NORTH CAROLINA – Technical apparel fabrics manufacturer Coats has launched a new range of ‘Synergex’ carbon–nylon composite fibres for application in the automotive and aerospace sectors, in a development which claims to provide the “perfect balance between strength, weight, and performance” without the need for resins or autoclave processing machines. 

To manufacture Synergex fibres, carbon fibre and nylon polymers are woven to create a “single commingled yarn”. This is then embroidered into shape using a tailored fibre placement (TFP) pre-forming process – a composite manufacturing technique based on sewing a continuous placement of fibrous material. 

Once the shape is stitched, it is then placed in a machine mould and pressed to form an item part. Coats says these parts can be finished to a high standard without the need to use resins or autoclave processing machines.  

This technique has been developed at Coats’ high performance carbon facility in North Carolina, US. 

Rajiv Sharma, CEO of Coats said: “This is a ground breaking new product range which will revolutionise composite technology across a wide range of industries. Our thread and yarn expertise has created an innovative product that can accelerate current manufacturing processes. It provides a simple solution for complex forms.”   

The manufacturing process for Synergex, which was demonstrated at this week’s JEC World composites exhibition in Paris, was put to use in a recently announced manufacturing partnership with New Zealand-based automotive parts manufacturer Elemental Group, in a move saw the development of a Synergex wheel arch for company’s ‘RP1’ sports car range. 

Speaking about the partnership, Peter Kent, composites director at Elemental Group said: “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. The properties of Synergex ticked all these boxes.” 

Web: www.coats.com