Zoltek receives new product award from Frost & Sullivan

Partnerships with Zoltek can be a tremendous value addition to automotive original equipment manufacturers seeking to manufacture lightweight vehicles. Automotive companies find it easier to comply with the U.S. government's stringent fuel economy standards by employing Panex 35.

Panex 35 is produced through a combination of a textile fiber precursor with a distinctive, high-throughput process. Zoltek introduces these carbon fibers with specially developed sizing chemistries in high-volume sheet molding compounds (SMC), thermoplastic compounded products and continuous fiber tapes, fabrics for resin transfer molding, and fast-curing prepreg systems.

The fiber is available in various forms, including continuous tow, chopped fiber, milled fiber, carbon fabrics and felts, prepreg tapes, and pultruded profiles. In a chopped fiber product format, the Panex 35 fiber is compounded with generic thermoplastic resins such as polycarbonate (PC) and high-temperature thermoplastic resins such as polyether ether ketone (PEEK) and polyetherimide (PEI) for higher strength-to-weight and stiffness-to-weight ratios than competing incumbent products.

"Panex 35 commercial-grade carbon fiber stands out in terms of capacity, quality, consistency and low cost (< $19/kg)," said Frost & Sullivan Research Analyst Sunney Fotedar. "Panex 35 applied to sheet molding compound applications enables the production of lighter parts and improved surface finish."

Zoltek, along with several partners, has developed low-cost thermoplastic tape products, specifically for high-volume applications, where localized areas of stiffening are required in combination with injection molding processes. This enables the production of low-cost and structurally optimized composite parts.

Another compelling feature of the Panex 35 is that it has better mechanical and electrical properties compared to competing products. Zoltek's 50K carbon fiber Panex 35 demonstrates enhanced tensile strength and higher modulus of elasticity and volume resistivity. This indicates that it is more suitable for use in the functional components in automobiles.

Zoltek has also developed a new low-cost Epoxy TowPreg for dry winding of CNG tanks. This product has found uptake among companies seeking to manufacture hood and trunk inner structures, traditionally manufactured using stitch preforms.

"Zoltek's competitive advantage, derived through its strong position in the wind energy industry, will enable the company to deliver value to its customers," noted Fotedar. "Even though Panex35 has higher material costs than steel and glass fiber, it can substantially lower tooling, maintenance, and machinery costs, and ultimately, increase the profit margin for the customers."