Felix Pohlkemper and Tim Röding from RWTH Aachen University’s Institut für Textiltechnik (ITA, Germany) are developing a technology with their startup company CarboScreen GmbH (Aachen) that makes complex carbon fiber production controllable through sensor monitoring.

With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 meters/minute to 30 meters/minute in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year. Pohlkemper and Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for their development. 

The production of carbon fibers is highly complex and in current state-of-the-art, the manufacturing process is only monitored manually by semi-skilled workers. However, even minimal fiber damage during production leads to a reduction in the quality of the carbon fiber. In extreme cases, it can also lead to plant fires. To ensure production quality, the production speed is currently limited to a maximum of 15 meters/minute. Using CarbonScreen’s technology could not only increase production speed and thus production volume, but could also reduce specific production costs of carbon fiber, potentially resulting in lower prices. This, in turn, would make it possible to drive carbon fiber and other composite materials more widely in markets like aerospace, wind and automotive.

The CarboScreen online monitoring system is currently being developed for industrial use. It is to be validated at an industrial plant in 2024. CarboScreen GmbH was founded as part of EXIST funding and offers AI-supported sensor systems for carbon fiber production. The sensor technology continuously monitors the fiber throughout the entire production process. Deviations are detected automatically.