VIP-Visons in Plastics - Lamilux is creating a new driving force in the production of high quality composite materials for lightweight construction. The company is one of the first manufacturers of fiber-reinforced composites to successfully manufacture carbon-fiber-reinforced polymers (CFRP) in a continuous flat-conveyor production process, producing sheet widths of up to 3.20 meters. Its ability to manufacture 1.0 to 5.0 millimeter thick CFRP sheets and panels at an "attractive price", using large-scale industrial production methods, makes the German company unique in the world. "The relationship between the costs of procurement and the high design engineering value of CFRP in lightweight construction is particularly advantageous", asserts Stefan Bachstein, engineer and technical manager at Lamilux.

Lamilux has developed a new epoxy resin system especially for the new high-strength composite. It ensures a solid bond between the carbon fibers and the matrix resin, which results in a high-performance material with outstanding tensile strength. "The matrix resin absorbs the applied forces and transfers them to the reinforcing high-strength carbon fibers", Stefan Bachstein explains. It is worth making a comparison with other materials such as those used as face sheeting in the walls of truck bodies, for example: "CFRP face sheeting is 30 to 50 % lighter than face sheeting made of steel or aluminum and its tensile strength is three to four times higher".
During the continuous production process - using Lamilux's three highly automated production lines, each more than 100 meters in length - the carbon fibers can be worked into the material as a lattice or as plies with various grammages and with uni-, bi-, tri- or multi-directional fiber orientation. According to Stefan Bachstein: "We select the fiber orientation to suit the individual application and stability requirements".

The Material of the Future for Lightweight Construction
Each of the various production variants meets the requirements of lightweight construction by providing a lightweight yet extremely high-strength material. "Here we have a future-oriented material that will realize its potential in the construction of vehicle bodies, trailers and electric vehicles; for example in the form of sandwich elements", Bachstein says. Over the last few months, a large German food discount concern has been testing refrigerated trucks with trailers constructed using Lamilux's CFRP. In addition to low weight and high stability, the low thermal conductivity of the material also plays an important role here in ensuring optimum insulation of the trailer.

Sturdy, Light and Extremely Resilient
"Our material forms the face sheeting of the sandwich elements used for side walls", Stefan Bachstein notes. During manufacturing, the composite sheets for this application receive a sealing gel coating, similar to a varnish coating. "This protects the material from UV radiation, ensures excellent weather resistance and creates a superior glossy surface". With its new carbon-fiber-reinforced composite, in which all the RAL, NCS and customized shades can be incorporated directly during the production process, Lamilux now offers a finished end product that is ready for immediate use, is extremely stable and light, and is suitable for both indoor and outdoor applications.