Expert Interview
A Greener Horizon with Loparex ‘3D Release’
Today, we have the pleasure of sitting down with the minds behind a revolutionary innovation set to transform the windmill industry’s sustainability narrative.
Vincent, can you tell us about the breakthrough you’ve achieved?
Absolutely. We’re thrilled to share that we’ve developed a release agent-free production process for rotor blades, a leap towards cleaner and more environmentally responsible manufacturing practices. This innovation addresses a critical need in the wind energy sector, reshaping how wind energy is harnessed.
What prompted the development of this groundbreaking innovation?
In the current landscape, rotor blades—the unsung heroes of windmills—are crafted through a highly manual and intricate process, using harmful release agents during the vacuum infusion process. This not only raises ecological concerns but also contributes to the carbon footprint associated with renewable energy generation. Our innovation offers a solution that streamlines production and champions a release agent-free approach, aligning with the growing global commitment to cleaner, greener energy solutions.
Matthias, can you walk us through the key features of your innovation?
Certainly. Our release-agent free process involves a specially developed release film with built-in release performance. Silicone-free and release agent-free, it provides a non-contaminated surface directly out of the mold. The blade surface is “activated” for the final top coat and it is possible to achieve up to 40% higher bond strength between the final coating and blade structure, eliminating the need for a primer. This not only shortens production cycles but also reduces health risks by epoxy dust and VOCs (editor’s note: ‘Volatile Organic Compounds’), overall production costs and expands the lifespan of the blade.
That sounds impressive. How did the development journey unfold?
The journey began in collaboration with Fraunhofer IFAM in the “OptiBlade” project, supported by the German Federal Ministry for Economic Affairs and Climate Action.
Our goal was to enhance the efficiency of rotor blade production and decrease manufacturing costs by leveraging our extensive release liner expertise and our in-depth knowledge of composite resins and film property adjustments. While adhering to this primary objective, we incorporated customer feedback and initiated a comprehensive product redesign which also enabled us to switch to a scalable production process. Collaborating with global players in the wind blade industry and working closely with our technical sales team allowed us to understand industry needs and optimize our offering efficiently.
Vincent, who is your target audience, and how does this innovation address their needs?
Our target audience is wind blade manufacturers seeking longer lifespan, cost efficiency, and more sustainable manufacturing solutions. The new release film can be implemented without significant investment, offering benefits such as mold damage prevention that reduces downtime and decreases the need for regular mold maintenance, which effectively leads to an output increase of up to 20%.
What sets your innovation apart from existing solutions?
Our release film process eliminates the need for manual and work intense sanding and use of chemicals to restore surface energy lost by release agent contamination. Its energized matt surface optimizes the bond between coating and structure, leading to the longer service life of the rotor blades as higher bonds are obtained between the buildup layers. Compared to existing processes, it not only addresses environmental concerns but leads to greater end product quality.
Matthias, can you share testing insights and user feedback?
We’ve successfully tested the solution in manufacturing sites worldwide, receiving very positive feedback on coating performance without using a primer. Users have recognized the prevention of mold damages as a significant advantage, along with positive economics when opting for the release film process over conventional methods.
Exciting news! Vincent, when can we expect the official launch of ‘3D Release’?
In fact, we have already introduced the product to two key customers. Everyone at Loparex involved in the project is very excited about the milestones we have already achieved together with our customers and the next steps ahead.
Looking ahead, what potential applications do you see for this innovation?
While wind blade manufacturing is the starting point, we’re already investigating applications in marine, aerospace, defense, vehicle manufacturing, and beyond. The experience gained from this breakthrough can potentially influence and reshape various industries.
In summary, could you please reiterate the key points?
Absolutely. Our innovative ‘3D Release’ solution provides a reliable, efficient, and sustainable choice for wind blade manufacturing, resulting in substantial cost savings, improved quality, increased output and an extended service life of the blades. If you are interested in learning more, please don’t hesitate to contact us. We are eager to hear your thoughts and address your questions as we embark on this revolutionary journey together. Please also note, that we have sample material readily available for testing, and can supply material at scale.
Thank you, Matthias and Vincent for sharing these insights about this exciting innovation.
Please reach out if you are interested to learn more about ‘3D Release’ via https://loparex.com/contact/
ABOUT LOPAREX
Loparex is the world’s leading developer and producer of release liners solutions, serving customers in key industries including Tapes, Building & Construction, Composites, Automotive, Electronics, Renewable Energy, Health Care, Graphics, Hygiene, Label, and Shipping & Mailing. Loparex partners with customers around the globe and enables sustainable performance through in-depth material science expertise and an industry-leading technology portfolio.
For more information, visit loparex.com.
Interview with Vincent Bachtrog – Business Development Director New Business & Application & Dr. Matthias Mauser – Global Technology Development Manager Engineered Films
Interviewed by Christoph Vogel – Director Corporate Development, Strategy and Marketing