View through a Transparent, load-bearing fiber-reinforced composite panel visor made of transparent, load-bearing fiber-reinforced composite panels

Revolutionary High-Strength Transparent Fiber-Reinforced Composite with Integrated Functionality

High-strength transparent glass has been available for decades — yet its substantial weight and the high energy consumption required for production remain significant drawbacks. For example, secured police vehicles can easily reach a total weight of up to 10 tons.

Within the joint research project TransComp, involving three members of AFBW, transparent and mechanically load-bearing fiber-reinforced composite panels were successfully developed. By combining novel transparent resin systems with glass-fiber-based reinforcement structures, the project created an innovative class of materials. This new material solution offers a lightweight and recyclable alternative to conventional glazing materials and has strong potential to contribute to CO₂ emission reduction.

Research and Development Contributions

  • The Institute of Aircraft Design (IFB), University of Stuttgart, established the essential manufacturing foundations.

  • The Institute of Polymer Chemistry (IPOC), University of Stuttgart, together with the German Institutes of Textile and Fiber Research (DITF), developed the advanced polymer chemistry required for optical and structural performance.

  • Extensive material characterization and transparency testing were conducted to achieve near-optical clarity. Ballistic and quasi-static mechanical testing was performed by project partner KRD Coatings GmbH.

Tajima GmbH: Tailored Fibre Placement (TFP)

Within the project, Tajima GmbH led all activities related to Tailored Fibre Placement (TFP). This automated laying and stitching technology enables load-path-optimized, geometry-adapted placement of reinforcement fibers and opens up new design freedoms for transparent, structurally stressed components.

Tajima’s focus included the qualification of suitable glass fiber base materials, rovings, and sewing threads that meet both the processing requirements of the TFP method and the demanding optical and mechanical performance criteria of transparent composite structures.

A key innovation was the process-integrated functionalization of the glass fiber preform. While heating elements in transparent components — particularly in automotive applications — are traditionally integrated separately in additional production steps, the TFP process allows thin heating wires to be placed directly and precisely alongside the reinforcement fibers on the same machine. This significantly increases efficiency while enabling multifunctional lightweight structures.

Visor Demonstrator

The visor demonstrator developed within the project was manufactured using glass fiber fabric as the base material. Reinforcement fibers, a precisely matched sewing thread, and an integrated heating wire (anti-fog functionality) were placed using TFP technology. The structure was subsequently infiltrated with a polymer system specifically tailored to the glass fiber architecture.

The demonstrator clearly illustrates the potential of Tajima’s TFP process for the industrial production of transparent, load-bearing, and function-integrated fiber-reinforced composite components.

Fields of Application

  • Automotive sector: police vehicles, secure vehicles for public figures and government officials, lightweight motorhomes under 3.5 tons

  • Aerospace: particularly eVTOLs and other light aircraft

  • Construction and agricultural machinery: impact-resistant protective glazing

  • Public infrastructure: vandal-resistant glazing solutions (e.g., bus shelters)

  • Protective equipment: helmet visors for police, pilots, and specialized applications

JEC World 2026

The visor demonstrator will be showcased at JEC World 2026 in Paris at the Tajima GmbH booth – P82-4, part of the joint Baden-Württemberg International and AFBW pavilion.