Coats Synergex cones

Coats launches revolutionary composite technology

Coats, the world’s leading industrial thread manufacturer, is launching Synergex, a range of advanced composite fibres which can be processed into fabric form and then used to mould strong, but lightweight, parts for industries including automotive and aerospace.

Synergex has high levels of hybrid fibre integrity and performance.  It can be processed into fabric form using many technologies including commingling and twisting.  The carbon and nylon commingled yarn delivers a perfect balance between strength, weight, performance and also recyclability.  The composite fibres can be embroidered directly into complex shapes and the final composite parts can be metal pressed. 

Rajiv Sharma, Global CEO, Industrial, Coats, said: ‘This is a ground breaking new product range which will revolutionise composite technology across a wide range of industries.  Our pioneering thread and yarn expertise has created an innovative product that can accelerate current manufacturing processes.  It provides a simple solution for complex forms.’   

The Synergex range has been developed by Coats Speciality using its state of the art carbon room at its Sevier site in North Carolina, US.  It is dedicated to developing high performance composite constructions.  From carbon processing units to aramid converting lines and fibreglass processing equipment, it is able to commingle and twist carbon fibres and various thermoplastic fibres.  This enables the manufacture of flexible thermoplastic prepegs which produce advanced thermoplastic parts for the wind, automotive, aerospace and sporting goods sectors.

Coats recently announced its partnership with Elemental Group Ltd in the creation and development of the forthcoming Rp1’s sports car wheel arch which features Synergex.  The wheel arch is made in four steps. The carbon fibre and nylon are woven together to create a single commingled yarn.  The yarn is then embroidered into shape using a Tailored Fibre Placement (TFP) preforming process.  Once the shape is precisely stitched, it is then placed in the machine mould and pressed to form the wheel arch.  The parts can be finished to a high standard without the need to use resins or autoclave. 

The TFP process using Coats commingled yarns will be demonstrated at JEC World, the international composite industry show, held in Paris, Tuesday 8 March to Thursday 10 March.  Coats Speciality is at stand K81 in Hall 6.

Peter Kent, Composites Director, Elemental, said: 'Choosing a material for the Rp1’s wheel arch presented a few challenges as it had to be lightweight, extremely robust and flexible to achieve the complex shape of the part.  The properties of Synergex ticked all the boxes.’


For more information and to request a photo of Anne Fahy contact:

Kristina Blissett, Head of Communications
T +44 (0)208 210 5084, M +44 (0)7714 539887

Notes to Editors

About Coats

Coats is the world’s leading industrial thread manufacturer and a major player in the Americas textile crafts market. At home in some 60 countries, Coats employs 19,000 people across six continents. Revenues in 2016 were US$1.5bn.

Coats’ pioneering history and innovative culture ensure the company leads the way around the world: providing complementary and value added products and services to the apparel and footwear industries; applying innovative techniques to develop high technology Performance Materials threads and yarns in areas such as automotive, composites and fibre optics; and extending the crafts offer into new markets and online.

Headquartered in the UK, Coats is a FTSE 250 listed company on the London Stock Exchange.

  • Each year we make enough thread to go into 8 billion pairs of jeans - that’s one for every person on the planet
  • Every month Coats produces enough thread to stretch all the way to the sun
  • More than 450 million pairs of shoes are made every year using Coats’ thread
  • More than 100 million car airbags are made using Coats’ Performance Materials thread every year
  • In 1879 Thomas Edison used Coats’ thread in his experiments to invent the light bulb
  • Our Red Heart knitting and crochet yarn brand has been named ‘America’s Most Recommended’ by the Women’s Choice Award for three years running
  • Our flame retardant Performance Materials threads can withstand temperatures as high as 1,000 degrees Celsius
  • Coats is the second largest supplier of zips to global brands