For Karl Mayer’s Warp Preparation Business Unit, the enormous demand for CCLs made from glass fabric means excellent order income level.
The rapid development of artificial intelligence (AI) is currently transforming entire industries – and is also driving a sustained boom in demand in the market for copper-clad laminates (CCL). CCLs are the base material for the manufacture of printed circuit boards and are thus a fundamental component of the entire AI infrastructure. They typically consist of a composite reinforced with woven glass fabric.
For Karl Mayer’s Warp Preparation Business Unit, the enormous demand for CCLs made from glass fabric means excellent order income level.
“Currently, around four billion meters of glass fabric are produced worldwide each year. By 2028, another two billion meters will be added – a massive market in which we lead with a major market share,” says Enzo Paoli, President of Warp Preparation Business Unit at Karl Mayer.
Technological leadership through innovative products and an outstanding reputation
The basis for this outstanding market position is a strong product portfolio: the FILSIZE-G sizing machine and the AM-G assembling machine. Both warp preparation systems deliver the highest level of process reliability, maximum efficiency, and consistently high warp quality. Even with frequent product changes, the quality of the fabrics produced remains at the highest level.
Its unique repeatability and productivity have made Karl Mayer the preferred partner of leading glass fabric manufacturers worldwide – for nearly 20 years.
The success story began as early as 2007 with the first deliveries for one customer in China and one in Taiwan. Through continuous further advancements in the warp preparation technology for glass processing, it soon became an industry standard. A major milestone was the sale of the 100th machine for electronic glass in China in 2020. With the rise of AI, this success story is now gaining even more momentum.
New requirements posed by AI servers and modern electronics
The requirements for glass fabrics are changing rapidly. In particular, the materials used are becoming more challenging. The growing computing power of modern AI systems also demands servers with highly complex printed circuit boards (PCBs). The number of CCL-layers has risen from 6 for standard electronics to 12 for electric vehicles and mobile phones to over 24 for AI data centers. As a result, the demand of glass fiber fabrics has increased drastically.
These new materials and layer structures present greater challenges for production processes. Precisely controlled yarn tension is particularly critical during warp preparation. Even the slightest deviations can cause local differences in density within the fabric. The result: propagation time differences in high-frequency signals, known as the fiber-weave effect or intra-pair skew. This is exactly where Karl Mayer’s technology comes into play.
Perfectly positioned for the AI era
The global expansion of AI data centers is driving enormous demand for high-performance printed circuit boards and, consequently, for high-quality glass fabrics. With its many years of experience, technological innovation, and market-leading solutions, Karl Mayer is exceptionally well-positioned to benefit from this growth.
Or to put it another way: While AI is shaping the digital future, Karl Mayer is providing the technology that lays the foundation for it today.