How Hexcel's latest innovations are paving the way for composite advancement

Backed by decades of innovation, Hexcel develops and manufactures innovative lightweight composite material solutions for key sectors, including aerospace, defence and automotive

As Chuck Cadena, VP global corporate & marketing communications, explains: “The key engine behind our business is R&D. In aerospace, our strong, lightweight materials address many issues for customers by providing the benefits of lower emissions, greater range, less fuel consumption. It’s not just the product itself, but the manufacturing processes and technologies as well.”

Hexcel’s diverse portfolio of lightweight material solutions spans high-performance carbon fibres, multi-weave fabrics, prepegs, resins, film adhesives, scalable thermoplastic solutions and more. International Design Engineer caught up with Cadena and other Hexcel experts at JEC World to find out how the company’s recent innovations and demonstrators are benefitting the commercial aerospace, defence and automotive markets.

CUTTING-EDGE PREPEG FOR HIGH-RATE PRESS MOULDING

HexPly M51 is a new, rapid-curing prepeg specifically designed for the high-rate production of primary structural composite parts using hot-in/hot-out press curing. According to marketing Matrix manager Europe Pauline de Cuttoli, the product delivers an optimal balance of speed, efficiency and performance for aerospace applications.

“M51 was developed to achieve high performance with a short cure cycle,” she explains. “The key benefit of this product is that it delivers the same performance whatever cure process is used. With M51, there is no compromise; it delivers speed, flexibility and performance.”

With a rapid cure cycle of 40 minutes at 180°C, HexPly M51 significantly reduces production time and cost. This is particularly important when considering the predicted increase in manufacturing rate of single-aisle aircraft by manufacturers such as Airbus and Boeing, Cadena explains: “The production rates of wide-body aircraft such as the A350 – the structure of which is made up of around 50% composite materials – are very low compared to single-aisle aircraft. The rate at which Airbus and Boeing are going to produce single-aisle aircraft is going to be much higher, so manufacturing composites more quickly is very important. The technology needs to meet the manufacturing profile.”

HexPly M51’s versatility also extends to other sectors requiring high-rate composite manufacturing, such as automated tape laying (ATL), automated fibre placement (AFP) and pick-and-place processes.

NEXT-GENERATION COSMETIC PREPEG FOR AUTOMOTIVE

For the automotive sector, HexPly M949 is a toughened, rapid-curing epoxy prepeg for high-quality carbon-look surfaces. Suitable for both press and autoclave, it is designed to deliver exceptional surface finish and high thermal resistance.

“Right now, circularity is key for the composite industry,” says Javier Munoz, group product manager industrial at Hexcel. “In M949, 15% of the carbon content in the resin comes from bio-based sources. We take carbon fibre that would otherwise be deposited in landfill and transform it into a prepeg that our customers can use to make automotive parts. The prepeg provides the same functionality, and the cosmetic aspect is even better than with traditional wovens.”

Hexcel’s recycled carbon fibre (rCF) prepeg range illustrates the company’s commitment to developing more sustainable composite solutions that lower carbon footprint and reduce landfill waste. “This is the first step, and in the future we will be launching more products with increasing recycled carbon fibre content and with higher performance,” Munoz adds.

INNOVATIVE TEXTILE FOR COMPLEX SHAPES

HexShape was developed with high design flexibility in mind, enhancing composite manufacturing with advanced woven net-shape fabrics engineered for complex 3D geometries. By integrating the final shape directly into the textile stage, HexShape simplifies production, reduces material waste and improves structural performance.

“The key benefit for customers is the ability to automate the process,” explains Béatrice Flageul, marketing reinforcements manager Europe. “With the continuous-fibre architecture, there is no weak point and less scrap. HexShape is ideal for complex shapes within commercial aerospace engines, for instance, fighter jets and missiles.”

HexShape ensures optimised mechanical properties, uniform fibre distribution and strong dimensional stability across complex shapes. Available in carbon, glass or quartz fibres with multiple weaving styles, HexShape is compatible with infusion, RTM and prepeg processes.

THERMOPLASTIC COMPOSITE STRUCTURAL SOLUTIONS

The Hexcel booth also showcased several examples of advanced thermoplastic composite structural components developed with its various industrial partners. Hutchinson and ATC developed an engineered U-shape structural profile based on Hexcel’s HexPly PEKK/IM7 thermoplastic which delivered increased stiffness and strength for structural applications. In parallel, ATC has also produced an Omega stringer up to 10 metres in length using a continuous compression moulding (CCM) process. The solution is compatible with welding technologies and supports the future integration of stiffeners in aircraft fuselage panels.

“We’re demonstrating the increased maturity of the processes we use for thermoplastics,” says Nathalie Schmitz, business development manager at Hexcel. “Thermoplastics are ideal for high-rate applications with short consolidation time. Our demonstrators highlight the potential of high-performance thermoplastic composites and show how fast and automated continuous processing technologies can be for long structural parts.”

THERMOSET FOR FILAMENT WINDING

Also on display at Hexcel’s booth was the company’s new hot melt Towpreg range which combines the performance benefits of Hexcel’s intermediate modulus carbon fibres with its expertise in epoxy resins and processing development. Manufacturing in partnership with Rimac Machines, Towpreg delivers precise resin content due to a novel impregnation process. The process enables faster processing compared with conventional wet winding, and also reduces machine cleaning and downtime.

Towpreg is suited to use in high-performance electric motors, as the hoop strength achieved in the carbon sleeve allows for higher rotational speeds. Towpreg can also be used in high-performance filament winding applications like high-pressure vessels.

STIFFER, STRONGER, LIGHTER CARBON FIBRE

Hexcel also highlighted the latest generation of its HexTow range, the HexTow IM11-R carbon fibre. Designed for advanced aerospace and industrial composite applications, the carbon fibre combines high strength, lightweight, superior stiffness, electrical conductivity, low thermal expansion, high thermal conductivity and corrosion resistance.

HexTow IM11-R offers excellent processability, ensuring near-perfect transfer of its mechanical properties to the overwrap vessel, and features a proprietary R-type sizing optimised for efficient winding. Benefits such as burst pressure capability, improved drop resistance and enhanced overall reliability allow for higher operating pressures, increased payload capacity and greater safety margins in demanding aerospace and space environments.

BREAKTHROUGH COMPOSITE SOLUTIONS

Hexcel’s suite of next-generation composite products and technologies underpin its role as a key partner for commercial aerospace, defence, space and automotive markets. The company promotes a partnership-driven approach to composite manufacturing, working with industrial partners across the supply chain to help build a robust circular economy. Hexcel also actively engages with industry associations and universities to support its R&D efforts and continue the advancement of composite technologies and manufacturing processes.