JEC Innovation Award 2018 in the category "Aerospace Process"For the development of a demonstrator with Ultrason as a foam core, as carrier for carbon-fiber laminates and overmolding material as well as the suitable production concept, a group from the research project "MAI Sandwich" won the JEC Innovation Award 2018 in the category "Aerospace Process." "MAI Sandwich" is part of the leading-edge cluster "MAI Carbon" which is promoted by the German Federal Ministry for Training and Research.The project was coordinated by the Chair of Carbon Composites at the Technical University of Munich, Germany. The other partners are Airbus, BASF, BMW, SGL Carbon, Foldcore, Neenah Gessner, New Materials Bayreuth and Werkzeugbau Siegfried Hofmann. The award-winning concept shows that long cycle times can be reduced drastically to five minutes for a panel of one to three square meters using the traditional production method. This result was possible due to the optimal interplay of the few materials used and the development of an innovative, fine-tuned production sequence that combines the three techniques of thermoforming, injection molding and fusion bonding in an automated facility.
Ultrason is the trade name for BASF's product range of polyethersulfone (Ultrason E), polysulfone (Ultrason S) and polyphenylsulfone (Ultrason P). It is used to manufacture lightweight components in the electronics, automobile and aerospace industries. The thermoplastic material can withstand high temperatures of up to 220°C without changing its characteristics, and shows extraordinary chemical resistance. The high-performance plastic is also used in water-filtration membranes and in components that come into contact with hot water and food. Because of their extraordinary property profile the Ultrason brands can substitute thermosets, metals and ceramics.