropriate materials (fibers, matrix) will be developed, combined, and characterized by the project partners. The material combinations will then form the basis for developing new processes. In this context, various technologies will be explored for direct component production and component manufacturing from semi-finished goods.

www.carbon-composites.eu/mai-plast

MAI Recycling

An integrated recycling process chain that starts with production waste or mixed materials and ends with treated carbon fiber which is suitable for further use in a variety of products.

Project volume: 3.2 MEUR
Project term: Jul. 1, 2012 – Jun. 30, 2015

Project partners:

bifa Umweltinstitut GmbH
Audi AG
BMW AG
Neenah Gessner GmbH
Fraunhofer Institute for Building Physics
SGL Carbon GmbH
Siemens AG
Voith Composites GmbH & Co. KG

Project objective:
The aim of the flagship MAI Recycling project is to develop an integrated recycling process chain that starts with production waste or mixed materials and ends with treated carbon fiber which is suitable for further use in a variety of products. In this context, various processes such as decomposition at high temperatures (pyrolysis), will be applied, scrutinized and optimized as potential recycling methods. The recycled carbon fiber will then be analyzed, categorized and treated based on its material properties, using quality assurance methods specifically developed within the project. The recycled carbon fibers are to be used in products which offer both high ecological and economic added value. The project will therefore make a major contribution to improving the quality of the recycling products and industrializing the recycling processes in the long term.

www.carbon-composites.eu/mai-recycling