FEATURE MATERIALS IN DESIGN & PROTOTYPING
COMPOSITES: THE KEY TO DESIGNING LIGHTER TRAINS
Professor Eric Moussiaux, vice president of technology at Exel Composites, explains how the Talent train project used innovative composite materials to overcome the challenges of creating lighter, more efficient trains, without sacrificing strength
I
n 1996, my friend and partner from Techno Composites, Anton Lügering approached me with a groundbreaking opportunity. Train
manufacturer Talbot in Aachen, Germany, had just been acquired by Bombardier and was developing a new regional train called the Talent. The vision was to build a lightweight regional
train, one that could serve as a faster, more efficient, mode of transport. But, achieving this meant breaking away from steel and aluminium. The Talent project afforded us the opportunity
to prove that composites – long valued for their lightweight properties – could also deliver the strength and durability required for modern trains. However, Talbot needed the new Talent train on the tracks in just 15 months.
A LIGHTWEIGHT DESIGN Six months in, we delivered our first prototypes to Talbot. The pultruded profiles we developed were innovative, strong and light. Along with moulded panels in between the windows, these materials would go on to form the exterior of the Talent train. One of the most exciting aspects of this
project was the adhesive bonding of composite body shells to an aluminium structure, an entirely new approach for the rail industry at the time. Despite the challenges of meeting unclear fire regulations for composites, our team found the right chemistry, both technically and in our collaboration with Techno-Composites and Talbot. The final profiles were manufactured with pultrusion in Exel’s Oudenaarde factory in Belgium, while Techno-Composites, based in Haselünne, Germany, took care of the machining, bonding, painting and kitting of the profiles into ready to be installed parts that were delivered to Talbot’s Aachen factory. In March 1998, I stood among a crowd of
hundreds in Aachen for the roll-out of the first Talent train. As it emerged, the sense of accomplishment was palpable. The Talent train was a testament to what happens when engineers, designers, and materials experts
54 DESIGN SOLUTIONS MARCH 2025
come together with a shared vision for the future. For over a decade, more than 800 Talent trains
rolled out of the factory, splitting evenly between diesel and electric engines. These trains, running throughout Europe and Canada, proved the long-term viability of composites. Beyond being lightweight, composite profiles offered something steel couldn’t – flexibility, precision and stability in manufacturing. With composites, we achieved tighter tolerances and better shape stability, reducing production costs and assembly time.
LONG-LASTING PERFORMANCE In May 2024, I had the pleasure of meeting Annemarie Kwade, the former head of Talbot’s buying team in Germany, also joined by Gerrit Mann, current owner and managing director of Techno-Composites. As we watched those same Talent trains glide into the Weisweiler station, it was clear that the decision to work together and embrace composites had been the right one. There was no sign of the typical bruised look of old metal train-sides, and customers have found the composite sidewalls easy to repair
with no need for spare parts. The greatest potential for composite materials is in the outer bodies of trams and regional trains. In this sector, lightweight construction is crucial due to the frequent starts and stops. While weight reduction used to be primarily a matter of operational costs, today it is a central factor in achieving a lower carbon footprint in public transport.
PUSHING THE BOUNDARIES The story of the Talent train is more than just a technical success – it’s a symbol of how far we can push the boundaries of materials science to create something truly innovative. As cities and regions strive to reduce their carbon footprints and meet growing transportation demands, the role of composites will only become more critical. At Exel Composites, we’re proud to be part of this journey, proving that with the right materials there’s no need to compromise between efficiency and strength.
Exel Composites
www.exelcomposites.com
NEW DAMPING NYLON RESIN SUITS COMPONENTS USED IN ELECTRIC AND AUTONOMOUS VEHICLES
Toray Industries has developed a damping nylon resin that maintains the high-temperature rigidity and moldability of standard nylon while delivering four times the damping performance of butyl rubber and other conventional materials. The company has started supplying samples to customers for various components to enhance comfort in electric and autonomous vehicles. As well as replacing flexible butyl rubber-based damping materials used in gaskets and seals,
the new material’s rigidity opens up opportunities for noise suppression applications in covers and larger structural components, such as chassis housings. The new ultra-damping nylon resin should find applications in mobility components, electrical
and electronic parts, industrial equipment and construction materials, the company explains. Toray aims to commercialise its new offering during the fiscal year ending March 31, 2027. The
company will fully leverage its core capabilities in synthetic organic chemistry, polymer chemistry, biotechnology and nanotechnology to materialize its corporate philosophy of ‘contributing to society through the creation of new value with innovative ideas, technologies and products’.
Toray
www.toray.com/global/
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