Projects

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

LuFo VII-1 Research project transStrukt kick-off

Tajima GmbH is pleased to be part of the research project transStrukt, which has been launched at the University of Stuttgart within the framework of the German Aviation Research Program LuFo VII-1. Together with our industry partner KRD Coatings GmbH and the University of Stuttgart, we are contributing to the advancement of transparent fiber-reinforced composite structures (tFRC) for future aerospace applications.

On the academic side, the Institute of Aircraft Design (IFB) and the Institute of Polymer Chemistry (IPOC) are working closely together to develop innovative solutions for next-generation aviation systems. The project focuses on the development of a lightweight, load-bearing, and transparent structural component designed for exterior use in electric vertical take-off and landing aircraft (eVTOL). These transparent composite components are intended to perform reliably across a wide temperature range while meeting demanding requirements for weight, functionality, and safety.

A key objective of transStrukt is the use of environmentally friendly materials and resource-efficient manufacturing processes. Their ecological impact is being systematically assessed through Life Cycle Assessment (LCA) methodologies. In parallel, the IFB is developing scalable and automatable production processes for manufacturing the components, while the IPOC is researching and optimizing novel polymer matrix systems.

As a project partner, Tajima GmbH contributes its expertise to the development and industrial implementation of preforms produced using tailored fiber placement, thereby supporting the development of transparent, innovative structural components that, thanks to TFP, offer load-bearing properties with seamless frame structures for use in the aerospace industry.