Off-Road Brake Covers Developed by Bcomp and KTM Technologies Shortlisted for JEC Composites Innovation Award

An off-road vehicle brake cover developed by Swiss sustainable lightweight company Bcomp and partner Austrian KTM Technologies has been shortlisted for the 2022 JEC Composites Innovation Award
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Combining the best properties of thermoset and thermoplastic polymers, the innovative part also reduces thermoset-related CO2 emissions by 82%
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The cover uses a pre-impregnated version of Bcomp's technical fabric, ampliTexTM, which forms the basis of a lightweight and rigid structure
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Once cured, the flax fiber composite part uses a CONEXUS coupling layer from KTM Technologies to bond stiffeners, fasteners and edge protection in the form of PA6, a thermoplastic
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CONEXUS has an innovative chemical composition that provides a direct bond between the thermoset resin and the PA6 thermoplastic component of natural fiber composites
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The PA6 is overmolded to provide complete edge coverage to the flax fiber section, while preventing interlayer damage from impact or flying debris—a shock that often occurs in trail racing—and provides an aesthetically pleasing finish
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Compared to conventional injection-molded components, Bcomp and KTM Technologies’ brake covers reduce weight, increase stiffness, and reduce vibration, while significantly reducing the component’s overall CO2 footprint thanks to the carbon-neutral ampliTexTM
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After the end of the product life, the coupling layer allows the parts to separate due to the lower melting temperature than thermoplastic materials
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Made entirely from flax, ampliTexTM is a versatile weave developed for sustainable composite production
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By integrating ampliTexTM instead of common carbon fiber and fiberglass layups, Bcomp and KTM Technologies reduced CO2 emissions from thermoset components by approximately 82%
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Another important benefit of using Bcomp's linen technology is that the components are safer for riders and referees
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Unlike the breaking and splitting of carbon fibers, composites made with ampliTexTM exhibit ductile fracture behavior
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It also means that punctures associated with carbon fiber will also be a thing of the past
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As sustainability and the circular economy become increasingly important forces in motorsport and mobility, projects like this brake cover are breaking new ground
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As the development of fully bio-based epoxy resin and bio-based PA6 continues to progress, KTM Technologies plans to develop a fully bio-based brake cover in the near future
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At the end of the component's useful life, thermoset and thermoplastic components can be easily separated thanks to the CONEXUS foil, PA6 can be recovered and reused, and natural fiber composites can generate electricity through thermal energy recovery
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Hans Lochner, head of the Materials and Applications team at KTM Technologies, commented: "With this demo part, we have successfully demonstrated the mass production capability of this technology
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This is our endeavour in the field of sustainable engineering and the use of bio-based composites An important milestone
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This demonstrates that using bio-based plastics and fibers, it is possible to mass-produce high-performance components
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In the production of motorcycles and scooters, the reduction of CO2 emissions will play an even more important role in the future
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Especially with electricity or e-fuel powered two-wheelers, due to their light weight, small footprint and high range, are an alternative to cars in everyday personal transportation
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Applications in this area will demonstrate numerous other components using this technology also has enormous applicability
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Christian Fischer, CEO and co-founder of Bcomp, commented: "This project is an exciting testament to the progress KTM Technologies and Bcomp are making, and we are delighted to be a finalist for the 2022 JEC Composites Innovation Awards
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The idea of ​​a sustainable body with efficient and beneficial end-of-life options is revolutionary and far reaching.

CONEXUS from KTM Technologies has been a key enabler of our ampliTex-based composites in new applications, enabling us to use thermoplastics Parts add local reinforcement, connection points and edge protection, while still gaining the advantages of our flax fiber composite technology
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The winners of the JEC Composites Innovation Awards will be selected at an awards ceremony, which will take place on April 26 in Paris, a week before the 2022 JEC World Congress, and will be broadcast live
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