DE EN FR ABOUT SAERTEX PRODUCTS SERVICES APPLICATIONS CAREER SUPPORT CONTACT Homepage / Applications / References / Reference Reference PROTOTYPES FOR ROLLS-ROYCE LIGHTWEIGHT CARBON FIBRE STRUCTURE DEVELOPED AND PRODUCED BY SAERTEX The engine and marine manufacturer Rolls-Royce used SAERTEX multiaxial fabrics and engineering expertise to assist in the development of a new carbon Azipull 65C propulsion system. The Carbon Azipull 65C propulsion system is specifically constructed for the superyacht Benetti F125 of the Azimut BenettiGroup. The previous components were made of steel and were significantly heavier than the newly developedcomposite component. The prototypes for the indoor and outdoor shells of the motors were produced in SAERTEX Stade with a completely new lightweight design in carbon. THE IDEA The new Carbon Azipull 65C is a mechanical steerable propulsion thruster with a pulling propeller, for propulsion of leisure craft and commercial vessels with speeds of up to 30 knots. Similar components are currently comprised mostly of steel. The idea was to optimize the component for a high power to weight ratio and hydrodynamic shape. In order to achieve these objectives, Rolls-Royce looked for a partner who could develop and manufacture new components using composites. Rolls-Royce sought to achieve technical advantages such as weight reduction, optimized design (based on flow optimization), corrosion resistance and better attenuation properties by using a composite solution manufactured by SAERTEX. This new component is an excellent example of our customized composite solutions – from development and prototyping to the serial production of demanding high-end products. TECHNICAL BENEFITS Weight reduction Optimized Design High Performance Better attenuation properties REINFORCING THIS IDEA CHALLENGE: THE LAYUP PLAN The layup plan and the fabric requirements were developed by our SAERTEX offices worldwide. This way, the strength of the part was considered along with its practical application, based on our extensive experience in composite parts. Due to the geometrically challenging shape, especially of the inner shells, particular attention had to be paid to the manual draping of the fabrics. CONSTRUCTION WITH IDEAL MATERIALS: THE MOLDS The prototype molds were made using a special polyurethane formula, CNC-milled from the block. This provided a cost-effective solution with the possibility of easy adaptions. The layout and all vacuum-infusion requirements were worked out in close contact with the mold builder, with whom we have a long-standing business relationship. ENDLESS OPPORTUNITIES: SAERTEX FABRICS For the outboard unit, a combination custom-made SAERTEX unidirectional carbon PES and bi-diagonal glass fabric were produced at our headquarters in Saerbeck. BEST POSSIBLE METHOD: VACUUM INFUSION The infusion concept for each part was developed based on experience and prior trials with the respective fabrics. Using epoxy resin and vacuum infusion also means no emission of any curing gases, particularly when compared to an open mold application. The primary reason for using a vacuum infusion is its inherently controllable process, with a specific resin-fiber ratio. Due to the optimized material consumption, the component exhibits high strength. Detailed documentation of every process and challenge has left us well prepared for any future serial processes. THE SUCCESS STORY EXCELLENT BASIS FOR A SERIAL PART: THE PROTOTYPES AND PRE-PRODUCTION All in all, two prototype sets and several preliminary articles were produced, consisting of 42 individual parts. Trimming and fairing was completed at SAERTEX Stade. A close exchange with our customer in Norway will allow us to learn from the assembly of the parts, so we can implement all amendments necessary for a perfect serial part. “It is still amazing to see components of such size in this quality. I really like what you did with the outer shells – using just two pieces of fabric joined right at the edge where the shape totally changes, so that it is not visible.“ Dariusz Dorochowicz, Mechanical Engineer bei Rolls-Royce Marine MORE REFERENCES Non-Crimp Fabrics: glass , carbon & aramid fibers SAERTEX fabrics, also known as NCFs (non-crimp fabrics), are characterised by stretched fibres within the individual layers. In comparison with crimped fibres, as found in woven textiles for instance, straight lay-up (non-crimp) fibres have the greatest possible load-bearing capacity. Wind energy: rotor blades and nacelles For many years we have been supplying our customers with reinforcing materials for increasingly longer rotor blades and larger wind turbines. ABOUT SAERTEX SAERTEX Group Production sites Distribution partner Values Composites Part Manufacturing Imprint Data Protection PRODUCTS Multiaxial Fabrics SAERcore® SAERfix® SAERfoam® SAERTEX LEO Material calculator APPLICATIONS Wind energy Aviation Automotive industry Boat Sport industry CONTACT SAERTEX GmbH & Co.KG Brochterbecker Damm 52 D-48369 Saerbeck Phone: +49 (0) 2574-902 0 Contact form This site uses third-party website tracking technologies to provide and continually improve our services, and to display advertisements according to users' interests. I agree and may revoke or change my consent at any time with effect for the future. 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