Emerging Innovations in Composites Market: Market Size, Trends and Growth Analysis

Table of Contents

2.1: Why innovation is required
2.2: Innovations in composites industry

3.1: Composites manufacturing technologies
3.2: Composite market- materials and applications

3.2.1: Composites market by material
3.2.2: Advanced composites market
3.2.3: Raw materials market

3.3: Value chain analysis
3.4: Growth drivers and challenges

3.4.1: Driving forces for the use of composite materials
3.4.2: Industry challenges in recent years

3.4.2.1: The energy cost squeeze
3.4.2.2: Challenges for glass fiber industry
3.4.2.3: Resin producers are relatively safe
3.4.2.4: Fabricators' challenge

3.5: Unmet needs analysis

3.5.1: Need for low-cost raw materials
3.5.2: Resins and fiber materials with higher strain to failure
3.5.3: Better UV- and chemical-resistant materials
3.5.4: Low-cost manufacturing process for large and small parts
3.5.5: Need for high temperature composite materials
3.5.6: Low shrinkage materials
3.5.7: Low wear and tear composite materials
3.5.8: Damping and noise resistance materials
3.5.9: Optimal resin and additive systems for closed molding operations
3.5.10: Products manufacturability and affordability

3.5.11: Flexible gel coats
3.5.12: Flame-resistant materials
3.5.13: Self-healing material
3.5.14: Manufacturing process with lower processing time
3.5.15: Flexible honeycomb core
3.5.16: Fabric wrinkling 
3.5.17: Method of cutting wet prepregs
3.5.18: Need for moisture-resistant honeycomb core

3.5.19: Fast cure epoxy resin

 

4.1: Innovations in glass fiber
4.2: Innovations in carbon fiber
4.3: Innovations in natural fiber
4.4: Innovations in resins
4.5: Innovations in compounds
4.6: Innovations in core materials
 

5.1: Emerging innovations in aerospace market
5.2: Emerging innovations in automotive market
5.3: Emerging innovations in wind energy market
5.4: Emerging innovations in construction market
5.5: Emerging innovations in composites manufacturing technologies

7.1: Glass fiber
7.2: Carbon fiber
7.3: Natural fiber
7.4: Resin
7.5: Compounds
7.6: Core materials

List of Figures

Figure 2.1: Six aspects of business values created by innovation
Figure 2.2: Unmet needs and the scope of innovation
 

Figure 3.1: Classification of composite processing techniques
Figure 3.2: Advanced composites market share in global composites industry in 2013
Figure 3.3: Advanced composites market size (Million Pounds) in global composites industry in 2013
Figure 3.4: Advanced composites market distribution ($M) in global composites industry in 2013
Figure 3.5: Advanced composites market size ($M) in global composites industry in 2013
Figure 3.6: Raw material shipment (Million Pounds) in global composites industry in 2013
Figure 3.7: Global composites market breakdown (%) by raw materials used in 2013
Figure 3.8: Raw material shipment ($M) in global composites industry in 2013
Figure 3.9: Global composites market breakdown (%, $M) by raw materials used in 2013
Figure 3.10: Composites industry value chain
Figure 3.11: Flow chart of value chain for the composites industry
Figure 3.12: Dollar ($) and gross profit flow chart through various nodes of the value chain (from raw material to end product)
Figure 3.13: Supply chain of composites industry

Figure 4.1: Single-end roving
Figure 4.2: Multi-end roving
Figure 4.3: Chopped strand mat
Figure 4.4: Veil mat
Figure 4.5: Chopped strand
Figure 4.6: Fabrics
Figure 4.7: Woven roving
Figure 4.8: Recent glass fiber product launches towards high strength
Figure 4.9: Recent glass fiber product launches towards high modulus
Figure 4.10: Fiber glass direct roving from Johns Manville
Figure 4.11: 248A and PerforMax 249A short fiber application parts
Figure 4.12: Chopped strand reinforcements
Figure 4.13: Glass fiber products from AGY
Figure 4.14: Type 30™ SE2307 single-end roving from Owens Corning
Figure 4.15: Recently launched glass fiber products by Owens Corning for automotive
Figure 4.16: Recently launched glass fiber products by Owens Corning for wind energy
Figure 4.17: Recently launched glass fiber products by Owens Corning for construction and others
Figure 4.18: Some of the other glass fiber product launches (I)
Figure 4.19: Some of the other glass fiber product launches (II)
Figure 4.20: Some of the other glass fiber product launches for application (I)
Figure 4.21: Some of the other glass fiber product launches for application (II)
Figure 4.22: Different types of carbon fiber forms
Figure 4.23: Typical continuous carbon fiber
Figure 4.24: Typical chopped carbon fiber
Figure 4.25: Typical metal (nickel)-coated carbon fiber
Figure 4.26: Recent carbon fiber product launches directed towards high strength
Figure 4.27: Tensile modulus of a few carbon fiber products launched since last five years
Figure 4.28: Carbon fiber structure
Figure 4.29: C-PLY ™ SPREAD from Chomarat
Figure 4.30: DIALEAD K13916 from Mitsubishi Plastics, Inc.
Figure 4.31: Some of the major carbon fiber product launches in automotive application
Figure 4.32: Some of the major carbon fiber product launches in automotive and aerospace application
Figure 4.33: Future innovations towards improving tensile strength in natural fibers
Figure 4.34: Tensile strength of natural fiber products launched during 2009-2012
Figure 4.35: Future innovations to improve strength-to-stiffness ratio in natural fiber
Figure 4.36: Areas of innovation in natural fibers
Figure 4.37: Recent launches of continuous natural fibers and their properties
Figure 4.38: AmpliTex light fabric properties and their markets
Figure 4.39: Expected increase in usage of natural fibers in pultrusion and filament winding processes in future
Figure 4.40: Natural fiber treatments methods
Figure 4.41: Study of viscosity of recently launched resins suggest more launches in low viscosity resins during last six years
Figure 4.42: Dow VORAFORCETM 5300 epoxy resin from The Dow Chemical Company
Figure 4.43: Beyone™ 1 resin for wind composites applications from DSM
Figure 4.44: Part developed with carbon fiber and epoxy resin
Figure 4.45: Profile and structure
Figure 4.46: EPIKOTE MGS RIMR 145 resin for wind turbine blade application from Momentive Performance Materials Inc
Figure 4.47: Some of the other resin product launches (I)
Figure 4.48: Some of the other resin product launches (II)
Figure 4.49: Some of the resin product launches for applications (I)
Figure 4.50: Some of the resin product launches for applications (II)
Figure 4.51: Short fiber, long fiber, and continuous fiber
Figure 4.52: Classification of thermoplastic composite materials
Figure 4.53: Sheet molding compound from core molding technologies
Figure 4.54: SymTerra sheet molding compounds (SMC) that combine renewable-resource raw materials
Figure 4.55: Hyperion air handler made of SMC from CSP
Figure 4.56: The “Canopy LENS Antenna” uses molded BMC IB-2240 for its frontal enclosure
Figure 4.57: LFT pellets
Figure 4.58: Some of the major compound materials product launches
Figure 4.59: Use of core materials in wind blade
Figure 4.60: Study of strength property for recent product launches in core materials
Figure 4.61: More core material product launches are concentrated in low density area
Figure 4.62: SAER foam from SAERTEX
Figure 4.63: ArmaFORM PET foam from Armacell
Figure 4.64: BALTEK® Banova lightweight panel from 3A Composites
Figure 4.65: ROHACELL®, PMI-based structural foam from Evonik
Figure 4.66: DOW Wind Energy
Figure 4.67: Some other major product launches of core materials (I)
Figure 4.68: Some other major product launches of core materials (II)
Figure 4.69: Some other major product launches of core materials (III)
Figure 4.70: Some other major product launches of core materials (IV)
Figure 4.71: Some other major product launches of core materials (V)
 

Figure 5.1: Forecast of buy material market in global aerospace and defense industry in B lbs. 2013-2025
Figure 5.2: Material dominance in aerospace industry
Figure 5.3: Composites usage in different Boeing models
Figure 5.4: Trends in materials usage
Figure 5.5: Aerospace market need and areas of innovation
Figure 5.6: Boeing’s B787 improvements over B767
Figure 5.7: Aerospace industry expectations from composites
Figure 5.8: Aerospace industry trends
Figure 5.9: Increased usage of carbon composites in primary structures
Figure 5.10: Increasing composites usage in all current and future leading programs
Figure 5.11: Genx CFRP front fan blades and front fan case
Figure 5.12: Current innovations to meet aerospace industry expectations
Figure 5.13: Lockheed martin incorporated CNRP into F35 lightning II wingtip fairings resulting in significant cost and weight reduction
Figure 5.14: Aerospace programs using automated material laying up techniques
Figure 5.15: Composites industry is shifting towards AFP and ATL processes
Figure 5.16: MAG’s Gemini (combing AFP and ATL together)
Figure 5.17: GroFi platform- Multi-Lay-Up approach
Figure 5.18: Increasing focus towards Out-of-Autoclave
Figure 5.19: Boeing’s different aircraft depicting reduced parts count
Figure 5.20: One piece fuselage of Boeing and HondaJet
Figure 5.21: Carbon fiber recycling as the innovation trend towards sustainability
Figure 5.22: Increasing need for recyclability of aircraft materials
Figure 5.23: Boeing’s CFRP recycling
Figure 5.24: Forecast of buy materials market in automotive industry in million pounds and material dominance in automotive industry
Figure 5.25: Automotive industry expectation from composites
Figure 5.26: Manufacturing expectation – low-cost precursor and processes for carbon fiber
Figure 5.27: Industry putting efforts on alternative precursors and improvization in manufacturing process to reach desired level of $5-$6/lbs
Figure 5.28: Manufacturing expectation – improvization of part manufacturing process cycle time
Figure 5.29: Improvization in part manufacturing processes cycle time
Figure 5.30: HP RTM in mass produced vehicles
Figure 5.31: HP RTM process steps in detail
Figure 5.32: Partners of HP RTM process and fabricators using this process
Figure 5.33: Lamborghini – Callaway forged composites
Figure 5.34: Forged composite and RTM costs overview
Figure 5.35: Forged composite production rate improvements
Figure 5.36: Gurit SPRINT CBS
Figure 5.37: Comparison of vacuum bag process and press molding process cycle time
Figure 5.38: Electric vehicle made from Toho Tenax Technology
Figure 5.39: Manufacturing expectation – part consolidation or one piece design
Figure 5.40: Part Consolidation – one piece Monocoque
Figure 5.41: Few examples of one piece design
Figure 5.42: Monolithic design concept, a composites car door
Figure 5.43: Sustainability – recyclability of carbon composites
Figure 5.44: Recyclable CFRP composites in BMW I3
Figure 5.45: BMW’s CFRP recycling technology
Figure 5.46: Sustainability – usage of natural fiber composites
Figure 5.47: Natural fiber composites in BMW I3
Figure 5.48: Cost reduction – inline compounding
Figure 5.49: Inline compounding system, such as D-LFT, D-GMT, and D-SMC
Figure 5.50: Forecast of buy materials market in wind energy industry in M lbs and material dominance in wind energy industry
Figure 5.51: Wind energy industry expectations from composites
Figure 5.52: Manufacturing expectation (wind energy) – increased usage of carbon fiber
Figure 5.53: Increasing demand of weight reduction in longer wind blades is leading to increased usage of carbon fiber
Figure 5.54: Industry focusing on higher MW size turbines and incorporating carbon fiber for reducing blade weight and increasing energy output
Figure 5.55: Manufacturing expectation (wind energy) – monolithic design
Figure 5.56: Monolithic design -- Siemens B75 - world's largest fiberglass component cast in one piece
Figure 5.57: Manufacturing expectation (wind energy) – seamless modular technology
Figure 5.58: Modular design -- blade dynamics using patented seamless modular technology for ETI’s* project of developing world’s largest blades
Figure 5.59: Blade dynamics’ D49 rotor blades for onshore using seamless modular technology
Figure 5.60: Manufacturing expectation (wind energy) – Fibramatic automated lay-up process
Figure 5.61: Automated manufacturing process Gamesa’s Fibramatic automated lay-up for 100% automated infusion wind blade
Figure 5.62: Construction industry expectations from composites
Figure 5.63: Manufacturing expectation (construction industry) – increasing usage of polyurethane urethane composites
Figure 5.64: Increasing usage of polyurethane urethane composites
Figure 5.65: Manufacturing expectation (construction industry) – use of FRP in waterless toilet system
Figure 5.66: Use of FRP in waterless toilet system
Figure 5.67: Sustainability (construction industry) – usage of natural fiber composites
Figure 5.68: Use of natural fiber composites in construction
Figure 5.69: Sustainability (construction industry) – reduce greenhouse gas emission
Figure 5.70: Need to reduce greenhouse gas emission
Figure 5.71: Major emerging trends in composites technologies

Figure 6.1: Innovation megatrends in composites market
Figure 6.2: Megatrend towards achieving light-weighting
Figure 6.3: Future direction towards improving performance
Figure 6.4: Innovations directed towards price reduction
Figure 6.5: Increasing use of eco-friendly materials
Figure 6.6: Emergence of monolithic design

List of Tables

Table 2.1: Key Emerging Innovations in Composite Materials

Table 3.1: Global composites shipment by raw material type in 2013 (Source: Lucintel)
Table 3.2: Impact properties of some selected materials (I)
Table 3.3: Impact properties of some selected materials (II)
Table 3.4: Maximum continuous use temperatures for various thermoset and thermoplastics
 

Table 4.1: Lucintel’s rating methodology
Table 4.2: Lucintel’s innovation attractiveness rating of new glass fiber technology from Johns Manville
Table 4.3: Lucintel’s innovation attractiveness rating of ME1510 EP multi-end roving from Owens Corning
Table 4.4: Lucintel’s innovation attractiveness rating fiber glass roving from Owens Corning
Table 4.5: Lucintel’s innovation attractiveness rating of S-3 UHM™ glass fiber from AGY
Table 4.6: Lucintel’s innovation attractiveness rating of type 30™ SE2307 single-end roving from Owens Corning
Table 4.7: Some more emerging innovations in glass fiber in 2014.
Table 4.8: Lucintel’s innovation attractiveness rating of CFRP lasso from Nanjing Loyalty Composite Equipment Manufacture Co. Ltd.
Table 4.9: Lucintel’s innovation attractiveness rating of C-PLY ™ SPREAD from Chomarat
Table 4.10: Lucintel’s innovation attractiveness rating of DIALEAD K13916 from Mitsubishi Plastics, Inc
Table 4.11: Lucintel’s innovation attractiveness rating of Dow VORAFORCETM 5300 Epoxy resin from The Dow Chemical Company
Table 4.12: Lucintel’s innovation attractiveness rating of Beyone™ 1 resin for wind composites applications from DSM
Table 4.13: Lucintel’s innovation attractiveness rating of EPIKOTE™ resin 05475 and EPIKURE™ curing agent 05500 system from Momentive Specialty Chemicals
Table 4.14: Lucintel’s innovation attractiveness rating of Daron 220 resin from DSM
Table 4.15: Lucintel’s innovation attractiveness rating of EPIKOTE MGS RIMR 145 resin for wind turbine blade application from Momentive Performance Materials Inc.
Table 4.16: Some more emerging innovations in resin in 2014
Table 4.17: Lucintel’s innovation attractiveness rating of sheet molding compound from Core Molding Technologies
Table 4.18: Lucintel’s innovation attractiveness rating of SymTerra® composites from Premix
Table 4.19: Lucintel’s innovation attractiveness rating of Hyperion air handler made of SMC from CSP
Table 4.20: Lucintel’s innovation attractiveness rating of canopy LENS antenna molded with BMC IB-2240
Table 4.21: Lucintel’s innovation attractiveness rating of a non-halogenated FR LFT-PP compound ECO-FORTE(TM) from RESIN (Products & Technology) B.V
Table 4.22: Some More Emerging Innovations in Compound in 2014
Table 4.23: Lucintel’s Innovation Attractiveness Rating of SAER Foam from SAERTEX
Table 4.24: Lucintel’s Innovation Attractiveness Rating of ArmaFORM PET Foam from Armacell
Table 4.25: Lucintel’s Innovation Attractiveness Rating of BALTEK® Banova Lightweight Panel from 3A Composites
Table 4.26: Lucintel’s Innovation Attractiveness Rating of ROHACELL®, PMI-Based Structural Foam from Evonik
Table 4.28: Lucintel’s Innovation Attractiveness Rating of DOW COMPAXX™ 900 Foam Core System from Dow
 

Table 5.1: Some emerging innovations in aerospace & defense in 2014
Table 5.2: Increasing usage of natural fiber composites applications
Table 5.3: Some emerging innovations in automotive in 2014
Table 5.4: Some emerging innovations in wind energy in 2014
Table 5.5: Some emerging innovations in construction in 2014
Table 5.6: Some emerging innovations in other industry in 2014
Table 5.7: Some emerging technological innovations in 2014

Lucintel has been in the business of market research and management consulting since 2000 and has published over 1000 market intelligence reports in various markets / applications and served over 1,000 clients worldwide. This study is a culmination of four months of full-time effort performed by Lucintel's analyst team. The analysts used the following sources for the creation and completion of this valuable report:

Extensive research and interviews are conducted across the supply chain of this market to estimate market share, market size, trends, drivers, challenges, and forecasts. Below is a brief summary of the primary interviews that were conducted by job function for this report.
 

Thus, Lucintel compiles vast amounts of data from numerous sources, validates the integrity of that data, and performs a comprehensive analysis. Lucintel then organizes the data, its findings, and insights into a concise report designed to support the strategic decision-making process. The figure below is a graphical representation of Lucintel’s research process.