A subsidiary of the Busch Group, a global specialist in vacuum pumps employing 8,000 people across 23 production sites worldwide, Composites Busch began operations in 1988 in Chevenez, manufacturing vanes for these pumps.
Now based in Porrentruy, this company, which employs 103 people, still manufactures these strips but has, over time, diversified into the medical, additive manufacturing, luxury goods and aerospace & mobility sectors.
To meet customer requirements, the company utilises a range of technologies for the production of composite materials: raw material preparation, cutting, lay-up, resin transfer moulding, high-performance compression moulding (Black-Shark® technology) and pre-preg moulding, high-temperature compression moulding, infusion moulding and autoclave curing.
Shift towards medical sector
The year 2004 marked a significant milestone in the development of Composites Busch with its entry into the medical market. Just over twenty years later, this market has become the company’s largest, accounting for around 60% of turnover. The company produces nearly 200,000 parts a year for this sector, including components for orthopaedic devices such as external fixators. These devices, which must be rigid, radiolucent and lightweight, are worn by patients for periods of up to several months and, in some cases, must allow for gradual adjustments throughout the course of treatment. The company also manufactures operating table components, orthoses and instruments for hip surgery and other surgical procedures.
The use of carbon fibre-based composite materials for these various products offers numerous advantages: in addition to design flexibility, the material’s lightness and mechanical properties, its X-ray transparency, for example, allows X-rays to be taken before, during and after an operation without the patient having to leave the operating table. Compatibility with magnetic resonance imaging (MRI) is also a key requirement.
This development prompted Composites Busch to invest in 3D printing. Today, additive manufacturing accounts for around 5% of the company’s business, largely in the medical sector, particularly for the production of single-use medical devices or components for artificial hearts, as well as for prototyping.
Composites Busch was the first company in the world to manufacture hockey sticks from composites materials. A few examples are presented by Sofia Membre and Manon Laureau.
Luxury and watchmaking sectors
The company’s watchmaking business began in 2004 and has grown steadily since 2013. It now employs some of the staff in moulding, prototyping, machining and finishing operations. “The cornerstone of this business, however, remains innovation and our expertise in materials,” explains Ahmet Muderris, the company’s director. "Drawing on our expertise, we bring creativity to the design of materials by combining them, for example, with minerals or precious materials. In this sector, we provide inspiration right through to the final machined component."
Aeronautics sector
Convinced that the use of composite materials offers numerous advantages for the aerospace sector, the company has invested significant resources in researching new technologies to extend the use of composite materials to parts with complex geometries. “For the past few years, we have been placing particular emphasis on one of these technologies: Black-Shark®. In an industry where weight reduction has become a key factor, Composites Busch is now able to produce parts that are 30 to 40 per cent lighter than those typically made from metal.” However, weight is not the only factor to consider. The company can, in fact, replace key components that are sometimes subject to geopolitical considerations, particularly regarding issues of sovereignty relating to the supply of titanium.
Having held EN 9100 certification (a standard covering, in particular, risk and safety management, traceability and document control, and supplier monitoring) for over six years, the company has established itself in the aerospace sector in areas such as the design, development, prototyping, testing and qualification of load-bearing parts with complex geometries.
Press systems
Extensive machine fleet
In addition to 15 three-, five- and six-axis machining centres, the company also has a waterjet cutting machine, a unit for watch finishing, and a wide range of equipment for quality control – including three-dimensional inspection and visual inspection under a binocular microscope – for watch and medical components.
Special products come with their own set of challenges
Regardless of the sector, Composites Busch faces numerous restrictions when using certain materials, including PFAS. In order to comply with the various standards, the company works regularly with testing laboratories. One of the objectives, for example, is to ensure that two components which comply with the standards when used individually are still compliant when mixed together.
Composite products may face other challenges: as their use in certain highly specialised fields is relatively recent, they must first prove their worth. A further challenge is that, as they offer high-value-added products, they must absolutely guarantee consistent quality and reliable performance.
Many tasks are carried out manually.
A customer-focused business philosophy
“The company’s strategic decisions should not be dictated by its own preferences, but by listening to its customers,” says Ahmet Muderris. The company has always taken a customer-centric approach and intends to further strengthen this approach in the future. “Our close relationship with our clients and our knowledge of the markets enable us not only to be proactive, but also to take the initiative. Our innovative approach is designed to help our clients create value.”
