SPECIAL jec composites show 2009

SPECIAL
jec composites show 2009
SOFTWARE
> Stand T45
FiberSIM 5.5 enhances composite manufacturability
Vistagy will be announcing FiberSIM® 5.5, the latest version of its composite
engineering software. FiberSIM is integrated into
commercial CAD systems and used for designing and
manufacturing composite parts and assemblies for the
aerospace, high-performance automotive, marine, F1
racing and wind energy industries.
The new release features improved tools for resolving
manufacturability issues encountered when using
automated fibre placement techniques, which automate
FiberSIM® simulation of a fibrethe creation and placement of bird beaks and bat ears
placed aircraft fuselage panel. The
solid green line indicates the outer in the preliminary stages of design. Early identification
boundary of a composite ply with
of minimum course length issues will help streamline
two holes, the dashed green line
the product development cycle. This version will also
shows the inner boundary, the
blue lines indicate the orientation
expand support to more analysis packages, providing
of the fibre paths, and the red lines
users with more ways of transmitting essential
highlight the areas that cannot be
manufactured as designed due to
information between the analyst and designer and
minimum course length limitations
downstream to manufacturing.
of the automated fibre placement
(AFP) machine. FiberSIM 5.5 alerts With the release of FiberSIM 5.5, designers will use an
users to minimum course length
enhanced producibility engine that offers improved
issues early in design, where
speed for reducing the overall design simulation time.
changes can be made quickly and
cost-effectively prior to reaching
There will also be a spreadsheet-like interface that
the manufacturing floor.
improves the designers’ ability to edit zone-based
laminate specifications and layer sequencing. Other enhancements include the use of
colour to visualize zones with different laminate specifications, an improved ability to
design parts that include cores, superior handling of complex ply drop-off scenarios,
and increased performance by limiting layer boundary updates to a designated area of
user interest.
www.vistagy.com
Programming software for AFP & ATL machines
> Stand M75
Mikrosam AD, a leading manufacturer of production equipment for composite
materials, is introducing the beta version of its MikroPlace off-line composite
programming software package for automated fibre- and tape-placement machines
(AFP/ATL).
MikroPlace provides a sophisticated environment
that enables the composite part designer to create
advanced composite structures and generate the
actual program to be executed on AFP or ATL
machines. The part designer can perform most of
the steps required to develop an advanced
composite part, right in the MikroPlace environment: drawing or importing the part’s
tool, creating ply laminates using several different strategies, exporting the composite
for analysis to popular Finite Element Analysis (FEA) software packages, analysing and
trouble-shooting production issues, and making custom post-processing modifications
of the final layup. The final program can then be simulated to detect production issues
beforehand, such as part-machine collisions, and optimized for maximum layup
productivity within the given machine’s dynamic limits.
MikroPlace provides faster and easier prototyping for R&D departments, and shorter
development cycles for products produced using automated fibre- and tape-placement
machines.
www.mikrosam.com
jec composites magazine / March-April 2009
New software
> Stand Q74
suite for
composite materials
JETCAM International will
demonstrate a new suite of
applications along with new versions
of its Expert CAD/CAM and nesting
software.
At the core of the suite is JETCAM
Expert, which provides the nesting
engine and NC code output for
composite cutting machines. Orders
are provided by links into existing
MRP systems and are automatically
processed. Associated geometry files
are located, profiling information
applied, plies are nested and NC code
is generated without human
intervention. Large spanning parts are
catered for using the “continue-aftercut” facility, which cuts the first part of
the ply, moves the material forward
using motorised beds (where available)
and then continues to cut the
remainder of the part. Other features
such as common line cutting further
reduce material waste and increase the
throughput on the machine.
JETCAM will also be putting a
challenge to visitors by providing a
benchmark comparison against their
existing nests. Visitors can supply
JETCAM with CAD files of parts, along
with a DXF of their best nest for those
parts, and JETCAM will provide a
comparison using its High Performance
Nesting engine, which usually
demonstrates a 5-15% material saving.
Existing customers such as Embraer,
Bombardier and many manufacturers
for the motorsport industry are
already benefiting from
the savings that
JETCAM
delivers.
www.jetcam.com
PREVIEW
Take control of your composites design
> Stand V50
The latest version of the pre- and post-processor software application Laminate Tools features numerous improvements and new
functionalities across all modules.
Just a few examples: flat patterns generated by the Manufacture module now take layer offset
into account, draping simulation now includes a safe option to eliminate numerical instability,
a unique interface is provided for the new Altair Optistruct lay-up optimiser commands, new
failure criteria are available such as LaRC05, an improved PlyMatch interface is provided and
more... This version is now also available for 64-bit platforms on a network floating licence at
no additional cost.
Laminate Tools has been adopted by major composite professionals, small consultancies and
academic institutions as it offers the best value for money for pre- and post-processing of
composite structures. It complements existing CAD systems and/or FEA environments, with
native support for Nastran and Ansys solvers. Laminate Tools helps optimise and manufacture exactly what is being designed and
saves valuable team time.
www.anaglyph.co.uk
PRODUCTION
Labour and material processing solutions
> Stand N32
Airtech RTL is a lean clean room offering designed to reduce touch labour (RTL) and
remove material waste (RMW) in the manufacturing process of composite parts.
Airtech recognises that the cost of converting vacuum bagging roll stock materials used
in the clean room is higher than the cost of the materials themselves. Rather than just
offering "products", Airtech RTL involves customer partnering with Airtech to identify
labour and material processing solutions by giving customers vacuum bagging
materials in a more usable form. Airtech can then deliver tailored solutions to meet
each customer's needs.
Dahlar® Release Bag 520 is a self-releasing multi-layer bagging
film for direct contact with prepregs for the fabrication of hollow
parts. Multiple layers of release polymer and nylon polymer
provide film release-off cured laminates and the vacuum integrity
of nylon. Dahlar® Release Bag 520 will maintain a vacuum at
temperatures up to 220°C and easily release cured resins such as
epoxy and polyester. It is available as lay flat tubing (LFT) and
gusset-folded tubing (LFT-G) for internal bagging of hollow
components.
www.airtech.lu
TAH introduces
> Stand D10
new T2 Turbo Mixer
The new T2 Turbo
Mixer™ from TAH
Industries features an
innovative design that
combines 21 mixing
elements in a standard
18-element nozzle.
The T2 mixer’s unique
bi-directional, 21-element geometry
provides mixing power comparable to
24-element static mixers in a smaller
package that allows the operator to get
closer to the workpiece.
Because the T2 mixer is approximately
20% shorter than comparable 24-element
mixers, it also provides a corresponding
reduction in waste.
www.efd-inc.com/fr
New generation of GRE and GRP pipe production lines
> Stand L70
Autonational is a global supplier of turnkey production lines for pipes, elbows and tees. The lines can produce GRE pipes up to 9
metres in length and 80 mm to 600 mm in diameter.
Autonational has developed a new-generation continuous production line. The continuous GRP pipe
production plant includes multiple components, the main one being the continuous pipe production
machine. This machine is equipped to continuously produce GRP pipes ranging from 300 to 3,000 mm in
diameter. A pipe wall structure is created by combining chopped roving, sand, hoop roving and resin. New
innovations have made it possible to produce pipes of consistently high quality at high production speed
with a minimum risk of machine failure. The machine was designed to enable fast mandrel change to
minimise down time.
A resin and peroxide skid is used for the fully automated raw material metering, mixing and supply to the
winding machine. A coupling grinding machine is used for the production of couplings. The leak tightness
of pipes and couplings is tested by hydrostatic testing equipment. The couplings are applied on pipes with
a joining machine. Laboratory equipment is included for testing raw materials and finished products.
www.autonational.com
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
Ultrasonic cutting equipment
> Stand S79
Decoup+ is a French company that specializes in the design and manufacture
of ultrasonic cutting and sealing equipment, especially for composite
materials. Ultrasound technology makes cutting easy, safe and accurate as
ultrasonic vibrations facilitate the penetration of the tool into particularly
complex fabrics. The ultrasonic equipment can be integrated in flat
weaving looms or multiaxial weft insertion machines for edge trimming or
centre cutting operations on fabrics such as Kevlar®, carbon fibre or glass
fibre. To meet manual cutting needs for all types of fabrics including
prepregs, Decoup+ offers a new ultrasonic bladeequipped gun. As easy to use as a cutter, this light,
easy-to-handle gun can cut fabrics without effort
and with minimum wear. Equipped with suitable
tooling, the gun can also be used to form sealing points for
the assembly of multi-composite material layers.
www.decoup.com
Portable impactor for
composite structures
An original feature of this machine is that
it can produce impacts on full-scale
structures in all positions. The testing
centre uses the impactor to research
damage tolerance on heavily loaded
composite structures.
Impact tests from 2 to 200 J at low speed
(< 5 m/s) using standard f16-mm
hemispheric impactor: length ≈ 1.2 m,
weight ≈ 70 kg.
Specific capabilities
Creating damage to a structure made of
composite materials.
Characterizing the impact (shape,
velocity, energy, load,
> Stand T30
displacement).
Applying stresses to the material to
assess performance losses.
Reduced-scale studies, then full-scale.
Characteristics
Two calibrated springs.
Impact mass: 16 kg in a straight line on
ball column.
System for adjusting spring tension
(screw and digital comparator).
Anti-bounce mechanisms (air cylinder
and optical sensor).
Measurements during impact: load,
displacement (velocity).
Measurement recording device (records
at 20 kHz).
Specific measurement data processing
system developed in-house to calculate
velocity and energy.
ASTRIUM Space Transportation patent.
www.astrium.eads.net/fr/space-productcatalogue/space-industrial-services
Wausau Paper natural release liners
> Stand F43d
Wausau Paper is introducing several natural base paper release liners for the advanced
composite industry. With its vertical integration, Wausau Paper controls the raw
materials and processes from the forest to the base paper and, finally, to the siliconecoated release liner. No bleaching chemicals are used in the process and pulp is
produced with 55% renewable energy. This all adds up to a more environmentallyfriendly way of producing release liners.
Natural release liners are available for aerospace, recreational and wind energy prepreg
requirements. Natural release liners coated with various silicone coating systems add
up to the perfect way to deliver high-tech prepregs.
www.wpcoatedproducts.com
jec composites magazine / March-April 2009
Custom-made
> Stand U70
machinery solutions
The use of coating products for prepregs
is growing. The development of adequate
coating technologies and the ideal
treatment of fibre materials for prepreg
products are a challenge for mechanical
engineers.
Coatema develops custom-made coating
machinery solutions that are adapted to
the products of each customer. Due to
the great variety of substrates and coating
chemistries, each machine offers a
unique solution. Coatema solutions can
handle woven fabric, uni-, bi- and
multidirectional fibre constructions and
products with more than one orientation
according to load directions in the final
application.
Different kinds of resins (matrix) can be
used as coating materials, such as
solvent- or water-based epoxy resins,
powder-like materials, hotmelt resins,
phenol systems, polyester/vinyl
ester/acrylic resin systems.
www.coatema.de
Diamond tool
> Stand M79
producer celebrates
50th anniversary
In addition to celebrating its 50 years of
manufacturing diamond tools (19592009), DK Holdings is launching a new
range of electroplated diamond tools
specifically designed for the composites
pipe industry
at the JEC
2009
exhibition.
These tools
are made
with a
completely new method and use special
diamonds that extend the service life of
tools by up to 20%.
As specialists in the design and
manufacture of special tools, the
company is now able to offer a wide
range of calibration wheels, drills, saws,
routers and holesaws for the GRP/FRP
pipe and wind turbine industries.
www.dk-holdings.co.uk
PREVIEW
Advanced composite structures in minutes
> Stand G43
Fiberforge introduces the latest generation of its patented Relay Station for the
production of fibre-reinforced thermoplastic composite structures. The innovative new
system produces parts up to six times faster than the original one, with increased
flexibility and adaptability and a more user-friendly interface. The Relay Station rapidly
lays up a multiply laminate out of unidirectional, fibre-reinforced thermoplastic
composite tape. The resulting product is a near-net shape preform, referred to as a
Tailored Blank™, which is then consolidated and thermoformed into a final part.
“Although our goal of rapidly producing tailored blanks has not changed, the
mechanics are fundamentally different in our new Relay Station,” comments
Fiberforge’s President and CEO, Jon Fox-Rubin. “Rather
than making incremental changes to our prior lay-up
technology, we leapfrogged it with a completely new novel
technique. The result is a much more robust and capable
system with tremendous throughput.”
According to David Cramer, Fiberforge’s Chief
Technologist, the new system is capable of processing well
over 454 metric tons of fibre-reinforced tape annually. With a part weighing 2.5 kg, a
single Relay Station can generate over two hundred thousand parts every year. “The use
of composites in volume applications has traditionally been limited by the time
required to produce a part,” says Cramer. “Fiberforge’s latest generation Relay Station
moves advanced composites closer to traditional materials, such as metals and plastics,
in terms of volume throughput and automation.”
The automated, programmable system significantly reduces the labour required to
produce composite parts, and produces parts with a significant reduction in scrap
compared with traditional methods – an important factor in reducing cost.
Fiberforge is a technology company offering a breakthrough manufacturing system for
the affordable production of lightweight advanced composite parts at high volumes.
Fiberforge’s proprietary Relay Station – protected with multiple patents and trade
secrets – produces parts with high fibre alignment, high fibre fraction, and long fibre
length at high speed with minimum scrap.
www.fiberforge.com
New German distributor of vacuum bagging
and tooling materials
> Stand N46
Flugzeug-Union Süd (FUS) has recently been appointed
official distributor of Aerovac’s complete range of vacuum
bagging and tooling materials for Germany and various other
European countries.
The range includes cost-effective vacuum bagging films up to
12 m wide (Vacfilm 400Y, Vacfilm 450V), reusable vacuum
bagging systems with silicone membrane, a complete range of
consumable materials and toolings for the resin infusion
process, and composite tooling.
By adding the Aerovac product range to the Richmond products that FUS has been
distributing for more than 20 years, FUS is now able to offer to the composite industry
the most complete range of vacuum process consumables provided by the leading
manufacturers in this field. The range includes high- and low-temperature vacuum
films, release films, breathers and bleeders, reusable vacuum bagging systems, resin
infusion materials and toolings, Schnee Morehead® sealant tapes, PFG® peel plies,
Frekote® liquid release agents, and Loctite® Hysol adhesives.
All items are available at short notice from FUS warehouse in Munich, Germany, along
with competent product support.
www.fus-online.de
Drier and oven technology
> Stand P76
for carbon fibre
manufacturers
The
German
system
supplier
Eisenmann
will be
presenting
its drier and oven technology at the JEC
Composites Show. This technology is
especially designed for the carbon fibre
industry.
Oxidation is one of the most important
processing steps in carbon fibre
manufacturing. Particular attention must
be paid to the air stream, as the large
quantity of heat accumulated in the fibre
band during the oxidation process must
be uniformly discharged. Oxidation
ovens from Eisenmann are consequently
characterized by a constant air
throughput and uniform temperature.
The range also includes pre-oxidation
ovens and drying systems for
downstream processes in the
manufacture of carbon fibre.
www.eisenmann.com
Electroplated
> Stand C24
wheels for
grinding fibre-reinforced
plastics
Muzzi Srl has added a new product line
to its standard production. Thanks to
significant investments in the new plant,
the company is now able to propose
custom-shaped wheels for the fibrereinforced plastic sector. From design to
final balancing, through machining and
electroplating, all production steps are
made in-house, so that Muzzi can
guarantee and certify the required quality.
Prompt delivery of special tools is
another fundamental issue for customers
competing in a
market where
production
scheduling is
tighter and tighter.
www.muzzisrl.it
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
Cutting and milling composites and
honeycombs
> Stand T34
Geiss develops and builds some of the leading machines on the
global market in terms of technology, quality and performance.
The machines are designed so they can be manufactured in any
customized size and adapted to special requirements.
CNC-controlled, high-speed, five- and six-axis cutting and
milling machines especially developed for trimming composite
and honeycomb materials are available. These machines are
completely closed and equipped with dust-extraction systems.
Geiss’ different milling spindles and ultrasonic cutting knives are
suitable for a wide range of applications. Sonotrodes designed precisely to match the
corresponding knife are available in different designs for cutting honeycomb materials.
Ultrasonically activated circular knives for chamfering honeycomb are available in a
standard diameter of 50mm or 25mm. The sonotrodes can be exchanged automatically.
Areas of application: thermoplastics, glass- and carbon-fibre-reinforced thermosets,
compression-moulded GMT and SMC parts, moulded foam parts for sandwich
construction, wooden panelling, shaped plywood parts, lightweight honeycomb
materials, blow-moulded parts, pattern-making foams for tool-making and prototyping.
www.geiss-ttt.com
New high-temperature composite tooling
infusion system
> Stand G11
The range of composite tooling materials from Axson Technologies has expanded to
include a high-temperature infusion resin for use up to 190°C. The EPOLAM 2090 /
2026 is an epoxy resin for the infusion of large, high-temperature-resistant moulds. It
is approved by numerous industries: aerospace, marine, transportation, etc.
Infusion provides results close to prepreg lay-ups
without the high costs linked to high-temperature cure,
ovens, cold storage and heat-resistant models. The low
viscosity of this epoxy resin, associated with a low
reactivity and a very long pot-life, is ideal for the
infusion of moulds exceeding five meters. The initial
viscosity is stable for 24 hours, the product does not
self-combust in bulk, and the viscosity of the resin is
stable during storage. Moreover, the EPOLAM 2090 / 2026 is compatible with a wide
range of auxiliary products.
www.axson.com
Complex milling
> Stand L80
Koller is a high-tech model-making company that specialises in complex milling
operations, using high-productivity five-axis CNC milling machines with linear drives.
The company’s range of services includes:
- design, manufacturing and machining of blanks made of polystyrene, sprayed or sheet
polyurethane foam, extruded or sheet epoxy resin, wood, medium, etc.;
- construction of scale models for the land transport sector (automotive, etc.);
- construction of master models and models for tank testing in the
boatbuilding sector;
- special tooling for the aeronautical and railway industries.
www.koller.fr
jec composites magazine / March-April 2009
New ATL and AFP
systems
> Stand P63
The Forest-Liné range of solutions for
processing fibre-resin composites is
continuously expanding. It presently
includes:
• ATL (Automatic Tape Laying) systems
both for flat and contoured large parts,
ranging from simple single-phase
machines to large dual-phase systems.
• WR Atlas laying machine: single-phase
automated system for standard 150 and
300 mm tapes.
• AFP (Automatic Fibre Placement)
machines: building on the success of the
Linear Atlas machine with its all-in-one
tape cutting and laying system, ForestLiné is now offering the FP Atlas
machine, which lays down 12 to 32 tows
simultaneously to produce large aircraft
fuselage parts.
A large system (32 tows x ¼”, see
picture) has been operating in production
in a large aerostructure factory since the
end of 2007.
www.forest-line.com
> Stand J14
Application
milling module for robots
With the new AMM (Application Milling
Module), Kuka offers application-specific
components and tools for quick and easy
operation of a robot as a machine tool.
AMM is specially designed for tooling
tasks that use a milling spindle with a
rated power of 8 kW, 12 kW or 16 kW
and is mainly applicable to materials
such as plastics, composites or wood.
The AMM contains the main equipment
required for using the robot as a machine
tool in milling, cutting or deburring
applications. Different types of robots can
be used according to the size of the part
and the material, from 60 daN to
700 daN. The AMM to be selected is
determined by the type of robot. Working
together with the Kuka
Sim Pro software, it
offers a turnkey
solution for milling
and machining without
robot programming
expertise.
www.kuka.fr
PREVIEW
In-mould painting of LFI parts
> Stand U39
The LFI process differs from other PUR processes in that the long glass reinforcing fibres are
wetted with PUR in the mixing head. In recent years, this technique has proved a
resounding success. What makes the system strikingly innovative is the fact that the highgloss surface to the LFI parts is achieved by spraying the paint directly onto the surface of
the mould. A barrier coat is applied between the paint layer and the LFI substrate to prevent
the glass fibres from spoiling the smoothness of the paint surface.
Successful endurance tests (12,000 hours in agricultural operation) have shown that parts
like engine covers are rugged and long-lasting. They have outstanding mechanical properties
and can withstand temperatures up to 100°C. The new production process has other
advantages, e.g. exact colour matching of the engine covers and injection-moulded front
ends, and the possibility of integrating metal inserts during the production process.
The commercial and utility vehicle industry has shown huge interest in this innovative
process from KraussMaffei. In-mould painted LFI applications include parts for buses, construction machinery, agricultural vehicles
and boat building.
www.kraussmaffei.com
Bespoke autoclaves
> Stand L65
Magnabosco Autoclaves is a branch of Magnabosco Engineering Group, which was
founded in 1960 by Mr Giuseppe Magnabosco. Its carbon-fibre autoclaves are the result
of heavy research on the heating process, temperature uniformity, autoclave
pressurization and vacuum systems.
All functions are controlled by a latest-generation PLC or PC, and Magnabosco
manufactures each machine entirely to individual
customer requirements. The autoclaves can be heated by
steam, diathermic oil, electric power, microwaves or by
a new system called N.E.S. (Night Energy Saving),
which reduces power consumption by 75% and takes
advantage of inexpensive night energy rates. In the case
of steam or diathermic oil heating, Magnabosco can
supply suitable boilers for customer production.
To save energy, all autoclaves have special internal and external insulation allowing
high heating and cooling speeds. Magnabosco took particular care in designing the
materials trolley to allow performing vacuum tests outside the autoclave. That way, any
loss can be identified before the material enters the autoclave, avoiding damage to the
material and the need for operators to enter the machine.
The first autoclave was built in 1963. As of January 2009, more than 1,600 units have
been built, including more than 330 for use on composite materials.
The production parameters are: Ø 300 mm ÷ 8000 mm, length 0.5 mt ÷ 90 mt,
pressure up to 60 bar, temperature up to 450°C. The autoclaves can be horizontal,
vertical or mobile (horizontal during the loading process, vertical for polymerization).
www.magnabosco.com
Large autoclaves and dedicated software
> Stand P64
Industrial Olmar, S.A. will introduce the latest version of its software for composite
autoclaves, along with new integrated peripherals such as
compressor(s) and vacuum/cooling systems that are designed to
minimize space requirements and reduce operational costs and
installation time (All-in-one Olmar System).
Industrial Olmar, S.A. will also present a new generation of
larger autoclaves designed to meet the industry’s changing
needs. Two autoclaves 6,000 mm in diameter are under construction.
www.olmar.com
Volumetric 3D
laser controller
> Stand F43E
The volumetric 3D laser controller
developed by Thermwood offers
volumetric 3D laser compensation.
Some of the better first-generation
controls allow for lead screw
compensation, i.e. they use a table to
compensate for position inaccuracy
along an axis. The table is created by
precisely measuring the actual position
along an axis with a laser. The only
problem is that moving along one axis
may cause inaccuracies on the other
two perpendicular axes. For example,
if the X axis rails are bowed, both the
Y and Z axis can shift slightly as you
move along the X axis. First-generation
compensation only corrects the X axis,
disregarding any effects on Y and Z.
The next-generation Gen2 Super
Control compensates all three axes in
every position within the working
envelope. Every inaccuracy or
misalignment is automatically
corrected regardless of its source.
The controller also provides advanced
parameter access. Because of the
change-over to Siemens Sinamics
drives, Thermwood’s Gen2
SuperControl displays real-time
information on the current draw,
voltages, torque, and temperature as
well as other parameters.
www.thermwood.com
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
New high-pressure compression and
lamination system
> Stand R12
Reliant Machinery Ltd will present their new Powerbond-HPC high-pressure
compression and lamination system. Reliant have been producing laminating and
compression equipment in the UK for forty years and exports their equipment
throughout the world. Many leading composite material producers use Reliant
machines.
The new Powerbond-HPC is designed to provide high
controllable pressure during the heating and cooling
cycles whilst allowing a continuous process to run.
Materials can be fed into the system in continuous webs
or in sheets. This makes the machine suitable for
composite materials such as fibreglass, aramid and
carbon. Materials can be fed directly into the machine
from weaving heads and creels as well as unwinding systems, which makes it suitable
for the lamination and compression of coaxial, multi-axial and unidirectional materials
and cross plies. Composite multi-layer sandwich boards can be assembled and fed in a
continuous process, making the Powerbond-HPC an extremely efficient operational
system.
The system is produced in 1,500 mm long heating and cooling modular sections,
which allows the machine to be assembled to any length and thermal energy capacity
so as to meet any process parameters. The system is available in widths from 60 cm up
to 300 mm.
www.reliant-machinery.com
New water-based semi-permanent mould releases
Compression
> Stand S29
moulding composites with
carbon and glass
VN Composites will be demonstrating
one of its key areas of expertise:
compression moulding composite
technology applied to carbon (CMC)
or glass (GMC). This
technology has been
validated for both
space and automotive
endurance world
championship
applications.
The main advantage of this technology
is its ability to provide the flexibility
needed for the rapid detailing of
complex parts with extremely thin
materials. The quasi-isotropic
properties of this new composite result
in superior mechanical performance,
making it possible to mould both small
and medium production runs.
www.vn-composites.fr
> Stand V46
Axel Plastics Research Laboratories will introduce several new water-based semi-permanent
mould releases.
The newest addition to AXEL’s product line is XTEND® W-102, a 100% water-based high gloss
mould release. The semi-permanent release is quick drying, easy to apply at ambient temperature
and requires no heat cure. It provides excellent slip and durability for polyester, vinyl ester,
prepreg and epoxy resins. The semi-permanent release is suitable for many processes including
hand lamination, infusion and RTM.
Other featured products at the expo will include XTEND WHS, a special water-based treatment
for mould flanges and edges, and XTEND WCX, a 100% water-based cleaner. These products join
AXEL’s wind blade release system designed for epoxy infusion: WS-50, mould sealer, and W-7838D matte finish mould release. All of
the products in the wind blade release system are 100 % water-based, non-flammable and odourless.
AXEL will also exhibit XTEND solvent-based mould releases for LFI and PU RIM, as well as a vast selection of resin- and processspecific MoldWiz® internal mould releases.
www.axelplastics.com
Zünd presents G3, the latest in digital cutters
> Stand U43
Zünd is launching G3, its newest generation of digital cutting/routing systems. Exceptional versatility and modularity are the main
distinctive characteristics of these new machines. This impressive line of cutters/routers is the result of more than 20 years of
experience in flatbed cutting technology. Developed specifically for round-the-clock operation, the G3 is a solid, heavy-duty yet
visually striking system. Besides offering maximum productivity, the new machine excels in user-friendly operation, ergonomics, and
reduced energy consumption. It is well designed from start to finish. With G3, Zünd is expanding on its
successful modular concept. All G3 models can accommodate all available Zünd tools and materialhandling features. Upgrading at any time and adapting to changes in production requirements has never
been easier or more cost effective. This translates into exceptionally high cost-efficiency and secure ROI
for customers in the short and long term. The primary focus in developing G3 was system productivity.
The G3 systems are covered by a 2-year warranty.
www.zund.com
jec composites magazine / March-April 2009
PREVIEW
Autoclaves from XS to XXL
> Stand P39
ASC Process Systems is now certified to build autoclave pressure vessels for operation
within the People’s Republic of China. With this certification, the ASC Econoclave™ is
now available in every country worldwide. After numerous requests from customers in
China who already use the industry standard CPC™ control package, this was a
natural step to enhance ASC’s worldwide capabilities.
Each Econoclave™ system is fully factory quality
tested prior to shipment to customers. The system is
as close as possible to “plug & play” configuration
when it arrives on the customer’s doorstep. Thus,
installation time and costs are greatly reduced to
provide customers smooth ramp up to production.
Complete packages are available at affordable prices.
www.aschome.com
Advancement in CNC machining
> Stand L74
CNC-machined composite components are more and more favoured in automotive,
aerospace, railway and yacht manufacturing. With their MK 7 series, Maka expand their
product range of 5-axis CNC centres for composite materials with a low-cost alternative
particularly suitable for cutting and finishing composite materials. This CNC centre of
monobloc design stands for the highest machining quality with maximum feed rates.
The machine's working units have been technically optimized by excellent mechanics,
electronics and construction units, requiring low maintenance in order to provide users
with high process reliability and profitability. Being completely encapsulated at its
bottom and lateral sides and provided with a canopy, this construction offers optimum
swarf and dust management. Various machine versions are available.
Another interesting innovation from Maka is a new tool-changing
system, the "tool shuttle" (150 rpm), minimising cut-to-cut
times to almost nothing and thus highly improving the
efficiency of single-head machines.
www.maka.com
Extrusion lines for PET foam sheets and
boards
> Stand C39
B.C. Foam offers extrusion lines for the production of:
- PET foam sheets suitable for thermoforming with coextrusion outside, inside or on
both sheet sides, for the food packaging industry;
- PET foam boards with a density ranging from 60 to 400 kg/m3 and thicknesses up to
100 mm, using two different technologies and different blowing agents, i.e. nitrogen,
CO2, HFC or hydrocarbons according to the required densities. The boards are used in
marine, aeronautics, automotive, wind energy and other special applications.
The range of extrusion lines covers productivities up to 500 kg/h. Lines with higher
productivity levels are currently being
investigated. For R&D activities, B.C. Foam has
set up a pilot line and a big industrial line
complete with downstream equipment making
it possible to run industrial-type productions in
order to support customers in the product
launching phase.
www.bcfoam.com
Innovative
machining robot
> Stand T81
Following several months of
development and tests with
CETIM (French
Mechanical Engineering
Technical Centre),
Stäubli is launching a
new machining robot for
the industry.
Stäubli has contributed several
technological innovations to the project.
The RX170 HSM robot has a PreciseFisher high-speed spindle integrated
directly into its forearm, an adaptation
that greatly enhances rigidity. The
harness containing the unit's power
supply, cooling system and lubrication is
installed inside the arm, with no external
ducting. The robot can be pressurized to
operate in difficult conditions. A new
software program called VAL HSM has
been developed.
Three models of Precise-Fisher highspeed spindle systems can be adapted on
the robot to machine parts at extremely
high speeds. Tests have been done on a
wide range of materials, including wood,
stone, stainless steel, aluminium, steel,
Inconel 600, composite materials, resin,
and glass. Excellent results were achieved
all round.
Apart from the robot's remarkable
performance, its price and features make
it an extremely attractive proposition
from both the capital investment and
operational standpoints. Engineering
shops will use it for different types of
machining operations such as
contouring, die trimming, weld bead
machining, prototyping, polishing,
milling, drilling, tapping, etc. It is a
future-proof solution
that will adapt to any
changes for multiple
application sectors,
including automotive,
watch-making,
nuclear,
aeronautics,
railway,
prototyping,
glass or wood
machining, stone cutting, and more.
www.staubli.com
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
Innovative robotic solutions for fibre placement > Stand M65
The fibre placement systems using robotic solutions developed by Coriolis Composites
have now reached the industrial stage. Used in production for 3 years, these innovative
systems are reliable and very attractive. They are simple and easy to maintain, highly
productive, cost-effective, versatile, flexible, and driven by user-friendly dedicated software.
Coriolis Composites is now developing the next
generation of products: a fibre placement system for
thermoplastic tapes and dry fibres, and a software
program that is fully embedded in CATIA V5/DELMIA.
The Brittany-based company (France) has grown from 3
to 21 engineers. It has already sold a total of 6 systems
for aeronautics applications in Europe. Its skilled
composite engineers are involved in the main R&D project in France and Europe,
working on the next generation of aircraft and aeronautic products.
www.coriolis-composites.com
Extremely lightweight design
and electrothermal heating
> Stand S34
The Tailored Fibre Placement (TFP) technology, originally
invented at the IPF Dresden, is capable of manufacturing stressadapted composite parts. These composite parts offer a much higher mass-specific
stiffness than parts made of standard multiaxial fibre materials, like fabrics or NCFs. By
using topological and material optimisation methods in connection with the TFP
technology, the full potential of the FRP material can be used for structural applications. As shown in the example of a reinforcement clamp made of CFRP, the massspecific stiffness can be increased up to 200% compared to standard multiaxial NCFs.
Qpoint Composite GmbH, the recently founded spin-off of IPF Dresden, offers
groundbreaking manufacturing equipment for all kinds of composite products and
innovative de-icing structures for aviation applications. Locally adjustable
electrothermal heating structures can be applied to 2D- and 3D-composite tools for
preform and injection processes. The manufacturing processes are characterized by
improved quality and a reduction in cycle times, energy and amount of work.
Electrothermal carbon de-icing structures for aircraft structures, such as slats or turbine
air entrances, increase the security and functionality of carbon structures.
www.qpoint-composite.de
New fibre placement head featuring
automatic change
> Stand F51
As part of the continuous development of its composite technology, Ingersoll has just
completed a series of qualification and endurance tests with the new fibre placement
machine Mongoose V1, Generation3, used in its vertical configuration here. During the
10-hour test (mostly in continuous deposition), the newly designed fibre delivery
system (head & creel module) with 16 tows ¼” width, has exceeded the most
optimistic expectations, depositing more than 150 kg of carbon fibre without any
roping or twisting of the material. Out of the 150,000 adds and cuts required during
the test, there was not a single failure. The Mongoose series, available in both vertical
and horizontal configurations, has the following feature: lay-up speed: 50-60 m/min;
cut speed: 50 m/min; add speed: 50 m/min.
Remarkably, the machine features “head & creel module” automatic
exchange to speed up productivity or to change the tow sizing and
number in order to fit different part geometries. Deposition heads
with 12-16-24 tows and widths of 1/8", 1/4", 1/2" are available in all
their combinations.
www.ingersoll.com
jec composites magazine / March-April 2009
Carbon foam
> Stand P52
prototype tooling system
GrafTech International has developed a
prototype tooling system based on the
GRAFOAM® carbon foam. This foam
has exceptional thermal stability and a
close match of thermal expansion with
carbon fibre
reinforced
composites,
making it an
ideal lay-up
mandrel tool
material.
GRAFOAM has
an open-cell structure. For prototype
tooling applications, the machined
carbon foam surface needs to be
properly sealed and finished to be
suitable for laying up prepreg
materials. The new sealing system is
easy to apply and dries at room
temperature with no additional
temperature cure needed. The system
maintains vacuum integrity and can be
used at temperatures up to 175°C. If
the surface is damaged, it can be easily
repaired with the sealant system.
www.graftech.com
Innovations in
plastics machining
> Stand S7
Hufschmied Zerspanungssysteme GMbH
has just released a new plastics machining catalogue containing new tools that
will make machining both easier and
more effective, as well as many useful
tips from highly-qualified technicians.
The Fiber-Line comes with many new
tools with specific geometries and
substrates developed to fit the needs of
glass and carbon fibre materials, as well
as fibre-reinforced materials. The
company’s carbon end mills offer various
types of serrations, in combination with
extremely wear-resistant tungsten
carbides and coatings, to achieve high
machining speeds and good surfaces with
these abrasive materials. This is, of
course, also valid for
the new Fiber-Drill
drill machining tools
and their partner tools
for manual work.
www.hufschmied.net
PREVIEW
Institut fuer Verbundwerkstoffe GmbH
> Stand D32
Novel system technologies
Tool carrier
In November 2008, IVW’s new RTM mould
carrier, type “MFT 10.5 x 12.5/10 universal GL”, manufactured at DEGUMA Schütz GmbH
in Geisa, was put into operation at the
Demonstrations- und Anwendungszentrum
(D.A.Z.). This universal mould carrier has a
maximum clamping force of 1000 kN. A
hydraulic rotation and tilting unit makes it
possible to place the RTM mould carrier in the
closing device in an ideal position for the
injection process. Furthermore, the closing
device is equipped with a synchronization unit which ensures parallel closing and
opening of the injection tool, while offering the potential to open the tool to a defined
cavity during the injection process. These technical developments will allow new
innovative approaches in the area of LCM.
3D computed micro-tomography system
A 3D computed micro-tomography system is now available at IVW for the analysis of
composites (distribution of material, pores and cracks) and their three-dimensional
display in microscopic resolution. The system features a maximum resolution of <500 nm,
an object diameter of 1 mm up to 200 mm, and a
maximum object height of 150 mm.
Robotic welding system
As part of recent research work, the conventional 2D
induction welding process has been enhanced and adapted
to an industrial robot system. This newly developed threedimensional welding process enables the joining of
complex and curved parts, adding a quality control system
and a high degree of automation. Large, heavy
components can be welded using a suitable handling
system such as articulated or gantry robots. For quality
control of the weld, the surface temperature of the
component is continuously measured. Quality problems,
such as insufficient heating or gaps in the welding susceptor, can be determined by the
temperature profile.
Thermoplastic tape placement process
The tape placement head technology developed
at IVW for in situ consolidation induces the
necessary melting heat in both the incoming
tape and the already placed substrate with a
main heater at the nip-point. During the
placement process, the substrate is held
constantly at elevated temperature to keep the
required heat input in the substrate as low as possible. It is also possible to use a
geometry adaptive roller to ensure good consolidation for complex geometries. The
fully automated head can be operated very flexibly with a robot or any other carrier
system. The integrated rotatable cutting device allows placing net-shape components.
www.ivw.uni-kl.de
New multiaxial
machine
> Stand S32
The Chemnitz-based subsidiary of Karl
Mayer is renowned for its high level of
innovation. For its new developments, it
works closely with the CETEX Institut
für Textil- und Verarbeitungsmaschinen
gemeinnützige GmbH (CETEX Nonprofit-making Institute for Textile and
Processing Machines). The two
companies are exhibiting on a joint stand
at the German pavilion at this year’s JEC
Composites Show.
Karl Mayer will present an innovative
new machine. To follow the rapid growth
of the composite industry, and especially
in view of the current developments in
the wind power sector, the manufacturer
has stepped up the development work on
its multiaxial machines and is now
launching the highly innovative
Malitronic® multiaxial machine onto the
market. This generation of machines will
be unveiled for the first time at the
JEC Composites Show. With its
completely new concept, it offers a level
of performance that has never been
achieved before in terms of productivity,
handling and fabric quality.
www.karlmayer.de
Sealer for porous > Stand M43
substrates like
foam & tooling board
The QuickSkin sealer
was developed for
rapid prototyping. It
cures at room
temperature in
minutes, permits
instant ability to
produce one-off or
short-run parts, and
expedites the creation of masters for
moulds or parts. No sanding or postcuring is required. QuickSkin can seal
machineable tooling blocks, PU foams of
any density, wood and more in just
hours. It can be repaired and its
performance can be extended by adding
release agents. It can be used to provide a
uniform pinhole-free surface for
atmospheric exposure.
www.zyvax.com
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
The answer to mould problems caused by
humidity
> Stand V26
Meguiar’s has incorporated a new breakthrough polymer technology into its liquid
mould release products, but without the harmful carcinogens or the typical foul odour
of some other products. The Velocity 2.0 Liquid products use unique chemistry to
provide exceptional performance in all environments, including high or low humidity
conditions. The Velocity #83 2.0 liquid mould sealer (MV8301) uses unique polymer
technology to seal microscopic pores and
invisible imperfections at a molecular level.
Three-dimensional, cross-linking action
chemically fuses the sealer to the mould
surface, which creates a bond so incredibly
strong it resists wearing off even in the most
punishing, high-volume production
environments. The Velocity #84 2.0 liquid
mould release (MV8401) has new scientificallyadvanced polymers that form a tough chemical bond to deliver an extraordinarily clear
and shiny surface to the mould, producing ultra high-gloss finished parts that require
little, if any, post-production buffing work. The Velocity #85 2.0 low-emission seal and
release (MV8501) is a high-slip, high-performance, semi-permanent polymer formula
for the composite industry that produces unparalleled results. With a shelf life of 3
years and the labour savings from multiple pulls, the Velocity #85 2.0 low-emission
formula is the ideal choice for today’s high-volume production composite
environments.
www.meguiars.com/international
Innovative NDT solutions for composites
> Stand V14
Olympus designs, manufactures and globally markets a range
of innovative non-destructive testing and remote
visual inspection instruments developed with a
commitment to technology, design and user
friendliness. These products are used for
inspection and maintenance in industrial and
research fields ranging from aerospace and
energy to transportation and manufacturing.
Olympus will display a variety of recentlyintroduced innovative products.
The new EPOCH 1000i digital ultrasonic flaw detector combines superior conventional
performance with the power of a phased array imaging software in a rugged and
portable package. It features a large VGA display, a new menu-driven user interface
with adjustment knob, and IP66 environmental rating. Software features include
dynamic DAC/TVG, DGS/AVG, and an optional interface gate.
The i-SPEED 3 is the latest addition to the Olympus high-speed video camera range.
The camera has been designed to an advanced specification providing high resolution,
extremely low light sensitivity, and up to 150,000 fps recording, making it the ideal
analysis tool for high-level applications: aerospace, automotive, R&D and ballistics.
The latest in videoscope technology, the IPLEX FX combines advanced functionality,
configuration flexibility, compact size and portability inside the industry's first MILSTD compliant housing. The new 6.2 mm diameter working channel scope is ideally
suited for foreign object retrieval applications.
www.olympus-ims.com
jec composites magazine / March-April 2009
RTM:
> Stand W65
hot-injection
machine for singlecomponent resins
The MonoMat-Epx500 RTM injection
machine is the latest in an already
well-stocked range of RTM machines
and accessories from Matrasur
Composites. The new machine opens
up new
possibilities
for users of
heatactivated
singlecomponent
resins
commonly
used in high-performance composites.
The machine is based on a hydraulicjack principle and offers an exceptional
operating range with a precisely
regulated flow of 10 to 1400 cc/min.
The wide range is possible partly
because of the brushless motor
technology and partly because of the
control system that adjusts the jack’s
speed in real time, as a function of the
pressure data provided by the tooling.
The machine can be regulated for
constant flow or speed as needed,
which cuts down on the injection time
without jeopardizing either the mould
or the part.
The exothermic risk is taken fully into
account through a gradual and staged
temperature management in the
machine circuit, meaning that the
machine can be loaded before heating.
This is also useful in terms of rinsing
operations, which are kept to a
minimum with this machine.
Six parameters are recorded, including
temperature(s), pressure(s) and
flow(s), with the data saveable to a
flash drive. The data can also be
exported in real time to a remote
computer through a server integrated
into the machine.
To meet the needs of the more highly
specific applications, Matrasur
Composites researches other versions
and accessories on a per-case basis.
www.matrasurcomposites.com
PREVIEW
RTM compression press for manufacturing body panels
> Stand N40
Market leader Pinette Emidecau Industries (PEI) has been manufacturing presses and automatic press lines for more than 150 years,
and works for the automotive, aeronautic and railway industries, among others. PEI recently developed high-capacity presses for
Sotira, with large platen surface area, long stroke and high load, to meet the requirements of producing RTM
body panels for an innovative electric sports car.
The press interfaces with the resin injection machine for better control over the full production cycle in terms of
clamping load, closing time, injection time, etc., in order to obtain the desired quality.
PEI researched and created these RTM compression presses with integration of the injection machine in order to
reach the level of performance required by the process. Sotira, which set up an entire production plant with
seven presses for the project, was very satisfied with the result.
www.pinetteemidecau.eu
FSD Optimization for Composite Structures
> Stand H6
FSD (Fully Stressed Design) Optimization for Composite Structures is a system and
process for developing optimized and manufacturable composite structures. The
system utilizes finite element-based material property-driven design tools to optimize
structures based on load, space, mounting, operational, and manufacturing constraints.
By using these tools, a design can be tailored to perform in specific load case or inservice conditions while considering the manufacturing process and process constraints
during the initial and preliminary design phases. Designs can be driven by the
optimizer and evaluated with FE while considering material properties, fibre angle,
geometric features and manufacturing requirements very rapidly with iterations being
analyzed and improved well ahead of actual part fabrication. This elimination of a
segregated design and manufacturing process greatly reduces the amount of physical
part iterations, tooling reworks and repetitive testing. This gain in design cycle and
manufacturing process development efficiency reduces the overall development time,
making the concept-thru-approved-first-article approval time much shorter and
reducing the cost of new product development.
Quatro's FSD Optimization tools used in conjunction
with one of Quatro's proprietary out-of-autoclave
processes, such as QPS3501, can provide a
continuous carbon fibre structural solution that can
reduce the weight of a similarly designed 7000 series
aluminium part by as much as 50%.
www.quatrocomposites.com
Metering, mixing and dispensing systems
> Stand D38
The PR70 fixed-ratio system from Graco accurately meters, mixes and dispenses twocomponent medium- to low-viscosity materials for potting, gasketing, sealing,
encapsulation and syringe filling. All the features needed in a compact, modular
design. The PR70v is a variable-ratio metering, mixing and dispensing system for
processing a wide range of two-component material formulations.
Designed for smooth, accurate gelcoat application, Glascraft gelcoat dispensing systems
are engineered to deliver reliable performance. Built with fewer wear items, they
consume fewer replacement parts. With reduced service expenses and less revenue lost
due to downtime, these systems are highly economical to own and operate
Glascraft gel-coat systems dispense polyester resin and vinyl ester chemicals. They offer
reliable, highly accurate catalyst percentages and provide high-efficiency performance
at low spraying pressures. They are available in internal and external mix
configurations.
Typical applications include marine and watercraft, pool and spa, bathware,
transportation and cultured marble.
www.graco.be
> Stand T20
The Aquitaine
& U26
region exhibits at
the JEC Composites Show
With their increasing use, composites are
becoming closely associated with
industrial innovation. The Aquitaine
region is a leader in this respect, e.g. as
the number one in France for heatactivated composites and nanostructured
materials. Its academic potential is also
strong, as it is structured around two
federative organizations, which are the
MIB Carnot Institute in Bordeaux and the
Materials Scientific Interest Organization,
with their 150 research scientists.
In 2009, Innovalis Aquitaine will muster
the region’s cutting-edge composite
companies and participate once again in
the JEC Composites Show, with the
support of the Aquitaine regional
council. Groups like Arkema, the leading
European carbon-nanotube manufacturer
(producing 10% of global volumes),
Soficar, a major carbon-fibre
manufacturer (10% of global volumes),
Snecma Propulsion Solide, global leader
in thermostructural composites, and
EADS Astrium will also be present
around the regional stand at the Show.
Some examples: Polycontact and its
customer Eversat will exhibit a briefcase
for reporters, which they can use to get a
satellite connection from anywhere in the
world to receive or transmit all kinds of
numerical, sound and video data.
Polyprocess has innovated in the area of
environment-friendly high-performance
gelcoats with low styrene content and
great durability (among other
characteristics), and will present models
of its creations.
ciglesias@territoires-co.com
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
Industrial-scale microwave hardening of
composites
> Stand Q51
At the JEC Composites Show in Paris, Vötsch Industrietechnik will be introducing the
world’s largest industrial microwave hardening system with a 7000-litre working
chamber volume for applications including composites.
The microwave unit, VHM HEPHAISTOS, is an internationally patented system. This is
the first successful development of microwave technology on a large-scale mature
industrial engineering level. The unit is
therefore characterised by extremely high field
homogeneity. It is possible to harden highquality products and materials such as carbon
fibre-reinforced composite materials (CFC) that
are employed in aerospace engineering and
increasingly so in the automotive industry due
to their potential for use in lightweight
constructions. Microwaves penetrate the
material directly and heat the product, while the oven remains cold during this process.
Reduced production costs through shorter warm-up, process and cooling times are
important advantages offered by the HEPHAISTOS system.
While CFC composites are still hardened at high pressure in heavy industrial ovens, the
HEPHAISTOS system operates on a principle that requires no additional pressure and
thus only involves inertialess heating of the component itself – the oven being no
longer actively heated. This provides a high heating rate generated by microwaves in
the component at low energy consumption. The system also includes newly-developed
inexpensive processes employed in the aerospace industry based on the injection of
resin as an adhesive between carbon fibres. Rapid, efficient and inexpensive production
of composite structures can thus be achieved.
It is also possible to introduce conventional metal tools and charging systems to the
microwave field. The familiar “firework display” given by metal tools and charging
systems in microwave fields is a thing of the past with HEPHAISTOS.
The innovative VHM HEPHAISTOS microwave system is produced by Vötsch
Industrietechnik in Reiskirchen and was developed as part of a technology transfer with
partners at the Forschungszentrum Karlsruhe research institute, the Institute for
Aircraft Construction (Institut für Flugzeugbau - IFB) at the University of Stuttgart, and
the EADS composite research centre in Munich. The name VHM HEPHAISTOS System
means High Electromagnetic Power Heating Automated Injected Structures Oven
System and was derived from that of the Greek god of craftwork and fire.
The modular system is available immediately, from laboratory-scale units (usable
volume 750 litres) to large-scale industrial plants.
www.voetsch.info
New options for innovative fabrics
> Stand T81
Especially suited for sophisticated or innovative fabrics, Stäubli Unival 100, Unival 200
and Unival 500 are marvels of technology. Weavers can experiment with different shed
settings while electronically controlling critical production stages. The market launch
of Unival opens the door to new developments in fabrics.
Ideal for weaving tasks where shed-changing parameters are decisive, the Stäubli
Unival concept serves a great range of applications. Many silk weavers have already
invested in several Unival 100 units, convinced of the weaving quality and the value
added to the finished product. Narrow fabric weavers are now free to create and
produce innovative articles with Unival 200. Regarding research in technical fabrics,
nearly every industry benefits from the technical advances offered by the Unival
concept.
www.staubli.com
jec composites magazine / March-April 2009
Laser projection
> Stand M78
Laser projectors combine the advantages
of contour templates and computer
control to automate the manufacturing
process of composite parts. Z-LASER
projectors are used for quick and
accurate positioning of plies, prepregs
and additional materials inside the
mould.
They are already used in the following
industries: boat building, vehicle
construction, aerospace, bridge and
model building, manufacture of railway
cars or rotor blades for wind turbines or
helicopters.
Laser projection is generally much faster
and more accurate than conventional
templating. The projectors provide
instant return on investment via direct
and indirect savings, including reduced
labour times, improved accuracy, safer
working conditions, quicker design-tomanufacturing lead times, increased
throughput, improved quality, reduced
errors and manual rework, compliance
with the required production process,
multi-instances, multi-tasking,
production monitoring, Windows XP and
Vista ready, customized and optimized
operation screen and devices.
Z-LASER pattern projectors are
commonly used in composite lamination
processes for high-value manual tasks.
They feature automated internal drift
compensation controlled by time and
thermal influences. The Z-LASER
Projection Manager Software has been
constantly improved over the past
decade, making the software more robust
and well proven. Multiple active files for
real-time switching are available in a
single instance of LP.
www.z-laser.com
PREVIEW
Custom-made coating machinery solutions
> Stand U70
Following a successful 2008 exhibition, Coatema will be exhibiting at the JEC Show again this year. The
company will be sharing information about prepreg coating and handling technologies.
With the growing use of coated products for prepregs, the development of adequate coating technologies and
the ideal fibre material treatment for prepreg products are challenges for any mechanical engineer.
Coatema develops custom-made coating machinery solutions to meet the specific requirements of customer
products. Each machine is a unique solution due to the great variety of substrates and coating chemistries
available. The company can handle woven fabrics, uni-, bi- and multidirectional fibre constructions and products,
with several orientations depending on the subsequent stress directions.
Coatema offers different matrix resins as coating materials, such as solvent- or water-based epoxy resins,
powder materials, hotmelt resins, phenolic systems, and polyester/vinyl ester/acrylic resin systems.
www.coatema.de/eng/index.php
High-speed
machining with
oil-free coolant
> Stand P69
Breton, a
specialist in
high-speed
machining
centres,
proposes a
new way to
machine
small to large carbon fibre parts using a
new technology that eliminates powder
pollution and air contamination
problems through the use of an oil-free
working fluid that is fully compatible
with carbon fibre materials and their
binders. This European patented
technology can machine carbon fibre
without generating dust, while improving
cutting parameters and tool life. The
working fluid is free of any animal,
vegetable or chemical oil, does not
require periodic change, and contains
only environment-friendly substances.
With this eco-friendly technology, it is no
longer necessary to install large
expensive powder suction and filtering
systems that do not fully eliminate
pollution problems. Unlike dry systems,
Breton’s technology uses a refrigerant and
lubricant system that increases
productivity by 25% and tool life by 35%.
Several customers from Normandy
(France) are already using a complete
solution that combines machine, coolant
and specific vacuum fixtures especially
designed and manufactured by Breton for
optimized machining. This solution
ensures great efficiency, high quality, time
savings and a healthy work environment.
www.breton.it
Vacuum bagging: two companies under a
global brand
> Stand T50
The new Richmond Aerovac logo
unites the two companies under a
global brand as the businesses take a
leap forward by entering into the
manufacture of vacuum bagging films,
strengthening their future in the
composite industry.
Aerovac Systems – with its subsidiaries
across Europe – and Richmond
Aircraft Products in the US are two of the world’s leading suppliers of vacuum bagging
materials for the composite industry. They supply a wide range of materials and
technical support to a growing number of international customers.
They are part of the Process Materials group within Umeco Composites, which recently
acquired IPM, a leading manufacturer of vacuum bagging films for the composites
industry and other markets. The acquisition of IPM provides Aerovac and Richmond
with a secure supply of key process materials, with the opportunity to innovate and
respond to the developing needs of their worldwide customers.
Aerovac and Richmond will now jointly market their range of products and services
under the Richmond Aerovac brand name, reflecting their ability to meet the needs of
global customers wherever they choose to develop their activities in the world.
www.aerovac.fr
Eliminating dust from your work environment
> Stand L57
Founded in 1969, Dynabrade has earned a reputation and position of continued
leadership in the innovative design and manufacturing of unique portable abrasive
power tools. Dynabrade tools grind, deburr, file, sand and polish to meet the needs of
many industries for fibreglass, composite, plastic, rubber, wood and metal applications.
Dynabrade offers a range of disc sanders mounted with vacuum shrouds that improve
the capture of dust at source, namely: 1.3 hp disc sander 52596 with a diameter of 127
mm and 0.4 hp disc sanders 50210, 50211, 50561 & 50570 with a diameter of 76 mm.
Made of clear, lightweight urethane, the vacuum shroud gives the operator greater
visibility of the work surface and improves abrasive and surface contact, maximising
dust extraction. This system provides a cleaner workplace and protects the operator
from dust inhalation.
Downdraft tables 64202, 64203 & 64204 are must-haves from the Dynabrade vacuum
range with a dual filtration system that ensures very effective dust removal. Available in
3 different sizes, the downdraft tables have casters that
boast easy manoeuvrability and the tabletops are made of
Rhino Linings®, a durable anti-slip material.
www.dynabrade.com
March-April 2009 / jec composites magazine
SPECIAL
jec composites show 2009
APPLICATIONS
Innovative active > Stand Q37
locking system
for composite pipes
The
innovation is
an active
locking
system
developed to
assemble two
composite
pipes. The active composite is a material
that changes shape when submitted to
electric power (Joule effect). This
property can be used temporarily to
assemble or disassemble two structural
composite parts like pipes. In normal
conditions of use, the composite material
is inactive.
Basically, electrical resistive fibres are
designed, calculated and embedded in
the laminate, which is cut into clips with
a special shape to lock the parts. The
deformation under internal heat (the
fibres are powered by electricity at a
given intensity) results from the
anisotropy of each layer and the
differential thermo-mechanical properties
of the laminate. When the power is
switched off, the active composite
recovers its initial shape, ensuring
mechanical locking.
A test bench was developed to test the
pipe assembly under tensile load. The
results show that the tensile strength
ranges from 150 kg to 300 kg depending
on the number of clips, the pipe
diameter, etc. The load intensity depends
on the thickness and Young’ modulus of
the composite layers.
This locking system has the advantage of
making assembly and disassembly easier,
while being sustainable (no more bonded
joints) and fast (no thermal curing
cycle). The locking step can be
performed on industrial sites using a
power generator. The main fields of
application are water or low-pressure
pipe networks and other systems
requiring easy and quick assembly and
disassembly.
These applications are patented.
www.cetim.fr
Films for lightweight underbody shields
> Stand H74
Mondi is an international paper and packaging group providing extrusion-coated,
laminated, siliconized and printed
solutions. Key operations are in Europe,
Russia and South Africa.
Mondi Technical Coatings Automotive
produces high-performance, tailor-made
extrusion-coated and laminated materials
for the automotive industry. It supplies
all sorts of specialized film/(non)woven
solutions for various applications such as
headliners or carpet backings. To meet the growing demand for environmentfriendly components, Mondi developed a range of films that reduce the weight of
underbody shields while maintaining all other properties, e.g. stone-chip
resistance and dimensional stiffness. The company also developed a coated nonwoven car cover material which protects the paintwork from weather influences.
This material is water resistant and allows moisture breathability, while still
providing chemical, UV and tear resistance.
Mondi Technical Coatings Specialties has developed superior barriers against most
organic and inorganic chemistry, whether in liquid or gas form, and a wide range
of functionalities such as release properties, monolithically breathable coatings,
flexibility vs. rigidity, easy tear vs. reinforcement, impact resistance, soft touch,
sound absorption and emissivity. It also developed some specific functional
coatings offering superior fire and heat resistance up to 1050°C, anti-slip,
antibacterial and anti-fungus properties, as well as conductive coatings with a
surface resistance down to 105Ω/m².
www.mondigroup.com
Racing bicycles and mountain bikes
> Stand D32
Together with Canyon Bicycles GmbH, Koblenz, IVW has been developing carbon
fibre reinforced polymer (CFRP) frames for high-performance racing bicycles and
mountain bikes since 2003. An extremely lightweight CFRP racing bike frame
achieved a world record stiffness-to-weight ratio when introduced on the market
in 2005 and subsequently won
the innovation award of the
state of Rhineland-Palatinate in
the category “Co-operation
Science/Economy”. Since then,
this racing bike frame has been
continuously improved and the
third generation is now
available on the market. CFRP
frames for full suspension and
hardtail mountain bikes were
also designed. Again, these frames received outstanding results in comparative
tests by the technical press and took top positions in international benchmarks.
www.ivw.uni-kl.de
jec composites magazine / March-April 2009