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Emerging Innovations in Composites Industry

  • February 2015
  • -
  • Lucintel
  • -
  • 163 pages

Background:

Composites have already proven their worth as the materials having excellent performance benefits. The current challenges lying ahead are to make them cost-effective and speed up the manufacturing process. The efforts to meet these challenges have resulted in the development of advanced manufacturing techniques and innovative materials. The future market is expected to be highly competitive, and companies with innovation capability can thrive and gain market share. The market for one of the composite materials, such as glass fiber, which is used as a reinforcing material for a variety of applications, such as boat, construction, wind, pipe and tank, and consumer goods, was approximately $8.1 billion in 2013. Manufacturers of glass fibers are expected to focus on continuously developing high-performance glass fibers to meet higher mechanical and chemical requirements of different applications.

Recently, PPG, 3B, Jushi Group, Owens Corning, and others have launched products to meet the requirements of the industry. Lucintel, a leading global management consulting and market research firm, has analyzed innovations in the global composites market by material, application, and technology and has come up with a comprehensive research report, “Emerging Innovations in Composites Industry”. This report provides an analysis of innovations in composites manufacturing technologies, applications and materials, including the market potential of materials, value chain, key drivers, unmet need, and the future roadmap for innovations in the composites industry. The study also includes the global composites market forecasts through 2025, by application.

Innovations in the composites industry are categorized or presented in the report as under the following headings:

Megatrends in composites by:
- Materials
- Applications
- Technology

Innovations in the global composites industry by material:
- Glass Fiber
- Carbon Fiber
- Natural Fiber
- Resins
- Compounds
- Core Materials

Innovations in the global composites industry by application:
- Aerospace
- Automotive
- Wind Energy
- Construction

On the basis of its comprehensive research, Lucintel expects significant innovations in the composites market in the next 50 years. Most of the innovations in composite materials are focusing on performance improvement and cost benefits.

Features of This Report:

To make any investment, business or strategic decisions, you need timely and robust market information. This market report fulfills this core need. This is an indispensable reference guide for composite material suppliers, product manufacturers, investors, researchers, engineers, distributors and many more, who are dealing with the composites industry. Some of the features of this market report are:
- Market size and growth rates of the global composites market. Market for FRP and advanced composites
- Global composite industry size in terms of value and volume
- Global composites industry trend (2008-2013) and forecast (2014-2019) in terms of value and volume by region and by application
- Market size estimates for reinforcements and resins
- Market breakdown by applications and key regions North America, Europe, Asia Pacific, and Rest of the World
- Composites market by countries such as China, India, US, and Germany.
- Competitive analysis between steel, aluminum, plastics and the composites industry
- Market breakdown by manufacturing process, by market segments, and by various material types
- Thermoset and thermoplastic composites market size, trends and forecast
- Market outlook and global trends in automotive, marine, construction, aerospace and other important market segments with needs and challenges of various market segments
- Value chain analysis. Dollar and gross profit flow through various nodes of the value chain (from raw material to final application)
- Material price and property comparison. Fiber and resin price history and forecast.
Material prices of more than 100 materials such as fibers, resins, fabrics, prepregs, adhesives, and metals.

Table Of Contents

Emerging Innovations in Composites Industry
1. Executive Summary
2. Innovations Overview
2.1: Why innovation is required
2.2: Innovations in composites industry
3. Composites Industry Insights and Unmet Needs Analysis
3.1: Composites manufacturing technologies
3.2: Composite market- materials and applications
3.2.1: Composites market by material
3.2.2: Advanced composites market
3.2.3: Raw materials market
3.3: Value chain analysis
3.4: Growth drivers and challenges
3.4.1: Driving forces for the use of composite materials
3.4.2: Industry challenges in recent years
3.4.2.1: The energy cost squeeze
3.4.2.2: Challenges for glass fiber industry
3.4.2.3: Resin producers are relatively safe
3.4.2.4: Fabricators' challenge
3.5: Unmet needs analysis
3.5.1: Need for low-cost raw materials
3.5.2: Resins and fiber materials with higher strain to failure
3.5.3: Better UV- and chemical-resistant materials
3.5.4: Low-cost manufacturing process for large and small parts
3.5.5: Need for high temperature composite materials
3.5.6: Low shrinkage materials
3.5.7: Low wear and tear composite materials
3.5.8: Damping and noise resistance materials
3.5.9: Optimal resin and additive systems for closed molding operations
3.5.10: Products manufacturability and affordability
3.5.11: Flexible gel coats
3.5.12: Flame-resistant materials
3.5.13: Self-healing material
3.5.14: Manufacturing process with lower processing time
3.5.15: Flexible honeycomb core
3.5.16: Fabric wrinkling
3.5.17: Method of cutting wet prepregs
3.5.18: Need for moisture-resistant honeycomb core
3.5.19: Fast cure epoxy resin
4. Emerging Innovations in Composite Materials
4.1: Innovations in glass fiber
4.2: Innovations in carbon fiber
4.3: Innovations in natural fiber
4.4: Innovations in resins
4.5: Innovations in compounds
4.6: Innovations in core materials
5. Emerging Innovations in Composites Applications
5.1: Emerging innovations in aerospace market5.2: Emerging innovations in automotive market
5.3: Emerging innovations in wind energy market
5.4: Emerging innovations in construction market
5.5: Emerging innovations in composites manufacturing technologies
6. Future Roadmap for Innovations in Composites Industry
7. Other Recent Launches
7.1: Glass fiber
7.2: Carbon fiber
7.3: Natural fiber
7.4: Resin
7.5: Compounds
7.6: Core materials

List of Figures

Chapter 2.Innovations Overview
Figure 2.1: Six aspects of business values created by innovation
Figure 2.2: Unmet needs and the scope of innovation
Chapter 3.Composites Industry Insights and Unmet Needs Analysis
Figure 3.1: Classification of composite processing techniques
Figure 3.2: Advanced composites market share in global composites industry in 2013
Figure 3.3: Advanced composites market size (Million Pounds) in global composites industry in 2013
Figure 3.4: Advanced composites market distribution ($M) in global composites industry in 2013
Figure 3.5: Advanced composites market size ($M) in global composites industry in 2013
Figure 3.6: Raw material shipment (Million Pounds) in global composites industry in 2013
Figure 3.7: Global composites market breakdown (%) by raw materials used in 2013
Figure 3.8: Raw material shipment ($M) in global composites industry in 2013
Figure 3.9: Global composites market breakdown (%, $M) by raw materials used in 2013
Figure 3.10: Composites industry value chain
Figure 3.11: Flow chart of value chain for the composites industry
Figure 3.12: Dollar ($) and gross profit flow chart through various nodes of the value chain (from raw material to end product)
Figure 3.13: Supply chain of composites industry
Chapter 4.Emerging Innovations in Composite Materials
Figure 4.1: Single-end roving
Figure 4.2: Multi-end roving
Figure 4.3: Chopped strand mat
Figure 4.4: Veil mat
Figure 4.5: Chopped strand
Figure 4.6: Fabrics
Figure 4.7: Woven roving
Figure 4.8: Recent glass fiber product launches towards high strength
Figure 4.9: Recent glass fiber product launches towards high modulus
Figure 4.10: Fiber glass direct roving from Johns Manville
Figure 4.11: 248A and PerforMax 249A short fiber application parts
Figure 4.12: Chopped strand reinforcements
Figure 4.13: Glass fiber products from AGY
Figure 4.14: Type 30â„¢ SE2307 single-end roving from Owens Corning
Figure 4.15: Recently launched glass fiber products by Owens Corning for automotive
Figure 4.16: Recently launched glass fiber products by Owens Corning for wind energy
Figure 4.17: Recently launched glass fiber products by Owens Corning for construction
and others
Figure 4.18: Some of the other glass fiber product launches (I)
Figure 4.19: Some of the other glass fiber product launches (II)
Figure 4.20: Some of the other glass fiber product launches for application (I)
Figure 4.21: Some of the other glass fiber product launches for application (II)
Figure 4.22: Different types of carbon fiber forms
Figure 4.23: Typical continuous carbon fiber
Figure 4.24: Typical chopped carbon fiber
Figure 4.25: Typical metal (nickel)-coated carbon fiber
Figure 4.26: Recent carbon fiber product launches directed towards high strength
Figure 4.27: Tensile modulus of a few carbon fiber products launched since last five
years
Figure 4.28: Carbon fiber structure
Figure 4.29: C-PLY â„¢ SPREAD from Chomarat
Figure 4.30: DIALEAD K13916 from Mitsubishi Plastics, Inc.
Figure 4.31: Some of the major carbon fiber product launches in automotive application
Figure 4.32: Some of the major carbon fiber product launches in automotive and
aerospace application
Figure 4.33: Future innovations towards improving tensile strength in natural fibers
Figure 4.34: Tensile strength of natural fiber products launched during 2009-2012
Figure 4.35: Future innovations to improve strength-to-stiffness ratio in natural fiber
Figure 4.36: Areas of innovation in natural fibers
Figure 4.37: Recent launches of continuous natural fibers and their properties
Figure 4.38: AmpliTex light fabric properties and their markets
Figure 4.39: Expected increase in usage of natural fibers in pultrusion and filament
winding processes in future
Figure 4.40: Natural fiber treatments methods
Figure 4.41: Study of viscosity of recently launched resins suggest more launches in low
viscosity resins during last six years
Figure 4.42: Dow VORAFORCETM 5300 epoxy resin from The Dow Chemical Company
Figure 4.43: Beyoneâ„¢ 1 resin for wind composites applications from DSM
Figure 4.44: Part developed with carbon fiber and epoxy resin
Figure 4.45: Profile and structure
Figure 4.46: EPIKOTE MGS RIMR 145 resin for wind turbine blade application from
Momentive Performance Materials Inc
Figure 4.47: Some of the other resin product launches (I)
Figure 4.48: Some of the other resin product launches (II)
Figure 4.49: Some of the resin product launches for applications (I)
Figure 4.50: Some of the resin product launches for applications (II)
Figure 4.51: Short fiber, long fiber, and continuous fiber
Figure 4.52: Classification of thermoplastic composite materials
Figure 4.53: Sheet molding compound from core molding technologies
Figure 4.54: SymTerra sheet molding compounds (SMC) that combine renewableresource
raw materials
Figure 4.55: Hyperion air handler made of SMC from CSP
Figure 4.56: The “Canopy LENS Antenna” uses molded BMC IB-2240 for its frontal
enclosure
Figure 4.57: LFT pellets
Figure 4.58: Some of the major compound materials product launches
Figure 4.59: Use of core materials in wind blade
Figure 4.60: Study of strength property for recent product launches in core materials
Figure 4.61: More core material product launches are concentrated in low density area
Figure 4.62: SAER foam from SAERTEX
Figure 4.63: ArmaFORM PET foam from Armacell
Figure 4.64: BALTEK® Banova lightweight panel from 3A Composites
Figure 4.65: ROHACELL®, PMI-based structural foam from Evonik
Figure 4.66: DOW Wind Energy
Figure 4.67: Some other major product launches of core materials (I)
Figure 4.68: Some other major product launches of core materials (II)
Figure 4.69: Some other major product launches of core materials (III)
Figure 4.70: Some other major product launches of core materials (IV)
Figure 4.71: Some other major product launches of core materials (V)
Chapter 5.Emerging Innovations in Composites Applications
Figure 5.1: Forecast of buy material market in global aerospace and defense industry in
B lbs. 2013-2025
Figure 5.2: Material dominance in aerospace industry
Figure 5.3: Composites usage in different Boeing models
Figure 5.4: Trends in materials usage
Figure 5.5: Aerospace market need and areas of innovation
Figure 5.6: Boeing's B787 improvements over B767
Figure 5.7: Aerospace industry expectations from composites
Figure 5.8: Aerospace industry trends
Figure 5.9: Increased usage of carbon composites in primary structures
Figure 5.10: Increasing composites usage in all current and future leading programs
Figure 5.11: Genx CFRP front fan blades and front fan case
Figure 5.12: Current innovations to meet aerospace industry expectations
Figure 5.13: Lockheed martin incorporated CNRP into F35 lightning II wingtip fairings
resulting in significant cost and weight reduction
Figure 5.14: Aerospace programs using automated material laying up techniques
Figure 5.15: Composites industry is shifting towards AFP and ATL processes
Figure 5.16: MAG's Gemini (combing AFP and ATL together)
Figure 5.17: GroFi platform- Multi-Lay-Up approach
Figure 5.18: Increasing focus towards Out-of-Autoclave
Figure 5.19: Boeing's different aircraft depicting reduced parts count
Figure 5.20: One piece fuselage of Boeing and HondaJet
Figure 5.21: Carbon fiber recycling as the innovation trend towards sustainability
Figure 5.22: Increasing need for recyclability of aircraft materials
Figure 5.23: Boeing's CFRP recycling
Figure 5.24: Forecast of buy materials market in automotive industry in million pounds
and material dominance in automotive industry
Figure 5.25: Automotive industry expectation from composites
Figure 5.26: Manufacturing expectation - low-cost precursor and processes for carbon
fiber
Figure 5.27: Industry putting efforts on alternative precursors and improvization in
manufacturing process to reach desired level of $5-$6/lbs
Figure 5.28: Manufacturing expectation - improvization of part manufacturing process
cycle time
Figure 5.29: Improvization in part manufacturing processes cycle time
Figure 5.30: HP RTM in mass produced vehicles
Figure 5.31: HP RTM process steps in detail
Figure 5.32: Partners of HP RTM process and fabricators using this process
Figure 5.33: Lamborghini - Callaway forged composites
Figure 5.34: Forged composite and RTM costs overview
Figure 5.35: Forged composite production rate improvements
Figure 5.36: Gurit SPRINT CBS
Figure 5.37: Comparison of vacuum bag process and press molding process cycle time
Figure 5.38: Electric vehicle made from Toho Tenax Technology
Figure 5.39: Manufacturing expectation - part consolidation or one piece design
Figure 5.40: Part Consolidation - one piece Monocoque
Figure 5.41: Few examples of one piece design
Figure 5.42: Monolithic design concept, a composites car door
Figure 5.43: Sustainability - recyclability of carbon composites
Figure 5.44: Recyclable CFRP composites in BMW I3
Figure 5.45: BMW's CFRP recycling technology
Figure 5.46: Sustainability - usage of natural fiber composites
Figure 5.47: Natural fiber composites in BMW I3
Figure 5.48: Cost reduction - inline compounding
Figure 5.49: Inline compounding system, such as D-LFT, D-GMT, and D-SMC
Figure 5.50: Forecast of buy materials market in wind energy industry in M lbs and
material dominance in wind energy industry
Figure 5.51: Wind energy industry expectations from composites
Figure 5.52: Manufacturing expectation (wind energy) - increased usage of carbon fiber
Figure 5.53: Increasing demand of weight reduction in longer wind blades is leading to
increased usage of carbon fiber
Figure 5.54: Industry focusing on higher MW size turbines and incorporating carbon fiber
for reducing blade weight and increasing energy output
Figure 5.55: Manufacturing expectation (wind energy) - monolithic design
Figure 5.56: Monolithic design -- Siemens B75 - world's largest fiberglass component
cast in one piece
Figure 5.57: Manufacturing expectation (wind energy) - seamless modular technology
Figure 5.58: Modular design -- blade dynamics using patented seamless modular
technology for ETI's* project of developing world's largest blades
Figure 5.59: Blade dynamics' D49 rotor blades for onshore using seamless modular
technology
Figure 5.60: Manufacturing expectation (wind energy) - Fibramatic automated lay-up
process
Figure 5.61: Automated manufacturing process Gamesa's Fibramatic automated lay-up
for 100% automated infusion wind blade
Figure 5.62: Construction industry expectations from composites
Figure 5.63: Manufacturing expectation (construction industry) - increasing usage of
polyurethane urethane composites
Figure 5.64: Increasing usage of polyurethane urethane composites
Figure 5.65: Manufacturing expectation (construction industry) - use of FRP in waterless
toilet system
Figure 5.66: Use of FRP in waterless toilet system
Figure 5.67: Sustainability (construction industry) - usage of natural fiber composites
Figure 5.68: Use of natural fiber composites in construction
Figure 5.69: Sustainability (construction industry) - reduce greenhouse gas emission
Figure 5.70: Need to reduce greenhouse gas emission
Figure 5.71: Major emerging trends in composites technologies
Chapter 6.Future Roadmap for Innovations in Composites Industry
Figure 6.1: Innovation megatrends in composites market
Figure 6.2: Megatrend towards achieving light-weighting
Figure 6.3: Future direction towards improving performance
Figure 6.4: Innovations directed towards price reduction
Figure 6.5: Increasing use of eco-friendly materials
Figure 6.6: Emergence of monolithic design

List of Tables

Chapter 2.Innovations Overview
Table 2.1: Key Emerging Innovations in Composite Materials
Chapter 3.Composites Industry Insights and Unmet Needs Analysis
Table 3.1: Global composites shipment by raw material type in 2013 (Source: Lucintel)
Table 3.2: Impact properties of some selected materials (I)
Table 3.3: Impact properties of some selected materials (II)
Table 3.4: Maximum continuous use temperatures for various thermoset and
thermoplastics
Chapter 4.Emerging Innovations in Composite Materials
Table 4.1: Lucintel's rating methodology
Table 4.2: Lucintel's innovation attractiveness rating of new glass fiber technology from
Johns Manville
Table 4.3: Lucintel's innovation attractiveness rating of ME1510 EP multi-end roving from
Owens Corning
Table 4.4: Lucintel's innovation attractiveness rating fiber glass roving from Owens
Corning
Table 4.5: Lucintel's innovation attractiveness rating of S-3 UHMâ„¢ glass fiber from AGY
Table 4.6: Lucintel's innovation attractiveness rating of type 30â„¢ SE2307 single-end
roving from Owens Corning
Table 4.7: Some more emerging innovations in glass fiber in 2014.
Table 4.8: Lucintel's innovation attractiveness rating of CFRP lasso from Nanjing Loyalty
Composite Equipment Manufacture Co. Ltd.
Table 4.9: Lucintel's innovation attractiveness rating of C-PLY â„¢ SPREAD from
Chomarat
Table 4.10: Lucintel's innovation attractiveness rating of DIALEAD K13916 from
Mitsubishi Plastics, Inc
Table 4.11: Lucintel's innovation attractiveness rating of Dow VORAFORCETM 5300
Epoxy resin from The Dow Chemical Company
Table 4.12: Lucintel's innovation attractiveness rating of Beyoneâ„¢ 1 resin for wind
composites applications from DSM
Table 4.13: Lucintel's innovation attractiveness rating of EPIKOTEâ„¢ resin 05475 and
EPIKUREâ„¢ curing agent 05500 system from Momentive Specialty Chemicals
Table 4.14: Lucintel's innovation attractiveness rating of Daron 220 resin from DSM
Table 4.15: Lucintel's innovation attractiveness rating of EPIKOTE MGS RIMR 145 resin
for wind turbine blade application from Momentive Performance Materials Inc.
Table 4.16: Some more emerging innovations in resin in 2014
Table 4.17: Lucintel's innovation attractiveness rating of sheet molding compound from
Core Molding Technologies
Table 4.18: Lucintel's innovation attractiveness rating of SymTerra® composites from
Premix

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