September 9th to 12th, the largest composite materials exhibition in the United States, "2024 Composites and Advanced Materials Expo" (CAMX 2024), was held with great fanfare. At the event, Hexcel Corporation, a global leader in carbon fiber manufacturing, launched several new composite material products. These include a new 1K carbon fiber fabric suitable for lightweight composite material applications and a medium-temperature honeycomb core material for next-generation aircraft engines.
Lightweight Composite Material with New 1K Carbon Fiber Fabric
On September 10th, Hexcel announced the launch of its new HexForce® 1K woven fabric for composite reinforcement. This lightweight fabric is made from Hexcel's proprietary HexTow® AS4C 1K carbon fiber, capable of producing high-strength, low-weight composite materials.
Imad Atallah, Vice President of Fibers, Reinforcements, and Matrix Products at Hexcel, noted that the addition of 1K carbon fiber fabric to the company's product portfolio allows for an unprecedented areal weight as low as 60 GSM, while maintaining the mechanical properties required for demanding composite applications. By vertically integrating carbon fiber and fabric processing, the company can offer a cost-effective solution to meet the growing domestic demand for reinforcement materials. It is reported that HexForce® 1K woven fabric is highly suitable for various industrial applications, such as golf clubs, hockey sticks, and automotive parts. Meanwhile, the company is also evaluating the material's application in the aerospace and defense sectors, such as structural components for advanced aerial mobility platforms, where the 1K fiber HSCP 4000 specification meets stringent product qualification requirements.
Atallah pointed out that the company's 1K reinforcement fabric represents a significant advancement in product capabilities. With the successful development of the 1K carbon fiber fabric, the company's product portfolio now extends to include 1K, 3K, 6K, 12K, and 24K material options, thereby better supporting customers' diverse needs in various composite applications. The company is currently working with selected customers to determine the suitability of the new 1K woven fabric for a variety of applications.
Medium-Temperature Honeycomb Core Structure for Next-Generation Engines Also
On September 10th, Hexcel announced the launch of its new non-metallic Flex Core® HRH-302 medium-temperature honeycomb core product. This innovative material, which uses bismaleimide (BMI) material, provides a key solution for the evolving thermal management needs of the aerospace industry. Bobby Rowe, Vice President of Engineering Core Product Management at Hexcel, stated that HRH-302 represents the company's commitment to staying one generation ahead and delivering products that meet customer needs. This new medium-temperature honeycomb structure achieves a unique balance between performance and cost, making it a game-changer for both commercial and military applications.
Flex Core® HRH-302 is designed for long-term use at temperatures up to 450°F (232°C), filling the gap between traditional phenolic-based materials and high-cost polyimide solutions. Leveraging Hexcel's expertise in thermoplastic resins, the product offers improved thermal performance while maintaining similar mechanical properties to existing honeycomb materials. Rowe further noted that the flexibility and thermal performance of HRH-302 make it highly suitable for the complex curvatures and increasing thermal loads in the engine bays of next-generation aircraft. The company also hopes to work closely with customers to showcase the advantages of this new material in key military and commercial projects.
The company is currently collaborating with leading aerospace original equipment manufacturers to test and certify the Flex Core® HRH-302 material. The product is expected to become a key driver in future engine designs and may also be used in emerging applications with high demand for lightweight thermal management materials in the urban air mobility market.