How composites changed the game for the Talent train

The challenge of creating lighter, more efficient trains without sacrificing strength has long been a focus for the rail industry. In this article professor Eric Moussiaux , vice president of technology at Exel Composites, explains how the Talent train project—a regional train developed by Talbot in Germany—used innovative composite materials to overcome these challenges, setting a new standard in train design while proving the long-lasting performance of composites.?

It was a Friday, the 13th of December 1996. I walked into the office at Exel Composites, then Bekaert Composites, and immediately heard the rhythmic hum of the fax machine. Page after page started pouring out, with drawings, tables, and numbers. The sender? Anton Lügering, my friend and partner from Techno-Composites. What we were looking at was a groundbreaking opportunity.?

Talbot, a train manufacturer in Aachen, Germany, had just been acquired by Bombardier. They were developing a new regional train called the Talent, and their vision was audacious: they wanted to build the entire outer body shell from composite materials. No one had attempted something like this before in the rail industry, but it was exactly the type of challenge we had been waiting for.?

At the heart of the project was a vision: to build a lightweight regional train, one that could serve as a faster, more efficient mode of transport. But achieving this meant breaking away from the traditional materials—steel and aluminum—that had long been the go-to options for train manufacturing.?

But the Talent project presented a different path.?

Over that weekend, Anton and I huddled together, pouring over Talbot’s specifications. We were determined to prove that composites—long valued for their lightweight properties—could also deliver the strength and durability required for modern trains. The stakes were high and the timeline tight: Talbot needed the new Talent train on the tracks in just 15 months.?

Innovation that redefined train manufacturing?

By May 1997—less than six months after that initial fax—we delivered our first prototypes to Talbot. The pultruded profiles we developed were innovative, strong, and light. Along with molded panels in between the windows, these materials would go on to form the exterior of the Talent train.??

One of the most exciting aspects of this project was the adhesive bonding of composite body shells to an aluminum structure—an entirely new approach for the rail industry at the time. Despite the challenges of meeting unclear fire regulations for composites, our team found the right chemistry, both technically and in our collaboration with Techno-Composites and Talbot.??

The final profiles were manufactured with pultrusion in Exel’s Oudenaarde factory in Belgium while Techno-Composites, based in Haselünne, Germany, took care of the machining, bonding, painting and kitting of the profiles into ready to be installed parts that were delivered to Talbot’s Aachen factory.?

Fast forward to March 13, 1998. I stood among a crowd of hundreds in Aachen, Germany, for the roll-out of the first Talent train. As it emerged, gleaming in bright red, the sense of accomplishment was palpable. This wasn’t just another train—it was a testament to what happens when engineers, designers, and materials experts come together with a shared vision for the future. The Talent was a beauty, an innovation that had taken risks and delivered results.?

For over a decade, more than 800 Talent trains rolled out of the factory, splitting evenly between diesel and electric engines. These trains, running throughout German-speaking Europe and even in the harsh conditions of Norway and Canada, proved the long-term viability of composites. Beyond being lightweight, composite profiles offered something steel couldn’t— flexibility, precision and stability in manufacturing. With composites, we achieved tighter tolerances and better shape stability, reducing production costs and assembly time.?

The legacy: composites prove their long-lasting performance?

However, as the rail industry evolved, so too did the demands. By 2006, the successor to the Talent—Talent 2—would return to steel for its frame, as the longer-distance trains required higher speeds and could handle the additional weight of features like roof-mounted air-conditioning units. But the legacy of the original Talent lives on, its composite sidewalls still as sleek and strong as ever, even after almost decades of service.?

In 2014, just before her retirement, Annemarie Kwade, head of Talbot’s buying team, reflected on what we had accomplished together. "These Talent trains still look as good as they did on day one," she said, a testament to the durability and reliability of composites. Ten years later, in May 2024, I had the pleasure to meet Mrs Kwade again in Germany, also joined by Gerrit Mann, current owner and managing director of Techno-Composites.

As we watched those same Talent trains glide into the Weisweiler station every 15 minutes, it was clear that the decision to work together and embrace composites had been the right one. There was no sign of the typical bruised look of old metal train-sides. Moreover, Mrs Kwade explained that the Talent customers have found the composite sidewalls easy to repair with no need for spare parts.?

Composites: the future of sustainable rail transport?

The greatest potential for composite materials is in the outer bodies of trams and regional trains. In this sector, lightweight construction is crucial due to the frequent starts and stops. While weight reduction used to be primarily a matter of operational costs, today it is a central factor in achieving a lower carbon footprint in public transport.?

The story of the Talent train is more than just a technical success—it’s a symbol of how far we can push the boundaries of materials science to create something truly innovative. As cities and regions strive to reduce their carbon footprints and meet growing transportation demands, the role of composites will only become more critical.??

At Exel Composites, we’re proud to be part of this journey, proving that with the right materials, there’s no need to compromise between efficiency and strength.?

Learn more about this story by watching the interview below by Eric Moussiaux ad Gerrit Mann.

To discover how Exel continues to lead in pultruded composite solutions for the railway industry, visit here.