Posted March 15, 2016
UXBRIDGE, England – Coats, one of the world’s leading industrial thread manufacturer, is launching Synergex, a range of advanced composite fibers that can be processed into fabric form and then used to mold strong but lightweight parts for industries including automotive and aerospace.
Synergex has high levels of hybrid fiber integrity and performance. It can be processed into fabric form using many technologies including commingling and twisting. The carbon and nylon commingled yarn delivers a perfect balance between strength, weight, performance and also recyclability. The composite fibers can be embroidered directly into complex shapes and the final composite parts can be metal pressed.
Produced in N.C.
Coats launches revolutionary composite technology
“This is a groundbreaking new product range that will revolutionize composite technology across a wide range of industries,” said Rajiv Sharma, Global CEO, Industrial, Coats. “Our pioneering thread and yarn expertise has created an innovative product that can accelerate current manufacturing processes. It provides a simple solution for complex forms.”
The Synergex range has been developed by Coats Speciality using its state-of-the-art carbon room at its Sevier site in North Carolina. It is dedicated to developing high-performance composite constructions. From carbon processing units to aramid converting lines and fiberglass processing equipment, it is able to commingle and twist carbon fibers and various thermoplastic fibers. This enables the manufacture of flexible thermoplastic prepegs that produce advanced thermoplastic parts for the wind, automotive, aerospace and sporting goods sectors.
Partnership with Elemental Group
Coats recently announced its partnership with Elemental Group Ltd in the creation and development of the forthcoming Rp1’s sports car wheel arch, which features Synergex. The wheel arch is made in four steps. The carbon fiber and nylon are woven together to create a single commingled yarn. The yarn is then embroidered into shape using a Tailored Fiber Placement (TFP) preforming process.
Once the shape is precisely stitched, it is then placed in the machine mold and pressed to form the wheel arch. The parts can be finished to a high standard without the need to use resins or autoclave.
“Choosing a material for the Rp1’s wheel arch presented a few challenges as it had to be lightweight, extremely robust and flexible to achieve the complex shape of the part,” said Peter Kent, Composites director, Elemental. “The properties of Synergex ticked all the boxes.”
Source: Coats