Showing posts with label composite manufacturing. Show all posts
Showing posts with label composite manufacturing. Show all posts

Thursday, May 6, 2010

Cutting Kevlar with a Waterjet



Cutting Kevlar or any aramid fiber is no easy task. It's tenacity wears our tools and blades, while cuts are often frayed. Probably the best method for cutting laminated aramid fiber, is using a waterjet (as seen above). Although not cheap, these cuts are CNC controlled, so very accurate, and the cut edges are clean and burr free...

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Wednesday, April 14, 2010

Lockheed Martin F-35 Joint Strike Fighter



The clip above demonstrates why the new Joint Strike Fighter needs to be as lightweight as possible. Carbon fiber is undoubtedly playing a role in reducing the weight. I caught a fascinating NOVA episode on the competition between Lockheed and Boeing in designing the F-35. It goes into a surprising amount of detail of the composite construction and even discusses how Boeing attempted to use a thermoplastic matrix. If you have Netflix, you can watch it instantly for free, or you can get the episode from Amazon below:


I highly recommended anyone interested in aerospace composites or this military program to check it out.

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Wednesday, February 17, 2010

Recycled Glass Bottle Composite Table

The annual ACMA Composites show was last week. All and all, it was a good show, and as always, some of the newest and best products go on display. This year, the "Best in Show" award went to Robal Glass – Monroe Industries, as seen above. They have a method of mixing resin with crushed post-consumer glass bottles. The coffee table on display was beautiful, and I could picture the material used in counter tops and bathrooms.

Being green was absolutely a theme at the show this year. The demand is originating from the end users of composite products, and this will likely only grow.

Tuesday, January 19, 2010

Fiberglass Windows Gaining Popularity

Fiberglass windows have been around for sometime now, but are only recently gaining serious momentum. Fiberglass windows, typically use pultruded profiles for the frames; and since the frames and windows are both essentially made of glass, they expand and contract at the same rate, this creates a longer life window. Less gaps are created between the glass and frame, creating a tighter seal with efficiency gains. Additionally, aluminum window frames, which are conductive, generally are not as energy efficient as fiberglass windows.

The Janurary/February 2010 issue of This Old House, reports that:
"While sales of windows sank 18 percent overall last year, the market for fiberglass models shot up 9.4 percent. Experts attribute the bump to consumers' growing familiarity with the material and that, unlike vinyl, the pricier fiberglass fiberglass is as printable as wood and lasts longer since it expands and contracts with window glass."
Fiberglass windows will likely continue to gain market share as advances in pultrusion resin systems, such as urethane, will lead to higher quality products with increased energy efficiency.

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Photo Credit: JAGwired via flicker

Tuesday, November 10, 2009

Critical National Need: Advanced Composites Manufacturing


The Technology Innovation Program (TIP) at the National Institute of Standards and Technology (NIST) was set up to "support, promote, and accelerate innovation in the U.S. through high-risk, high-reward research in areas of critical national need." The institute helps fund (through 50% cost sharing grants) R&D projects that may be too risky for the traditional investment community.

The 2010 NIST TIP program has identified 4 areas of "critical national need," they are:
  • Civil Infrastructure
  • Healthcare
  • Energy
  • Manufacturing
Manufacturing was identified as a highly important aspect of our economy because as of 2007, manufacturing represented 11.7% of the total GDP and 14 million US jobs. (This number has likely dropped in the last two years.) In order for the US to maintain global leadership in manufacturing technology, new and revolutionary innovations are required. In this recent NIST White Paper, the following 3 materials in particular are sited as in need of continued technology advancement:
  • Nanomaterials
  • Composite Materials
  • Super/Specialty Alloys and Smart Materials
Additionally, the paper identified the following problems and promises of composite materials:
  • Aerospace industry’s emphasis on fuel efficiency favors the use of polymer-matrix composites instead of aluminum
  • Automotive industry recognizes advantages of weight reduction, parts consolidation and increased cost-effective design options for polymer-matrix composites;
  • Energy sector’s growing use of wind energy has led to increased demand for polymer-matrix composite turbine blades;
  • Better processes and tools needed to recognize special properties such as the anisotropic nature of these materials (strength and stiffness greatest in direction parallel to axis of the embedded reinforcements);
  • Need to overcome cost barriers to use such as expensive starting materials, time-consuming fabrication processes, and autoclaves and expensive tooling;
  • Multiple industries require accommodation of production of large, structurally complex parts; and
  • Increased application of recyclable composites can reduce carbon footprint.
Some of the best and brightest minds of our nation who work for NIST identified the above as the future of composite materials. If you are a composite material company, I would suggest reading the entire white paper as it may inspire innovation. In particular, I like that NIST identified recyclable composites as a future component of composite material manufacturing. I imagine thermoplastic composites will play a major role in the recycalability of composites, as post consumer plastic (such as the PET bottles in the picture at the top) can be used as a replacement for thermoset resin.

Photo Credit: ThreadedThoughts via flicker

Thursday, August 13, 2009

Pultrusion: Tooling and Prototype Costs


The pultrusion process is known as the most cost effective method of manufacturing FRP composite profiles. this is because once a pultrusion machine is up and running, there is little labor involved. However, in prototyping of profiles manufactured by pultrusion, costs can be extremely high. The largest cost being the manufacturing of a precision ground die (although this is a one-time cost).

Other fixed costs in pultrusion include tooling, set-up, and clean up when finished. These costs are present whether 10 feet, or 10,000 feet are pultruded.

To help lower prototyping costs, Virginia Tech has developed a
"Novel and cost effective pultrusion die technology streamlines the construction processes and reduces tooling costs by as much as 11%. Lead times are cut by almost 50%.

Technology utilizes rapid prototyping and tooling techniques to produce shaping elements comprising the die core with an exterior core housing constructed from readily available pre-cut metal bar stock."

This technology is available for license from the University, and for more information please visit their website here.

Photo Credit: Ebert Composites Corporation

Wednesday, July 22, 2009

Machining Composite Materials


Interesting article about machining composites: machinery.co.uk

Photo Credit: Ebert Composites Corporation

Monday, June 22, 2009

Boeing Workers - Playing with Composite Materials

As colleges attempt to prepare students for real world jobs in growing industries, many schools are now offering courses in renewable energy, turbine blade manufacturing, and composite materials.

It is interesting to hear that Edmonds Community College in the Everett, Washington area is offering multiple composite material construction classes. In one such class, students have the opportunity to construct a composite snowboard by hand. Ironically, many Boeing workers, some of which work on the new 787 Dreamliner, are enrolled in this composite course.

Feeling a touch of envy, I checked with my local higher education institutions to find zero oportunties for similar composite material related courses. This is surprising, as the San Diego has 3 large Universities (UCSD, USD, & SDSU) and multiple community colleges.

Colleges around the country should take note, as composite manufacturing skills are increasing in demand. (I am guessing there are a few job searching art history and communcation majors wishing they took these courses)

Read the article: HearldNet

Photo Credit: Forcefeed