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    eVTOLs: Making the Alliance Stronger Between Composites and Mobility

    According to a recent report on eVTOLS by Stratview Research, yearly eVTOL production volumes would reach 5,000+ units by 2028, generating a demand for ~7.4 million kilograms of composite materials around the same time.

    Published: 15 Jul 2023

    If we do a quick recap of the top-tier international composite and aviation-related trade shows in 2022, we can easily conclude that eVTOLs stood out to be among the most talked-about innovations throughout those events. And though they’ve been the industry’s favorite thing to write about for a long time now, the fact that we are now able to see several of those full-scale demonstrators in a single event just gives us a really good idea about how close the anticipated Advanced Air Mobility(AAM) revolution is. eVTOLs will be one exciting paradigm shift to witness in the mobility industry and according to the claims being made by the leading eVTOL OEMs, a few handpicked cities (cities with high traffic congestion and a supporting UAM infrastructure like Los Angeles, Miami, etc.) might be witnessing hundreds of them as soon as 2025. Since it’s mobility that we are talking about and that too, electrically powered; lightweighting has to be among the key design requirements, and considering the formidable alliance that lightweighting has with advanced materials and composites, the eVTOL industry will be among the huge demand generators for composite materials in no time. Composites Taking it to the Skies with eVTOLs: According to a recent report on eVTOLS by Stratview Research, yearly eVTOL production volumes would reach 5,000+ units by 2028, generating a demand for ~7.4 million kilograms of composite materials around the same time. Taking into account, the potential changes in the cost of carbon fibre, and resin, the demand thus generated in the year 2028 for composite materials, by the eVTOL industry is estimated to be worth $517 million in value. Fig. 1: eVTOL units manufactured annually & Corresponding composite material demand (2024-2028) What must be noted here is, as per the disclosed information, Joby is running at least one step ahead of others in the certification race since it has already received the Means of Compliance from the FAA, and still has a commercialization target of 2025. On the other hand, some OEMs still don’t have their certification basis confirmed with the concerning regulatory authorities, which is the step before receiving the means of compliance; and yet they are planning to start commercialized operations in 2024. But, regardless of the year of entry into service, the demand for composite materials from the eVTOL industry will more than double every year during the initial 2-3 years of commercialization and it will happen primarily because of two factors. All leading eVTOL OEMs are planning to scale their manufacturing volumes very rapidly, by a factor >2x every year, once they receive a nod from the regulatory authorities. Though tentative, many leading OEMs have several hundreds of pre-orders in their respective order books. Another factor contributing to the high demand for composite materials from this industry is the high penetration as compared to its allies in the transportation industry. For instance, the pioneers of composites usage in aircraft, namely the Boeing 787 and Airbus A350 XWB, are both ~50% composites by weight. For light vehicles, the percentage is generally <15% and for eVTOLs, even the lower range is higher than the higher range of other industries, i.e., 70%, and for some programs, it can go as high as >90%. Some major applications of composites in eVTOLs are shown in the figure below. Fig. 2: Major applications of composites in eVTOLs Structures and propulsion systems combinedly will consume about 75-80% of the composite materials used in these aircraft, with interior applications like floor panels, beams, etc. being second in line with an approximate share of 12-14%. The remaining share will belong to avionics and other smaller applications. It’s no wonder that the cost breakdown for the manufacturing of eVTOLs, as suggested by leading OEMs, also follows a similar distribution. For example, according to the estimates by Vertical Aerospace, 40% of the manufacturing cost will be spent on battery and propulsion systems, followed by another 30% being spent on structures and interiors. Avionics will account for ~20% of the manufacturing cost and the rest will be the cost of assembly.

    Innovations Drive Improved Orthopedic Prosthetic Implants

    Mobility is one of the fundamental requirements for any human. Accidents can be avoided, but conditions such as inflammatory diseases, degeneration of bones, and the many bone issues that come with aging are inevitable. It is quite clear that in the coming years, the population using prostheses will continue to rise. Orthopedic prosthetic implants are utilized either to replace a damaged body part enabling proper functioning with improved strength, or to make an available fixation point of bone to hold the implant.

    Published: 01 Jul 2023

    The first ever bone plate that was implanted in a human body is reported to be in the 1560s, centuries before the advent of anesthesia. Since then, there has been no looking back in the implants sector, and further upgrades in medical inventions have led the way to the development of orthopedic prosthetic implants. Orthopedic prosthetic implants are utilized either to replace a damaged body part enabling proper functioning with improved strength, or to make an available fixation point of bone to hold the implant. Each year, more than 500,000 patients globally suffer a spinal cord injury for reasons ranging from sports-related trauma and road accidents to increasing incidences of spondylolisthesis and disc degenerative conditions, and more, according to the National Center for Biotechnology Information. These incidents lead to severe health conditions, and in some cases, a patient can even be confined to a wheelchair. In many cases, orthopedic prosthetic implants can enable such patients to get regain their mobility. Artificial limbs, spinal fusion, joint replacement, and plates and screws are a few orthopedic prosthetic implants in use today. Although these implants don’t create a new life, they surely improve the quality of life, allowing patients to live without the discomfort that chronic pain, deformities, or injuries bring. Types of Prosthetic Implants and their Uses Orthopedic implants can be permanent, such as replacements of knees, ankles, shoulders, and hips, or temporary, such as screws, pins, and plates, which are used for inserting and fixing implants in the correct position of the body. The most common types of orthopedic prosthetic implants are screws, plates, and prostheses. Table 1. The five basic types of orthopedic plates. Screws. They look similar to the ones found at any hardware store and also serve the same purpose. The screws used during implant surgeries tighten the damaged areas, produce compression, and repair a fractured bone. Plates. In the 1880s, orthopedic plates were used to fix long bone fractures, and since then, these plates have been and remain a successful treatment for fractures or reconstruction. Plates should have a proper thickness, width, and length to hold and support both sides of the fractured bones. There are five basic types of orthopedic plates (see Table 1). Prostheses. Artificial body parts that are used to replace affected areas are counted under prostheses. In some cases, prosthetic materials added with a healthy bone are used to replace any spoiled or damaged bone.

    Below-Grade Waterproofing Market, Having a Strong Growth Foundation

    The below-grade waterproofing market is expected to contract by near 14% in 2020 and then rebound impressively to reach a market size of US$ 1.45 bn by 2025.

    Published: 24 Jun 2020

    One of the most critical elements that decide the life of any structure is the quality and extent of its waterproofing. Though a waterproofing system typically amounts to less than 1% of the total construction cost, it plays a critical role in ensuring the quality and longevity of the structure. Poor focus on waterproofing of a structure can significantly undermine the expenditure incurred on every other aspect of the building. The role played by below-grade waterproofing is even more critical due to the complex infrastructure of modern cities, the time and disruption caused by maintenance and repair far supersede the cost involved in applying below-grade waterproofing. Because of such challenges, it becomes more significant when compared with above-grade, and also because they are exposed to the withering forces of water and corrosion for prolonged periods and with greater intensity. Below-grade waterproofing systems are popularly used in the public infrastructure and construction sector for structures, such as basement slabs, foundations walls, planters, tunnels, bridges, sidewalk vaults, elevator pits, plaza decks, split slabs, sub-structures, and drainage systems. They are an integral part of almost every structure. The global waterproofing market was estimated at around US$ 8.0 billion in 2019, and out of which below-grade waterproofing accounted for a 15% share. The share is expected to increase as more complex structures are the need of the day. Diving Deeper into the Below-Grade Waterproofing Market The touchstone of excellent below-grade waterproofing material is the set of qualities such as- uniform thickness, flexibility, being able to resist the constant hydrostatic pressure, chemical erosion, especially under high groundwater conditions and have a low absorption rate to protect the structures. It is through membranes, that below-grade waterproofing is done. They are subsumed under two categories- Sheet-Based Membrane and Liquid-Coated Membrane. Material: Sheet-based membranes are made of Polymers, Bentonite, and Rubberized Asphalt. Liquid-coated membranes, on the other hand, are made using Bitumen and Cementitious materials. Market Share: Sheet-Based Membranes are more popular with around two-thirds of the share owing to properties like robustness, self-reinforcement, and controlled thickness; there is no need for mixing or specialized equipment either. Growth: Increasing usage of breathable waterproofing membranes and environmentally safe materials are driving the growth of sheet-based below-grade waterproofing market. The selection of the type of sheet and its materials depends on a wide array of factors such as site and soil conditions, water table information, service life, total cost of ownership, and the construction process. Here is a quick material-based analysis: Polymers Largest material segment due to advantages such as lightweight, flexibility, high efficiency, and environmental safety. HDPE (High-density polyethylene), PVC (Polyvinyl chloride), and TPO (Thermoplastic olefin) are the main polymers. Bitumen Is the second largest segment and is highly popular in Europe.          Bentonite-based It is a fast emerging popular material with unique absorbent properties. Sodium bentonite is most commonly used in blind-side waterproofing systems.                                                                   Hybrid Development began with bentonite being combined with HDPE and thermoplastics to obtain high-performance membranes. The failure of Styrene-Butadiene-Styrene (SBS) and Atactic Polypropylene Plastomeric (APP) bitumen to act as a water barrier, led to the development of hybrid membranes. There are four ways in which below-grade waterproofing can be applied and they are: Fluid-Applied: Covered around less than half of the market in 2019, due to high affordability and use of Bitumen. There are three ways in which fluid-application is done: Spray-Applied, Cold-Applied, and Hot-Applied. Self-Adhered: Impressive growth of this segment is due to the qualities like controlled thickness, excellent reliability, excellent chemical resistance, no VOCs, and high crack coverage. Fully bonded: Highly suitable for basement waterproofing as they come in 1-2 meter wide rolls and bond with concrete to prevent lateral water underflow and migration. Loose-laid: Are easy to install and are economical. The Steady and Impressive Growth Dynamics The COVID-19 crisis has upended every industry, without exception. But our estimates foretell a sanguine picture of growth which is expected to rebound in 2021, after a period of growth hiatus in 2020. The below-grade waterproofing market is expected to contract by near 14% in 2020 and then rebound impressively to reach a market size of US$ 1.45 bn by 2025.

    Leaf Spring - An Emerging Application in Automotive Composites

    Earlier, the forte of steel, the Leaf Springs now have caught hold of attention of the composites industry. Composite leaf spring occupies a miniscule share of the total leaf springs market, but its market is growing impressively to reach over USD 90 million by 2024.

    Published: 31 Jan 2020

    Composites are Engineers Best Friends! This post is the first in the series of Stratview Research’s articles on “Attractive Composite Applications”. Well, it’s not only the humans who are on a diet today. Transportation industry, which is the backbone of the global economy, has been fasting rigorously for the past few years now. The vehicles are being put on diet with the governments across the globe pressing for improvement in fuel efficiency. The regulations like CAFE (Corporate Average Fuel Economy) have set the benchmark of emissions across the world. The world today is serious about its commitment to reduce emissions. Composites are apparently one of the favourite ingredients in the automotive industry’s high-strength diet plan. Composite was used in cars like the Chevrolet Corvette, as early as the 1950s; seven decades hence the penetration of composites remains quite low. But a lot has changed with time and we have come to a point in time where the speed of change is much higher than ever before.  The coming decade seems to hold the key to composites. Automotive industry is now one of the leading consumers of composites with the annual demand of composite materials to reach over $15.5 billion by the year 2024. (Source – Automotive Composites Market Study) Composites now find usage in all the major application areas in an automobile including the interior, exterior, and under the hood applications. Here is the sneak peek of the composite applications in a car. We are bringing an exclusive white paper on automotive composites market for our readers soon. Like & follow our page for updates. Composites Usage Spring up in Leaf Springs Composites are spreading their wings by adding new applications under their ambit. Earlier, the forte of steel, the Leaf Springs now have caught hold of attention of the composites industry. The earliest automotive application of spring finds its origin in Roman ingenuity. They used leaf springs to dampen the shocks to their chariots; or possibly even before it, in the fabled chariots of Egyptian demigod Tutankhamun. Owing to their capacity to bear massive weights, leaf springs have become an inalienable part of the transportation industry. Leaf springs can be categorised as; Parabolic leaf spring and Multi-leaf leaf springs. Parabolic leaf spring is a single leaf spring, mostly used in the front axle, but the adaptation at the rear side has been seen recently. Multi-leaf spring has a set of leafs one on top of the other, they can support greater loads compared to the mono-leaf springs and provide higher spring rates with lesser rates for rebounds which is useful in supporting and controlling a vehicle’s axle wrap-up. Nearly two-thirds of the vehicles have multi-leaf leaf springs installed on them, as per our research published on automotive leaf springs market prospects. Composite leaf springs offer multitude of benefits over steel counterparts. Weighing as low as 1/7th of steel leaf springs, composite leaf springs are five times more durable stronger and lighter better in damping properties excellent in fatigue resistance silent in terms of vibration and noise Have a look at the chart below to understand the magnitude of weight reduction offered by composites in leaf spring application.

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    Tags:

    EU Clean Aviation programme | Composite Battery Casing | Polyetheretherketone (PEEK) | Composites in Aerospace and Defence | PEEK | Carbon Fiber Reinforced Plastics | Prosthetics | Orthopaedic Composites | Marine Composites | Membrane |

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