Manufacturing of Composite Materials

Manufacturing of Composite Materials-Carbon Fiber Composites and Glass Fiber Composites. Investment Opportunities for Entrepreneurs to Start Own Business.

A composite material consists of a minimum of two materials, which combine to offer properties superior to those of the individual constituents. A composite material (also called a composition material or shortened to composite, which is that the common name) may be a material which is produced from two or more constituent materials. These constituent materials have notably dissimilar chemical or physical properties and are merged to make a material with properties unlike the individual elements. Within the finished structure, the individual elements remain separate and distinct, distinguishing composites from mixtures and solid solutions.

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Typical Engineered Composite Materials Include:

Reinforced concrete and masonry

Composite wood such as plywood

Reinforced plastics, such as Fibre-reinforced polymer or fiberglass

Ceramic matrix composites (composite ceramic and metal matrices)

Metal matrix composites

Other advanced composite materials

There are various reasons where new material can be flavoured. Typical examples include materials which are less expensive, lighter or stronger when related to common materials.

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Types of Composites

Particulate composites

Flake composites

Fiber composites

Nano composites

Classification of Certain Materials as a Composite:

1. Combination of materials should result in significant property changes

2. Content of the constituent’s constituents is generally more than 10 %

3. In general, property of one constituent is much greater ( ≥ 5) than the other

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Why Use Composites?

The primary reason composite materials are chosen for components is because of weight saving for its relative stiffness and strength. For example, carbon-fibre reinforced composite can be five times stronger than 1020 grade steel while having only one fifth of the weight. Aluminium (6061 grade) is much nearer in weight to carbon-Fibre composite, though still somewhat heavier, but the composite can have twice the modulus and up to seven times the strength.

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Where are Composites Used

Today thermoset composites are used in a wide range of industries including:

Aerospace

Thermoset composites are being specified for wings, fuselages, bulkheads, and other applications in commercial, civilian and military aerospace applications.

Appliance/Business

Thermoset composite are being used in frames, equipment panels, handles and trims in appliances, power tools, business equipment and many other applications.

Thermoset composites for the appliance industry are used in washers, dryers, refrigerators, freezers, ranges, ovens, dishwashers for components that include control panels, handles, knobs, vent trims, side trims, motor housings, kick plates and many others.

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Automotive/Transportation/Farm/Construction

Composites are now being used in vehicle and equipment applications, including, panels, frames, interior components and other parts.

Civil Infrastructure

Some composite infrastructure applications include buildings, roads, bridges and pilings.

Construction

Thermoset composites are replacing many traditional materials for home and offices architectural components including fixtures, doors, wall panels, roofing, window frames, moulding, vanity sinks, shower stalls and even swimming pools.

Corrosive Environments.

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Composites are ideal for applications in corrosive environments, such as chemical processing plants, pulp and paper converting, oil and gas refineries and water treatment facilities.?Common applications include fans, grating, tanks, ducts, hoods, pumps and cabinets.

Electrical

With strong dielectric properties including arc and track resistance, Thermoset components include substation equipment, microwave antennas, standoffs and pole line hardware and printed wiring boards. Applications and components include switchgear, motor controls, standoff insulators, control system components, circuit breakers, arc chutes, arc shields, terminal blocks, terminal boards, metering devices, bus supports and lighting components.

Marine

With their corrosion resistance and light-weighting attributes, Marine composite applications include boat hulls, bulkheads and other components for military, commercial and recreational boats and ships.

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The Composites Market Can Be Divided Into The Following Industry Categories:

1. Aerospace,

2. automotive,

3. Construction,

4. Marine,

5. Corrosion resistant equipment,

6. Consumer products, appliance/business equipment

7. Others. The range of materials can be classified into the categories: (2) Metals, Polymers, Ceramics and Inorganic glasses and Composites.

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Composite Applications Sectors

Aerospace

Automotive & Road Transportation

Building & Civil Engineering

Defence, Security & Ballistics

Design, Furniture and Home

Electrical, Electronics, Telecoms & Appliances

Equipment and Machinery

Marine transportation & Shipbuilding

Medical & Prosthetics

Oil & Gas

Other Composite End-use areas

Pipe & Tanks, Water treatment and sewage

Railway Vehicles & Infrastructure

Renewable Energy

Sports, Leisure & Recreation

Market Outlook

The global composites market size is projected to grow from USD 74.0 billion in 2020 to USD 112.8 billion by 2025, at a CAGR of 8.8%. The composites industry is growing due to the rise in demand for high performance materials, globally. The major factors driving the market is the increasing technological advancements in the field of material science However, high cost of composite materials is hindering the growth.

Another major factor driving the market studied is emerging use of 3D printing with composites. North America accounts for the very best market share and is predicted to dominate the market during the forecast period. Over the past years there are variety of changes within the application areas for carbon fiber. Aerospace & defense applications have grown significantly and are now the most important consumers of carbon fiber. The increasing demand for electric vehicles in countries like China and us is additionally a serious driving factor for the demand for composite material.

Global composite materials market is expected to witness steady growth over the forecast period owing to increasing use in industries including construction, marine, pipe & tank, electrical & electronics, automobiles, and energy. Rising lightweight material demand in aerospace industry is expected to drive the market. Application industry growth including aerospace, construction, and transport is expected to further drive composite materials market demand. Superior properties of composites including corrosion resistance, low maintenance, high strength, and longevity as compared to other conventional materials such as steel and aluminum are anticipated to fuel the market growth over the next seven years.

However, uncertain raw material availability resulting in high cost is expected to hamper the market growth. Technological advancements in orthopedic surgery including prosthetics are expected to create growth opportunities over the forecast period. Growing popularity and acceptance of fiber-reinforced polymer composites in various industries including construction, marine, and wind energy owing to low maintenance costs and high durability is anticipated to propel the market demand for composite materials over the next few years.

Global Composite Materials Market for Automotive: Growth Factors

Government support for fuel efficiency and increasing demand for fuel-efficient vehicles boost the global composite materials market for automotive in the near future. Major original equipment manufacturers (OEMs) are getting associated with composite material manufacturers, which is expected to boost the global market growth. Growing automotive industries also fuel the global market owing to automotive interiors such as seat covers, door panel, and steering wheel, dashboard, and so on made of composite material. Composite materials are accepted by many automotive industries for safety standards and are anticipated to show significant growth in the market in future.

Natural fiber-reinforced plastic composite is majorly preferred for automotive interiors due to varied applications such as gear knobs, flooring, seat trims, and others. However, carbon fiber-reinforced plastic (CFRP) is prominently used in the sports and luxury vehicles for automotive interiors and dashboards. It possesses high appearance and strength-to-weight ratio; this is anticipated to fuel market growth in future.

Based on application, the automotive composite materials market can be divided into interior and exterior. The exterior components of the vehicle such as bonnet, side valences, bumper, chassis, and front fascia are made from composite material. Similarly, composite materials are utilized in several interior components of the vehicle such as inner deck lid, front end carrier, under the hood applications, truck box tail gate for pickup trucks, and top sleeper in trucks. Composites possess remarkable properties such as high strength, stiffness, modulus, and are proven materials for providing high crashworthiness. These properties of composite materials are expected to provide lucrative opportunities for the exterior segment in the automotive composite material market during the forecast period.

Industry Trends

Carbon Fibre Composites Market size was worth over $16 billion in 2016 and its demand is projected to cross 290 kilo tons in 2024. Increasing adoption in aerospace and automotive sectors will primarily drive the industry from 2017 to 2024. The proliferating demand from developed regions including Europe and North America will escalate the overall revenue generation. This can be credited to rising need of immediate supply of carbon Fibre, the U.S. export controls have resulted in considerable vertical integration across the globe, fostering the carbon Fibre composites market till 2024.

Regular innovations have led to reduction in process and cycle time that has resulted in significant fall of overall processing cost. Increasing demand for lightweight and high-performance composites owing to stringent regulations and safety concerns will lead to huge growth potential for carbon Fibre composites market share over the next eight years. These products offer enhanced stability at extreme temperatures and durability that will further impact the industry growth positively. However, fluctuations in prices of raw materials may hamper the product demand.

Increasing usage in aerospace industry for interior & exterior aircraft structures owing to their high-end performance and superior strength will increase product demand. Compliance with the mandatory environmental standards is another factor positively influencing the overall carbon fiber composites market from 2017 to 2024.

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Key Players:-

Ahlstrom Munksjo Fibercomposites India Pvt. Ltd.

Chevron Glassfibre Reinforcements Ltd.

Cosmos Fibre Glass Ltd.

Everlast Composites Pvt. Ltd.

Goa Glass Fibre Ltd.

Hindoostan Technical Fabrics Ltd.

Ineos Styrolution India Ltd.

Jushi India Pvt. Ltd.

Magnus Composites Synergies Pvt. Ltd.

Owens Corning Inds. (India) Pvt. Ltd.

Teijin India Pvt. Ltd.

U P Twiga Fiberglass Ltd.

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