Preview of CAMX - The Composites and Advanced Materials Expo

September/October 2015 ompositesManufacturing C The Official Magazine of the American Composites Manufacturers Association Can You See the University Face? Composite R & D Façade Honors an Aboriginal Automotive Leader Market Update Thermoplastics Gain Traction

AMERICAN COMPOSITES MANUFACTURERS ASSOCIATION www.compositesmanufacturingmagazine.com It’s the CompositesManufacturing Lean Mean Process Machine... Redux It’s the Lean Mean Process Machine….Redux. A three-day event with over 20 closed mold and advanced process demos in a massive enclosed staging area. Building real-world parts, from aerospace nose cones and mini nacelles, to marine dashboards and the coolest long boards you’ll see anywhere! Watch a Light RTM work cell in action, see time-lapse video showing a 3D-printed mold go from concept to reality in hours, and talk to closed mold and advanced process experts. Leave with new ideas and insights, and maybe even a tricked-out skateboard if you win this year’s raffle. Experience it LIVE at Booth #S94 during CAMX 2015 in Dallas, October 27-29.

Presented LIVE by Composites One, the Closed Mold Alliance and our industry partners

CMP-407 CAMX Redux ad FINAL.indd 1 8/5/15 10:40 AM September/October 2015 CompositesManufacturing The Official Magazine of the American Composites Manufacturers Association

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10 Features Composites in the Fast Lane ...... 14 Automakers are featuring CFRP in an increasing number of applications, from body structures to wheels. And research centers across the globe are finding ways to enhance carbon fiber-based materials and manufacturing techniques, all in the hopes of increasing composites usage in the auto industry. By Mary Lou Jay A Peek into the Future...... 20 20 Universities throughout the United States are working on innovative R&D projects. Read the latest lab news from MIT, USC, University of Central Florida, Purdue, Market Segments Missouri University of Science and Technology, and Washington State University. Architecture...... 8 By Patrice Aylward and Melissa O’Leary Composite Façade Thermoplastics Are on the Rise...... 29 Sports & Recreation ...... 10 Short cycle times, tough resins, processing possibilities and recyclability. These top the CFRP Hydroplane Hulls list of reasons why thermoplastic composites are gaining market share. By Susan Keen Flynn Departments & Columns From the ACMA Chair ...... 2 Deep in the Heart of CAMX...... 34 Best Practices ...... 4 CAMX, the Composites and Advanced Materials Expo, hits the Big D this October. Inside ACMA ...... 42 And the lineup of conference sessions and exhibitors is as big as Texas. Plan for the show Ad Index ...... 47 Postcure Chatter ...... 48 with this CAMX preview. By Evan Milberg

About the Cover: Swanston Square, Melbourne. Photo credit: Peter Bennetts From the ACMA Chair Composites Manufacturing Volume 31 | Number 5 | September/October 2015

Official Magazine of the CAMX Hits the Big D American Composites Manufacturers Association

Publisher rom Oct. 26 – 29, we will host our second annual Tom Dobbins FComposites and Advanced Materials Expo (CAMX) in [email protected] Dallas. Attendees will network with major players across Editorial Managing Editor the industry, participate in live demonstrations, see product Susan Keen Flynn [email protected] and equipment displays and discover new products and Communications Coordinator technologies. You do not want to miss the composites event Evan Milberg of the year! [email protected]

I’m looking forward to connecting with my customers and Advertising Sales The YGS Group peers and spending a few days learning about what is new in 717-430-2282 the industry. Keeping up with recent developments can be difficult, so seeing them all [email protected] first-hand in one place makes efficient use of my time. Editorial Design & Production Keane Design, Inc. I’m particularly excited for this year’s general session keynote speaker, Dr. J. Gary [email protected] keanedesign.com Smyth, executive director of global research and development at General Motors. He will provide a viewpoint of the automotive industry’s use of composites, lessons learned All reprint requests should be directed to The YGS Group at 717-399-1900. from the Corvette’s long-term use of composites and insights into the transformational change going on in the auto industry today. (Before you head to CAMX, check out the update on the automotive industry on page 14.)

A newcomer to CAMX is the Institute for Advanced Composites Manufacturing American Composites Manufacturers Association Innovation (IACMI). This organization is embarking upon programs to drive step change 3033 Wilson Blvd., Suite 420 Arlington, Va 22201 growth in the composites industry. Attendees will learn what the IACMI center means to Phone: 703-525-0511 Fax: 703-525-0743 the industry, what projects it is working on and who is involved in driving its success. Email: [email protected] In response to feedback from last year’s conference, we have extended the dedicated Online: www.acmanet.org exhibit hall hours and streamlined the conference program so there is less overlap in Composites Manufacturing (ISSN 1084-841X) is published bi-monthly by the American Composites session topics. Concurrent sessions will cover everything from business issues and Manufacturers Association (ACMA), 3033 Wilson Blvd., regulatory affairs to the latest in materials research and manufacturing innovations. Suite 420, Arlington, VA 22201 USA. Subscription rates: Free for members and non-members in the U.S., Canada If you missed the inaugural event last year, you will certainly be impressed with and Mexico; $55 for international non-members. A free online subscription is available at cmmagazineonline.org. CAMX. From my experience last fall, I know how important it is to plan your time Periodical postage paid at Arlington, VA and additional wisely. The exhibit hall is huge, with nearly 550 companies. Review the list before you mail offices. POSTMASTER: Send address changes to Composites arrive to ensure you visit the companies you want to see, plus have time to peruse the Manufacturing, 3033 Wilson Blvd. Suite 420, Arlington, hall for new ideas. Networking is important, too, so use the social networking and VA 22201. The magazine is mailed to ACMA members and is also available by subscription. Canada Agreement appointment setting tools at MyCAMX Planner, available at camx15.mapyourshow.com/. number: PM40063731 Dallas is a great venue for the conference, with easy access from most destinations and Return Undeliverable Canadian Addresses to: Station A, PO Box 54, Windsor, ON N9A 6J5, Email: returnsil@imex. plenty of restaurants and entertainment. Can’t wait to see you in the Big D! pb.com. Copyright© 2015 by ACMA. All rights reserved. No part of this publication may be reprinted without permis- sion from the publisher. ACMA, a nonprofit organization representing the composites industry worldwide, publishes Composites Manufacturing, circulation 9,000, as a service to its members and other subscribers. The reader should note that opinions or statements of authors and advertisers appear- Jeff Craney ing in Composites Manufacturing are their own and do not Crane Composites necessarily represent the opinions or statements of ACMA, its Board of Directors or ACMA staff. ACMA Chairman of the Board [email protected]

2 CompositesManufacturing Setting the standard for unmatched reliability and trust

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Composite Structural Connections

s the polymer composites industry Mechanical Connections where the connector “bears” against the Acontinues to grow, questions Mechanical connections, which utilize composite inside the drilled-hole; forces arise concerning connections between traditional fasteners such as bolts, screws, are transferred between the composite and composites and between composites and rivets and pins, are currently the preferred the connector at the surface around the other materials such as metals, wood, connection method between composites circumference of the drilled hole. Testing concrete or plastics. This column will and between composites and other and calculations can be easily produced to briefly discuss the current industry materials such as steel, concrete and wood. determine strengths of these connections. methods for making these connections Published test data is readily available for In bearing-type connections, bolt shear from the point of view of a registered the typical, hex-head bolt as well as screws, seldom controls in pultruded composite design professional practicing in the rivets and pins, all of which can be carbon connections since stainless steel bolts are pultrusion industry. It will focus on steel, stainless steel or even polymer the norm and have greater shear strength two common types of composite composites. Nylon rivets and pins are than the composite’s pin-bearing strength. connections – mechanical connections available as well. Mechanical connections provide and a combination of mechanical and In designing these mechanical resistance to tensile and compressive bonded connections. connections, engineers most often refer forces, but what about the well-known to them as bearing-type connections rigid, or semi-rigid, steel connection

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4 CompositesManufacturing CompositesManufacturing 5 Best Practices

(“moment connection”) that offers between the parts, normal to the composites’ from one member to the next over a rotational strength, bearing and shear surfaces. Note that epoxy and resins are often greater area. strength and stiffness in a mechanical an exception to this due to their bonding A less common method for connecting connection? Although the pultruded capabilities to many materials. pultruded shapes is to bond the parts composites industry would benefit from together using epoxy resins or similar having a semi-rigid composite connection Mechanical and Bonded resins. Reliability of bonded connections is method, it hasn’t yet been formally Connections more difficult to achieve in the field due to developed. While it can be achieved – and A common method for increasing the variability in ambient conditions. It can be has been done in composite design and strength and durability of a traditional successfully performed, and interest and manufacturing – it is very difficult and mechanical connection is to use adhesives. experience in this method is increasing. isn’t common practice in our industry. Epoxy resins are known for their Pultrusion manufacturers and molded An additional example of a mechanical bonding capabilities to many materials, fabricators have information available connection is integrating pultruded therefore epoxy adhesives are often used for performing each of these connection composites, or even traditional materials, in connections between composites and types: You can call them, purchase a into molded parts. This integration between composites and other materials professional publication or download a has been in practice for many years, assembled with bolts and adhesives. Two- well-tested guide. Their recommendations and opinions vary on the best method. part urethane adhesives are available with will most often include years of successful A mechanical connection between a reliable results as well. The adhesives are practice and details supported by pultruded shape and a molded shape can applied to the prepared mating surfaces, laboratory test data. be achieved by fully encapsulating the and the connection is assembled with pultruded composite in the molded part the completing step being permanent The guest columnist for this issue’s “Best so that the connection will not solely installation of the mechanical fasteners. Practices” column is Stephen E. Browning, rely on bonding one or more pultruded Strength capacities of this connection P.E., a structural engineer with Strongwell surfaces to the molded part during the lay- are generally higher than mechanical Corporate in Bristol, Va. Email comments up process. Forces are ideally transferred connections because the load is transferred to [email protected].

6 CompositesManufacturing BGF weaves innovation into every fabric design to create distinctive materials for engineered composite solutions. For over 50 years, we have provided advanced materials for aerospace, marine, automotive and infrastructure applications. If you can imagine it, we can engineer the precise fiber matrix to make it happen. Find out what BGF can do for you by visiting BGF.com.

8545_2015_Comp Manufacturing_MECH.indd 1 1/27/15 9:14 AM Architecture

Swanston Square apartment tower features an image of indigenous tribal leader William Barak on its south side. More than 400 GFRP panels of varying sizes are attached to the building to create the image. The panels were made using mouldCAM’s ShapeShell™ building material.

that tell a story,” says Jesse Judd, project director at ARM Architecture, the Melbourne-based firm that designed the building. The image is created by placing white panels of different heights on the building, which produce the illusion of light and dark lines and collectively form the face. The project was only possible through the use of a highly-customized GFRP, which enables the panels to be cost-effectively manufactured to exacting and differing dimensions. “Composites were quite a good fit for this variability,” says Judd. Early in the project, ARM Architecture investigated using aluminum panels. But test fabrication revealed that was an expensive choice because of the amount of labor involved in machining, welding and finishing prior to painting. Ultimately, a composite solution was less than half the cost of aluminum. ARM Architecture relied on a photo Composites and several paintings of Barak for its rendering of the tribal leader. The firm Gain Face then partnered with mouldCAM, a global manufacturer of complex shapes and composite structures. mouldCAM Time designed, engineered and fabricated the panels. There were more than 400 double- nside, it’s a typical upscale apartment curved panels, each 5½ inches thick and building. Outside, the newly completed 15 feet long. They ranged in height from ISwanston Square mixed-use tower in one to seven feet, with shorter heights Melbourne is not ordinary at all. Viewed used where darker lines were needed. from a distance, the building’s southern The monocoque panels use structural façade reveals the face of William Barak, skins to carry the load across all sides, an important elder of the indigenous much like a shell does for an egg. The Wurundjeri tribe that originally owned the panels were independently tested and land on which the apartment sits. It’s as if taken up to a load of 6.4 kilopascals Barak’s 32-story-high image is gazing out without any signs of cosmetic or over the modern city. structural damage and without any

“We’re interested in the idea of buildings Photo Credits: Peter Bennetts residual deformation. Strength was critical 8 CompositesManufacturing because the panels are vertical cantilevers, anchored only at the top and extending out from the building as far as eight or more feet. The panels were attached to the building on each floor at the edges of the balcony slab with custom-designed steel bolts and brackets. They are angled out to minimally obstruct the view from apartments, with the panels essentially acting as quirky-shaped frames of the cityscape. While strong, the panels are also lightweight – another important characteristic because each one had to be hoisted into place and fastened to the building. Using a GFRP panel made assembly easier and safer for construction workers, who didn’t have to wrestle heavy panels into place hundreds of feet above ground. The panels rely on the free form version of mouldCAM’s structural composite technology, ShapeShell™, a product that took the company nine years to research, develop, test and refine. “It is a matrix of reinforcement, vinyl ester resin and adhesives that has been developed to address the needs of the construction industry,” says Toby Whitfield, group managing director of mouldCAM. ShapeShell is impact and corrosion Photo Credit: Peter Bennetts resistant. It’s also fire retardant, meeting Composite panels on the apartment building’s façade frame the residents’ views of Melbourne. specifications pertaining to flame spread and smoke propagation as set forth in Australian building codes. not surprising, given that what’s on the Building At-a-Glance Each panel has a foam core that was cut outside is so different from a run-of-the- to precise specifications on a CNC router. mill apartment tower. “It’s an absolute The eye-catching Swanston The panels were fabricated via vacuum knockout of a building,” says Judd. Square building will capture infusion and post cured at 70 C for six the attention of the more than hours at an off-shore contract facility. 1.6 million people that visit Afterward, each panel was numbered so Hank Hogan is a freelance writer based in Melbourne annually. Here are construction crews would know exactly Albuquerque, N.M. Email comments to some quick facts about the where to place them on the apartment [email protected]. building: building to create Barak’s face. Design, documentation, testing and For more stories like this, visit Opened: 2015 certification of the project took four CompositesManufacturingMagazine.com Height: 377 feet months, with manufacturing lasting and check out the Architecture articles Apartments: 536 another six months. Completed in late under the “Market Segments” tab. ShapeShell™ Panels: 406 2014, the Swanston Square building has Barak Portrait: 980+ square feet won awards and attracted attention. That’s CompositesManufacturing 9 Sports and Recreation

Improved Hulls for Hydroplane Racers

The world’s fastest racing boats, unlimited hydroplanes, skim across the water at speeds over 200 mph. Accidents happen, and the ability to easily replace a hull with a single composite piece could mean returning these boats more quickly to the water.

composites program, which seeks to build skilled trade workers. This boat project provides a unique learning opportunity. Cameron quips, “Teaching composites is a lot like teaching people to fly: it’s a hands- on business.” In this case, those extra hands are helping create all graphite, high-temperature molds capable of producing high-temp Photo Credit: H1 Unlimited epoxy pieces for hydroplanes. One mold forms the bottom and sides of the boat, while a second mold creates the top deck. Each piece can be produced in under an hour, but speed isn’t the big benefit: it’s the cost. The one-piece hull is less expensive to produce – and repair – than hulls urdo Cameron, a former airline made of multiple pieces and materials. pilot and composites enthusiast, (Today, most hydroplanes are made from a Mmay have found a way to make combination of aluminum, GFRP, CFRP the extreme sport of hydroplane racing and graphite composites.) For national faster and more thrilling. The owner Photo Credit: Cameron Aircrafts sponsorship, teams must have a minimum of Cameron Aircrafts is working with of two hulls on hand. Using these molds North Idaho College’s (NIC) Aerospace leads to faster repairs; in case of damage, Composite Technician program to a one-piece mold allows fabrication of the develop a new manufacturing process for entire damaged area. And with minimal the racing boats, using CFRP to create a glue joints and less overall weight (a strong, lightweight, cost-effective hull. reduction of 50 to 60 percent compared Typical replicas of classic hydroplane Using vacuum infusion to create a to traditional boats, Cameron says), added boats are made up of roughly 6,000 hydroplane’s bottom in a single composite benefits include a better overall strength pieces. But Cameron’s replica of the Miss piece should prove more cost-effective and load paths. Spokane, a vintage unlimited hydroplane than traditional means of manufacturing “I feel the bigger the part, the better that ran from the late 1950s to the early these racing boats – and lead to the load characteristics, the better the 1960s, uses a hull made in two pieces. potentially better performers. handling,” Cameron says. The massive “If you damage a piece – which you do parts of the Miss Spokane replica run with these boats all the time – you can go closer to 200 mph – in order to reduce roughly 31 x 13 feet. With few pieces, back to the mold and recreate that piece the chances for damage. Cameron saw a Cameron expects these boats to have and then bond it back into the boat,” way to combine his passion for vintage better load transfers. “Part count is Cameron explains. boats with the speed of today’s unlimited everything in composites. Let’s get the part Today’s vintage hydroplanes are generally hydroplanes, the fastest boats in the world. count down, get the fasteners out of there featured in demonstrations rather than Now, Cameron is sharing his passion and make it in one piece,” he says. true races, scaled back to a mild 130 to with local students. The former flight To test this theory, two racing teams 140 mph – rather than achievable speeds instructor serves on the board of NIC’s have donated the use of their hydroplanes 10 CompositesManufacturing From TAPES to SHAPES

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12 CompositesManufacturing for the school to cast the molds that will decades back relied on an aluminum- form the basis of the vacuum-infused clad bottom and Teflon paint to create hulls. For Cameron, vacuum infusion is a smooth surface, today’s racers feature Safe, Green the means of making this project a cost- slots on the bottom called fish scales. The effective venture for boat owners and other molds allow for customization of these Acetone racing enthusiasts. His early work with slots as well as various venting options. Replacement composites – including a replica of a P-51 There’s another option that Cameron Mustang aircraft – relied on autoclaves. is exploring – getting steel out of the roll pproaching our sixth decade After some convincing, Cameron turned to cage. Each hydroplane is built with a A in the marketplace, U.S. vacuum infusion processing as a far cheaper steel cage around the cockpit to protect Polychemical Corp. is proud to alternative, and he hasn’t looked back since. the driver if the boat flips, and Cameron announce the availability of our Cameron offers two tips for working with would like to see these replaced with Polychem Acrastrip line. vacuum infusion. First, proper planning a composite product. He explains his Polychem Acrastrip is a safe, green prevents poor performance. Second, “It’s reasoning with a comparison to the alternative for all your cleaning temperature, temperature, temperature and automobile industry: the full-body steel needs within the composite industry. vacuum.” By that he means that keeping frames of the 1950s might have kept the U.S. Polychemical has partnered the workspace, mold and materials infusing car intact following an accident, but not with the EPA’s Design for the at a steady 77 to 80 F, in combination with necessarily the driver. Today’s quick-to- Environment (“DfE”) program to a heated airtight tool, helps to turn out crumple cars are designed to redirect crash promote the use of products with consistently good parts. forces and better protect the occupants. improved environmental and For a mere $1,500, Cameron designed a Cameron expects that composites can, in human health characteristics. sine wave oven that allows him to heat the this way, help better protect hydroplane Polychem Acrastrip is non- composites on the bottom while a metal racers, if costs can be minimized. fl ammable, biodegradable, has no tool attached to the top of the oven creates First, however, Cameron’s composite HAPS and is re-usable. Designed as the vacuum. Cameron works closely hydroplanes need to get off of the ground a solvent and acetone replacement with composite engineers from Vectorply and into the water. He is in the process of product, it will effectively clean, and uses unidirectional fiberglass from assembling his vintage boat and working fl ush and strip uncured or cured Vectorply and SAERTEX. with interested owners to make use of his polyester, vinyl ester, epoxy resins, “I’ve come around to using the vinyl molds to create a modern turbine vehicle. as well as adhesives and coatings. ester resins with an epoxy backbone,” Making these ultra-fast classic hulls In addition to our Acrastrip line Cameron says. “When it comes to available at a price point more speed-lovers Polychem has introduced infusion, I’ve not found a great epoxy can handle might be just what it takes to “Bio-Lock” a revolutionary way infusion resin that will do big parts.” inject new interest into this thrilling sport. to eliminate grinding and sanding Cameron explains that the strength in for secondary bonding! most composites comes from the fiber Megan Headley is a freelance writer based Feel free to contact us at itself. He’s now found that it’s possible to in Fredericksburg, Va. Email comments to www.uspoly.com or use a vinyl ester with an epoxy backbone [email protected]. and get the same allowable that he would 1-800-431-20721 800 431 2072 with an epoxy on the structure. For more stories like this, visit Despite the seemingly finished nature CompositesManufacturingMagazine.com of the molds, there’s room for flexibility and check out the Sports & Recreation with each boat. While hydroplanes a few articles under the “Market Segments” tab.

ACMA Launches LinkedIn Group ACMA has a new group on LinkedIn! This group will serve as a forum where individuals at all levels of the composites industry can come together to share ideas, ask questions, find business leads and engage with ACMA members. To join, go to LinkedIn and search for “American Composites Manufacturers

“Recognized for Association” to access the group. Feel free to take part in safer chemistry” www.epa.gov/dfe/ an ongoing discussion or start your own!

CompositesManufacturing 13 669099_USpoly.indd 1 04/12/13 2:34 PM Photo Credit: BMW Group

Composites in the Fast Lane The industry is evolving quickly to meet automotive lightweighting demands.

By Mary Lou Jay

eadlines are looming for CAFE fuel efficiency standards systems and 60 to 70 percent for carbon fiber systems. So it’s not in the U.S. (54.5 mpg fleet average by 2025) and for surprising that Persistence Market Research predicts the global DEurope’s required reductions in CO2 emissions (40 composites automotive market will more than double in size in percent decrease for fleets from 2007 to 2021). In response, the coming years, going from $3.06 million in 2014 to $7.01 automakers and OEMs are working more closely than ever with million in 2022. the composites industry to produce lighter, more efficient vehicles “The CAFE standards are really what’s been driving the to meet the new requirements. growth of composites,” says Laura K. Gigas, senior product According to the U.S. Department of Energy (DOE) a 10 manager, Ashland Performance Materials. “Composites are percent reduction in vehicle weight can improve fuel efficiency by lighter than steel, and they have other qualities like corrosion 6 to 8 percent or increase the range of a battery-electric vehicle resistance and the ability to consolidate multiple steel parts into by up to 10 percent. Compared with steel, composites can offer one composite part.” a mass reduction ranging of 25 to 30 percent for glass fiber

14 CompositesManufacturing BMW’s new Series 7 models feature a lightweight body structure with elements of CFRP, ultra-high tensile steel and aluminum.

Chevrolet will use Continental Structural Plastics’ TCA Ultra Lite SMC, a polyester-based Class A SMC with a specific gravity of 1.2, in 21 body panel assemblies in the 2016 Corvette. Components include doors, deck lids, quarter panels and fenders. The use of composites will save money, since tooling costs for composites for production volumes under 150,000 can be as much as 50 to 70 percent less than those for stamping steel or aluminum. Ford researchers have been experimenting with both injection molding and compression molding for composite components made from chopped fibers. “The properties look very, very good for future applications,” says Matt Zaluzec, global materials & manufacturing research – VES Technical Advisory Board, Research & Advanced Engineering at Ford. But random fiber composites provide less predictable, less reproducible results than composites made with continuous fiber. Composites in the Fast Lane That’s not an issue in body panels, but it is essential in structural, safety-critical components. Ashland is working with resins and processes such as prepregs and high pressure resin transfer molding (HP-RTM) to improve the structural stability of both glass and carbon continuous fiber composites.

Hyundai: Using a CFRP Frame Automakers like CFRP because of its weight (70 percent lighter than steel and 40 percent lighter than aluminium), high strength- to-weight ratio, stiffness and corrosion resistance. For its new Intrado crossover, Hyundai is using a rigid CFRP structure in combination with lightweight steel. At the core of the Intrado’s frame are CFRP sections that begin life as beams containing overbraided carbon fiber and flexible foam cores. Hyundai says the composition makes laying-up and bending into shape easy – no pre-forming steps are necessary - while the enclosed foam reduces frame mass and cost. A vacuum- assisted RTM process is used to create the final material. Precisely-shaped, continuous loops made from CFRP form self- contained modular frames for the roof, hood and door aperture on either side of the car. Hyundai bonded the carbon loops along their lengths, rather than at cross-sections, to make the frames stronger and reduce torsional stresses. The seals of opening panels shut directly against these frames, further reducing weight and showcasing the CFRP whenever the doors, hood or trunk are opened. Body panels are made from advanced, super lightweight steel, but the strength and rigidity Lightweight and cost effective of the central CFRP frame structure means Hyundai could make Although carbon fiber has grabbed much of the attention in them from any material. the automotive world, OEMs today are using a wide range of A “floating” center console beam, also made of CFRP, runs the composites in their vehicles. length of the Intrado. This beam provides the vehicle with its Sogefi, working with Owens Corning, unveiled the first unique strength, connects the passenger areas and powertrain composite material coil springs for automotive suspension to the CFRP frame and serves as a mounting point for essential systems last fall. Audi will use the GFRP coil for its mass- controls and protective padding. produced A6 Avant 2.0 TDI ultra. The composite coils weigh 40 Hyundai says the unique qualities of the Intrado make it more to 70 percent less than traditional springs made of steel and will repairable than typical CFRP structures, as damaged sections reduce the weight of the vehicle by approximately 9.7 pounds. or parts can be replaced without the use of expensive tooling They also will reduce noise and decrease CO2 emissions up to or ovens. The Intrado’s minimalistic, self-supporting skeleton- 1.1 pounds per 0.62 miles. like frame structure is highly stable and extremely lightweight, CompositesManufacturing 15 Photo Credit: Ford Motor Co.

Wheels on the new mass-produced Ford Shelby GT350R Mustang are made from CFRP, which cuts the weight in half compared to aluminum.

saving 70 percent weight compared to a conventional chassis In April it signed a joint development agreement with DowAksa and around 30 percent on the overall vehicle weight without to advance research on high-volume, automotive-grade carbon compromising safety attributes, according to the company. fiber. The goal is to produce cost-effective composite parts that are much lighter than steel, but also meet automotive strength Ford: Bonding Composites with Aluminum requirements. A CFRP passenger cell will anchor Ford’s new GT high- performance, limited-run supercar, scheduled for production BMW: Building Composite & Metal Hybrids in late 2016. The vehicle will include aluminum front and rear Building on the carbon fiber technology introduced in the subframes encapsulated in structural CFRP body panels. The BMW i vehicles, the German automaker’s new Series 7 luxury CFRP in the GT’s chassis tub and bodywork will be hand laid. sedans feature a lightweight body structure with elements of Ford also will use CFRP in a mass-produced car, offering CFRP CFRP, ultra-high tensile steel and aluminum. According to wheels as a standard feature on its Shelby GT350R Mustang. The BMW, the combination increases the strength and rigidity of one-piece wheel is half the weight of an equivalent aluminum the vehicle’s passenger shell while substantially reducing weight wheel (18 pounds versus 33 pounds). Australia’s Carbon (up to 287 pounds). BMW incorporated CFRP in the B and C Revolution worked with Ford to develop the wheel, which pillars, rocker panels, roof bows and rails, transmission tunnel includes a thermal barrier coating and a special durability coating and rear deck. to resist corrosion. The team also developed several new processes BMW is producing the Series 7 at its Plant Dingolfing, using to produce the wheels’ high-gloss black finish. wet pressing for components made only with carbon fiber. Carbon Revolution manufactures the wheels by placing fabrics For hybrid parts, the pressing process involves impregnating woven with carbon fibers into a mold, infusing the mold with resin carbon fiber fabrics with resin before placing them, still wet, in a and then curing it at high temperatures. The resulting one-piece molding die with steel sheet. The two materials are then pressed wheel ensures maximum strength and eliminates the need to bond and hardened, combining them into a hybrid component. or glue the wheel’s spokes and barrel components together. The GT350R also features an injection-molded, CFRP grill Speeding Up Carbon Fiber Adoption opening reinforcement (GOR). Although the material costs Automakers and OEMs would be likely to incorporate more are higher than lightweight steel or aluminum, composites carbon fiber into their vehicles if the composites industry could reduce weight and can be formed into a single part. The capital overcome problems like cost and cycle times. The industry is expenditure is less overall because instead of 15 stamped parts that investing time and money in research to solve these problems. require joining, the GOR is made in one piece with a single tool. Dow Automotive Systems, for example, has reduced traditional Ford is pressing ahead with carbon fiber on other fronts as well. 20- to 30-minute molding cycle times to less than 60 seconds 16 CompositesManufacturing Photo Credit: Carbon Nexus

Australian-based Carbon Nexus, which researches and develops carbon fiber-based materials and manufacturing techniques, has 11 industry partners from nine countries. It has produced 75 different batches of carbon fiber for research trials, equaling approximately five tons of material and 2,250 bobbins.

with its VORAFORCE 5300 epoxy resin. “We were able to bring Carbon Nexus has signed an agreement with DowAksa to work new chemistries to this industry that would enable fast processing on some automotive development projects. of structural composites to be able to meet the manufacturing Basic research at Carbon Nexus involves four areas: reducing volumes the OEMs are interested in,” says Peter Cate, associate the cost of carbon fiber, improving its performance, reducing marketing director, new business platforms. VORAFORCE cycle time and improving surface treatment and sizing to 5300 offers both super-low viscosity (10 millipascal seconds) enhance carbon fiber performance. and viscosity latency. It will work with both RTM and wet The facility has already made some significant improvements compression molding systems. in the amount of energy used for the oxidation and Government-backed research centers are investigating ways carbonization processes. Eighteen months ago, the basic to overcome the obstacles, too. Carbon Nexus, part of the operating energy consumption for the carbonization line was Australian Future Fibres Research and Innovation Centre at 822 kW; researchers have now reduced it to 377 kW, less than Deakin University, is the world’s only open access carbon fiber half the initial expenditure. manufacturing and research facility. “End users can come and “This is not focused on inventing new equipment to do the learn and try things out,” says Derek Buckmaster, Carbon Nexus process,” says Buckmaster. “It’s focused around optimizing the way director. “It’s a big benefit for them, because until now they had you use the equipment. We think that’s going to be most relevant to rely on their suppliers, who may not have a great interest in to the companies who are manufacturing carbon fiber today.” this kind of development.” To further reduce costs, Carbon Nexus researchers are The center has two processing lines. One, focused on investigating precursors with higher carbon content in hopes fundamental research, is capable of producing small quantities of of gaining better yields as well as lower cost and bio-based carbon fiber materials. The second, an industrial-scale pilot facility, precursor materials. can make 110 metric tons of carbon fiber material annually. In the U.S., Oak Ridge National Laboratory (ORNL) is home On the applied research side, researchers at Carbon Nexus to the DOE’s Carbon Fiber Technology Facility, which has a are currently working with one OEM interested in minimizing 390-foot-long processing line and can produce up to 25 metric production and processing costs for carbon fibers. The facility tons of carbon fiber a year. ORNL recently 3-D printed the also is partnering with Carbon Revolution – producer of 50th anniversary version of the Shelby Cobra, using 20 percent the CFRP wheels for Ford’s GT350R – and with Quickstep, carbon fiber reinforced ABS material. Australia’s largest exporter of CFRP composites. Quickstep While ORNL will continue to conduct its own carbon fiber now has a division focused on developing and optimizing their research, it is now a key part of a larger endeavor, the Institute process technology for the automotive industry. In addition, for Advanced Composites Manufacturing Innovation (IACMI). CompositesManufacturing 17 demands of high-volume automotive production. (Zaluzec says he’d like to see some entrepreneur do for the composites industry what Andrew Carnegie did for steel, building multiple plants across the country.) And while OEMs are intrigued by the possibilities in CFRP and other composites, they are also interested in the breakthroughs in other lightweight materials. “I love the materials industry because we have more options today than we’ve ever had; our product development engineers can choose from steel, aluminum, glass fiber or carbon fiber composites,” says Zaluzec. “We’re material agnostic, so every material will be considered. We want the right material on the right product at the right time.” Ironically, one of the benefits of composites – the vast range of material and resin choices and formulations – puts them at a disadvantage in this The Oak Ridge National Laboratory 3-D printed the 50th anniversary version of the Shelby competition. “People know steel, Cobra, using 20 percent carbon fiber-reinforced ABS material. they know aluminum, they know the mechanics and the different grades and Launched in June, IACMI comprises 123 partners/members, specifications,” says Kevin Richardson, global marketing manager including ACMA, manufacturers, material suppliers, government of long fiber thermoplastics (LFT) at PPG Industries. “But when and academia, who are involved in advanced composite research, you get into composites, they are made up of a number of raw development and production. Automotive manufacturers like materials and those raw materials can be changed or modified as Ford, Honda R&D and Volkswagen are IACMI members; so far as percentages. So you don’t have that nice little book that you are composite industry companies like Ashland Performance can open up and say composite A is going to get this performance Materials, Continental Structural Plastics and Materials and composite B will get this.” Innovation Technologies. Because automotive engineers and designers don’t understand IACMI will focus on three areas of applied research – the properties of composites, they don’t take advantage of their automotive, compressed gas storage and wind. The goal is full potential. “You just can’t swap out a part and put a composite to move new technology out of the research lab and into the one in its place,” says Keith Bihary, corporate sales director, production line within two to three years. For the automotive Molded Fiberglass Companies. “It really needs to be designed industry, researchers will do initial work at ORNL and then up front to get the real benefits of parts consolidation, proper move to the labs at Michigan State University, which has 4,000 material selection, etc. It needs to be happening early on rather to 5,000-ton presses capable of producing full-scale components. than after the fact.” Since the DOE is a primary sponsor of IACMI, much of The composites industry needs to keep pushing to educate the research will involve removing entrained energy in glass engineers and to find the answers that the automakers need. “It and carbon fiber composites. The 10-year goal is to reduce will be too late if we wait three or four years; somebody else will manufacturing costs by 50 percent, reduce energy costs by 75 come along with the solution,” says Gigas. “It’s not just about percent and increase the recyclability of composites to more than bringing them a material or a resin; it’s bringing them solutions 95 percent. to their challenges, and that’s who’s going to win.” “It’s all with an eye to mass production – 100,000-plus platforms is the goal,” says Craig Blue, CEO of IACMI. “So we’re Mary Lou Jay is a freelance writer based in Timonium, Md. also going to be looking heavily at cycle times and reducing cycle Email comments to times south of two minutes.” [email protected].

Winning Business in a Competitive Industry Get the Inside Scoop on Auto There are other issues that the composites industry must To learn more about what these developments mean, address to win full acceptance in the automotive industry. make sure to attend CAMX in Dallas on Oct. 27 at 9 Composite manufacturers must find cost-effective resins that a.m. to hear GM’s Dr. J. Gary Smyth’s insights on the produce little or no VOCs. The industry must also ensure growth of composites in the automotive industry. that there is a sufficient supply of carbon fiber to meet the

18 CompositesManufacturing CompositesManufacturing 19 A Peek into Photo Credit: Sangbae Kim the Future

In experiments on an indoor track, MIT’s cheetah robot hurdled over obstacles up to 18 inches tall – more than half the robot’s own height – while maintaining an average running speed of 5 mph. University research and development projects prove composites drive innovation and solve problems. By Patrice Aylward and Melissa O’Leary cross the world, composites are being increasingly and hand-wrapped around the core. recognized as the material of the future. Helping to shape Although Kim used epoxy resins and polyurethanes to build A that belief is the cutting-edge research and development earlier versions of the legs, he now soaks the reinforcements in being conducted at universities and research centers. super glue before wrapping. “That’s a faster and easier way to In this issue, Composites Manufacturing highlights research create a surface composite on a 3-D printed part,” he explains. projects at six American universities that demonstrate innovation That’s especially important because the legs, which get the most and potential real-world applications. Imagine a world where wear-and-tear, need to be rebuilt every few days. recycled composites get a second life, bridges withstand The cheetah’s feet have an outer GFRP skin – or ‘shoe’ – that earthquakes and robots contribute to rescue missions. Here’s is made using a 3-D printed mold, the lab’s vacuum chamber a peek into some of the research projects trying to make these and room temperature vulcanizing polyurethane. This stiff outer things – and more – a reality. shoe is then filled with a very soft rubber. The result is a tire-like structure that can absorb much of the impact when the cheetah Robotics on the Run lands. The legs and feet used to be fabricated in one piece, but Project: Robotic cheetah made from CFRP because the legs have to be replaced frequently they are now School: Massachusetts Institute of Technology (MIT) fabricated separately and attached to the legs with zip ties. Location: Cambridge, Mass. The 70-pound cheetah runs 13 mph and can sense and jump Principal Investigator: Sangbae Kim over 18-inch obstacles. It’s capable of much more, but the team Armed with composite legs, feet and body frame, MIT’s hasn’t yet figured out how to land it safely. “It could jump 60 pioneering robotic cheetah can run and jump in an centimeters very easily if you don’t care about landing,” says Kim. extraordinarily animal-like and efficient manner. This is big Kim’s team continues to fine tune the robotic cheetah, which news for robot research as most “legged” robots are quite slow, was funded by the Defense Advanced Research Projects Agency according to Sangbae Kim, associate professor of mechanical (DARPA) for four years. But the project isn’t just fun and engineering at MIT. games: It has a larger mission than creating a cool robot. With Kim began the robotic cheetah project six years ago with the additional funding, Kim believes that a legged rescue robot goal of developing fundamental technologies for transportation could be developed within five years to locate people in fires that will allow legged systems to replace or augment wheeled or disaster areas. Other applications could improve mobility systems. This is important, he stresses, because most of the earth for the physically disabled. Says Kim, “Imagine a wheelchair is covered with non-flat surfaces – from curbs and stairs to hills that, instead of having wheels, has articulating legs or some and mountains. Yet, he notes, our current foundational mode of combination of the two so that you don’t need to worry about transportation – wheeled vehicles – is best suited for flat surfaces. finding a ramp.” Kim and his team began the project by studying animal biology and biomechanics. He points out that mountain goats can climb Salvaging the Scrap Heap 70 degree slopes and lions can safely jump off heights equivalent Project: Reuse of uncured scrap prepreg to a three-story building. And they do so with material that is School: The University of Southern California much weaker than engineered materials. For example, Kevlar® Location: Los Angeles aramid fiber is 20 to 30 times stronger than tendons, says Kim. Researchers: Gaurav Nilakantan and Steven Nutt “We have engineering material that far exceeds animal material, Could medical parts, snowboards and composite structures but somehow we cannot build machines like a gazelle or a deer – soon be made of scrap prepreg composites? The possibility is these very thin-legged animals that can run, jump and land and getting closer as the University of Southern California’s M.C. are still very robust,” he says. “We still don’t know how to build Gill Composites Center wrapped up a research project on the machines that can handle that kind of impact.” reuse and upcycling of uncured scrap prepreg material. According The robotic cheetah required research in three main areas – its to Gaurav Nilakantan, who served as a senior research associate motor, control mechanism and structure. Kim and his team at the center, uncured scrap prepreg is primarily disposed of in developed an electric motor optimized with a transmission and landfills at a high cost to the environment. And the volume of a light detecting and ranging (LIDAR) sensor system that allows uncured scrap prepreg is likely to grow given the increased use of the robot to “see” and autonomously jump over objects. The carbon fiber in the aerospace and automotive industries. cheetah’s structure is made from composites. “There is a need for reclamation techniques that will keep Fabricated by ProTech Composites Inc. in Vancouver, Wash., scrap prepreg out of the waste stream,” says Nilakantan, now the body frame is made of ½-inch thick carbon fiber high-density a research scientist at Teledyne Scientific. “U.S. environmental foam sandwich panel that is CNC milled to create its shape and regulations on mandated levels of reuse and recycling are ramping to add mounting holes for aluminum fasteners. Kim selected this up, creating a compelling need for upcycling processes that can construction because it is both light and stiff. quickly be brought to market.” Kim says it’s critical that the robot’s legs mimic the way Through the National Science Foundation G8 Funding that bones and tendons work together to reduce the stress of Initiative on Materials Efficiency and Sustainability, of which impact. The cheetah’s legs are made of a stiff, 3-D printed core reuse and recycling of composite materials is a major thrust, the made from a polycarbonate-ABS industrial thermoplastic (the M.C. Gill Composites Center set out to develop novel strategies bones) and bidirectional, woven carbon fiber and Kevlar® (the to reuse ply cutter scrap and out-of-spec prepreg material (such tendons). The woven reinforcements are soaked in super glue as material beyond its out-time or freezer life), thereby realizing

CompositesManufacturing 21 rotary and lineal cutters,” says Nilakantan. A clicker die cutting press also was trialed, which regularized the output and created what Nilakantan found to be an optimal rectangular chip size that’s 0.3 inches wide and between 1 and 2 inches long. The team then researched the fabrication of sheets from the scrap chips since a sheet form would facilitate faster production and structural consistency through constant areal weight. In a production environment, chips are uniformly dispersed between sheets of backing paper and fed on a conveyor belt between heated pinch rollers of progressively decreasing gaps to create a uniformly thin sheet with a smooth surface. In a semi-continuous batch process, multiple stacks of chips and backing paper are compression molded under low heat and high pressure to create sheets. A low temperature was required to partially liquefy the resin film in order to bond the chips together, but ensure that the The Gazelle™, a composite prosthetic foot, is the most complex prepreg did not fully cure. High compaction pressure was used to part made so far from upcycled prepreg by the team at USC. generate a flat sheet. “Varying the parameters for chip geometry, orientation and consolidation, as well as the thickness of the their full commercial value. final sheet, created the opportunity to customize for different The team cut the prepreg scrap into individual rectangular chips applications we had in mind,” says Nilakantan. of varying aspect ratios and geometries, and then compression The prepreg sheet, Infinipreg, can be processed through molded them into flat panels and non-flat structures. Additional conventional methods such as vacuum bagging, hot pressing and research investigated the conversion of chips into a continuous, autoclaving, although compression molding proved to be the most flexible sheet and roll forms. Next, the team characterized effective process for forming new shapes. Laminates fabricated the microstructure and mechanical properties of scrap-based from the scrap prepreg chips demonstrated excellent stiffness and laminates and identified feasible applications. strength retention compared to virgin prepreg counterparts. “We assessed different methods of converting the random In addition to their green appeal, scrap prepreg sheets can be shapes of uncured prepreg into chip form, first using a series of processed with temperature ramps higher than that specified by

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22 CompositesManufacturing From left: Jihua Gou, a professor in the Mechanical and Aerospace Engineering Department and director of the Composite Materials and Structures Laboratory at the University of Central Florida, displays the digital manufacturing SDM machine alongside John Sparkman and Xin Wang, two graduate student research assistants in the lab. the suppliers of virgin prepregs, which reduces overall cure cycle still most associated with small consumer-oriented projects or times. This upcycled scrap prepreg material form, which is ready larger demonstration projects. Jihua “Jan” Gou, a professor in for commercialization, holds the promise of reduced costs given the Mechanical and Aerospace Engineering Department and the lower expense of the reclaimed material compared to virgin director of the Composite Materials and Structures Laboratory prepreg and the relative ease of manufacturing. at the University of Central Florida, hopes to expand additive One of the initial prototypes manufactured by the USC manufacturing – also referred to as 3-D printing and digital research team was a composite prosthetic foot – called the manufacturing – into large scale markets like aerospace, Gazelle™ – made completely from uncured carbon fiber/epoxy electronics, biomedical and automotive. To do that, Gou and scrap converted to sheet form. Other products manufactured a team of graduate student researchers created a new digital included cell phone cases, skate boards, cylinders and foam-based manufacturing process called spray deposition molding (SDM). sandwich structures for shipping containers. SDM uses multiple nozzles, contained in a vacuum chamber The project wrapped up in July, and a technical paper will be with a heated base, to create layers of material. One nozzle published this fall with details on the effects of chip architecture sprays nanomaterials, such as carbon nanotubes (CNT), and process parameters, an analysis of mechanical properties carbon nanofibers, graphene flakes or carbon black that have versus virgin prepreg and various other parameters that affect first undergone sonication (applying sound energy to agitate performance. “The technical publication should help commercial particles), in a solvent with the aid of a dispersant. Another processors decide if upcycled scrap prepreg is right for their nozzle sprays a thermoplastic or thermoset polymer solution. project platform,” says Nilakantan. The nozzles, which are controlled along the X and Y axis, can spray materials on top of and around each other. They lay Expanding 3-D Printing Processes the material onto the substrate (controlled on the Z axis) with Project: Digital nanocomposites 235 microns accuracy. Initially, Gou utilized a spray infiltration School: The University of Central Florida process that used a vacuum to pull the solvent through a filtered Location: Orlando, Fla. membrane. However, the process now uses an evaporation Principal Investigator: Jihua Gou method to remove the solvent. Though applications for additive manufacturing have been There are several existing additive manufacturing processes: on the rise since the early 2000s, the method for creating Fused deposition modeling uses heat to extrude the thermoplastic objects by laying down computer-directed layers of material is to build up the necessary layers, and PolyJet technology

CompositesManufacturing 23 uses atomized droplets like SDM and UV light to cure the resin. Three others – digital light processing, stereolithography and selective laser sintering – use lasers as the processing mechanism. In contrast, SDM deposits both nanomaterials and polymers by evaporating the solvent from the solution. Gou says that SDM also allows for the use of multiple materials to create the desired composition, distribution and microstructure of a nanocomposite. For example, SDM can create a nanocomposite that contains both CNT and graphene in a side-by-side and/or layer-by-layer structure. According to Gou, one of the major challenges in developing SDM was the accumulation of the nanoparticles in the nozzles, which caused clogging and halted production of samples for testing. Another challenge was developing an effective nozzle control method to precisely deliver the right material to the correct location at a specific time and in the right amount. Architectural The project, which is funded through the Florida High Tech Corridor (FHTC), began 18 months ago. During stage one, Domes Gou and his team designed, built, tested and evaluated the SDM with Composite Materials machine. That work is now completed, and they are moving on to stage two – material formulation for improved printability and Adaptive Lightweight Complex final properties. The first test product fabricated by SDM was a Strong Non-corrosive Shapes shape memory polymer nanocomposite that was actuated using Joule heating (passing an electric current through a conductor Imagine endless possibilities… to release heat). “The digital fabrication of the nanocomposites www.janicki.com | 360.856.5143 to a desired location allowed for a better distribution of the heat throughout the sample,” says Gou. Although it will be a few years until SDM is ready for

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24 CompositesManufacturing Top-down view of bridge column designs. Left: The hollow column designed by Missouri University Photo credit: Sam O’Keefe/Missouri University of Science & Technology of Science and Technology features a GFRP exterior tube and steel interior tube filled with concrete. Middle: The tubes prior to the addition of concrete. Right: A traditional solid concrete and rebar column.

commercialization, Gou says the new digital fabrication process a doughnut. The steel tube is entrenched into the reinforced shows promise for a variety of industries. For example, SDM concrete footer with an embedded length 1.6 times the tube’s could be used to fabricate digital nanocomposites for Joule diameter, while the GFRP tube ends at the footer. heating applications such as an aftermarket film for deicing Using pipe with fiber orientation at ±53º, ElGawady compared airplane wings without the use of chemicals. This composite the performance characteristics of solid concrete columns with film could also function as a “power film” to provide controlled a hollow column design featuring a high-performance epoxy heat to cure composite structures out of an autoclave. Other and glass fiber matrix typically used in the oil industry and then applications may include flexible electronics for phones, watches with tubes made from a lower cost iso-polyester FRP matrix and other wearable devices and strain sensors for structural health used for drainage pipes. “We tested different numbers of layers monitoring and damage detection of composite structures. and matrix systems of FRP to produce columns that would “Digital nanocomposites are the next generation of composites. cost-effectively respond to local requirements,” says ElGawady. They will integrate structural performance with multi- “For instance, columns incorporating 3/8-inch epoxy FRP tube functionalities all in a single manufacturing operation,” says Gou. have more strength and durability for use in high-traffic zones, “The SDM process can tell the computer what composite product while columns with 1/8-inch polyester FRP tube would be more you want and then produce it accurately and efficiently. In other appropriate for low traffic zones.” words, what you get will be exactly what you see on the computer.” The elements of the hollow column work together to act as a complete engineering system to achieve significantly higher Building Better Bridges strain, strength and ductility compared to the solid reinforced Project: Hollow bridge columns concrete column. The inner steel and outer GFRP tubes function School: Missouri University of Science and Technology as a continuous confinement for the concrete shell, while the Location: Rolla, Mo. steel tube also adds flexural and shear reinforcement. The Principal Investigator: Mohamed ElGawady concrete shell delays localized buckling of the steel tube. The The idea that hollow bridge columns could perform better outside GFRP tube improves corrosion resistance and provides than solid concrete ones seems counterintuitive, but according environmental protection. Additionally, characteristics of the to research conducted at Missouri University of Science and GFRP tube improve both collision and seismic performance. Technology that’s the case: Hollow columns covered by a GFRP Cost estimates for the hollow columns are higher than for coating could extend the lifespan of a bridge. a reinforced concrete column. “While the upfront cost is Research funded by the Missouri Department of Transportation higher, the total life cycle cost should be much less, particularly and the Mid-America Transportation Center compared the considering reduced repair and maintenance and improved performance of hollow-core GFRP, concrete and steel bridge performance,” says ElGawady. The hollow column uses 60 to 75 columns to conventional rebar-reinforced solid concrete columns. percent less concrete material, reducing the column’s weight by a Mohamed ElGawady, associate professor of civil, architectural minimum of 45 percent, thereby lowering transportation costs to and environmental engineering, developed a hollow bridge the construction site. column consisting of an outer GFRP tube with a steel tube Pre-fabrication of the hollow bridge columns takes a few hours inside. During construction, self-consolidating concrete typically in a much less labor-intensive process since the steel pipe and used for bridge columns is poured into the gap between the inner FRP pipe serve as a stay-in-place framework for the poured steel and outer GFRP tubes, forming a concrete wall shaped like concrete. In comparison, a concrete bridge column takes 15 to 18 CompositesManufacturing 25 hours to manufacture. grant from Washington’s Joint Center for Aerospace Technology The Missouri S&T report showed encouraging results for Innovation to study carbon fiber reinforced thermoplastic GFRP’s potential use in bridge columns. Under extreme axial composite waste recycling. So he agreed to help Lilly. and combined axial-flexural loads, the rebar in the conventional “Carbon fiber and fiberglass composite waste provides a whole concrete column ruptured at a drift point of 10.9 percent. In stream of material that we are currently not utilizing but instead comparison, the hollow GFRP column did not fail until it sending to landfills,” emphasizes Englund. Recycled fiberglass reached a 15.9 percent drift point and did so gradually when usually ends up as filler in concrete, he says, where it doesn’t the steel tube finally buckled, followed by a rupture in the add much value. He hopes to change that. “The goal is to create GFRP tube. value-added products that do more than serve as filler – products For vehicle collision testing, the research team used finite where the fact that they are recycled is icing on the cake,” he says. element modeling of heavy vehicles traveling at 35 kips (a He believes getting there requires a commercial partner like GFSI unit of force equaling 1,000 pounds-force) and high-speed to ensure the products are economically viable. vehicles traveling at 70 mph, looking at peak dynamic force and Founded in 2008 to create quality products from recycled equivalent static force. Vehicle impact simulations indicated fiberglass, GFSI initially explored sourcing fiberglass from that both designs would withstand the same amount of force. decommissioned boats and Boeing aircraft before settling Concrete bridge columns showed localized damage which would on wind turbine blades. The company harvested its first require immediate repair. In comparison, modeling of impact decommissioned blades from a wind farm in The Dalles, Ore., in showed the force being transferred throughout the hollow 2010. GFSI harvests the 165- to 173-foot-long blades by cutting column’s structure, minimizing damage to the pillar. them into large pieces that it transports on flatbed trucks, a ElGawady also conducted earthquake simulation tests method that allows GFSI to offer blade recycling for significantly measuring the flexibility of the hollow bridge columns. The less than the cost of sending blades to landfills with large trailers. expected average flex in bridges during moderate earthquake By the time Englund receives the blade material, it has been cut conditions is 4 percent, but the hollow columns withstood a into 2 x 2-inch blocks that will accommodate the lab’s shredders, flex of up to 15 percent. “This should make the hollow columns hammer mills and disc mills – equipment that was previously using GFRP of particular interest in the 36 states where design used to break down wood products. Englund runs the blocks for seismic force is required,” notes ElGawady. through the shredders and mills to produce different particle sizes The report from Missouri S&T calls for additional testing of in just a few seconds. fiber orientation, resin type and the use of thicker GFRP layers at Englund then creates and tests panels made from different key points in the column to optimize the hollow column design. combinations of the fiberglass particles, resins and fillers to The results are likely to create further interest in GFRP’s use for determine suitability for various products developed by GFSI. bridges. “The United States has a rapidly aging infrastructure,” Although details of the combinations are proprietary – or the says ElGawady. “Over one-fourth of all bridges are structurally “secret sauce” as Lilly puts it – he acknowledges he uses bio-resins obsolete. With this new formation of columns, I see the potential with low to no VOC emissions and fillers include rock, minerals to exceed the typical 50-year lifespan of a bridge.” and additives. The company uses a heated platen press to consolidate the test panels, which are cured at room temperature A Second Life for Wind Blades for 60 to 90 minutes and come out of the mold “as is.” Project: Wind turbine blade recycling Englund says wind blades are great for research because each School: Washington State University Location: Pullman, Wash. Principal Investigator: Karl Englund Old wind turbine blades go to landfills to die. Yet a single FRP blade contains between 14,500 and 22,000 pounds of material – most of it glass fiber. That is a treasure trove of research material for Karl Englund, associate research professor and extension specialist at Washington State University’s Composite Materials and Engineering Center. Englund, who has been dubbed “the garbage guy” by colleagues, has spent 10 years working on creating new composite materials out of recycled carpet, wood waste, plastics and agricultural waste from corn cobs to rice husks. Englund turned his attention to wind turbine blades in late 2014 when he received a call from Don Lilly, CEO of Global Fiberglass Solutions (GFSI) in Mill Creek, Wash. “Don asked if I could help him figure out what to do with decommissioned wind blades from wind turbines,” recalls Englund. Englund was already keenly interested in end-of-life problems Decommissioned wind blades are cut into large pieces and sent with composites, in part because of neighbor Boeing’s recent to a lab at Washington State University, where they are cut into move to replace cheaply recycled metal airplanes with not-so- 2 x 2-inch blocks, ground into small particles and fabricated into easily-recycled carbon fiber ones. He also had a 2014 research test panels for eventual use in new GFRP products.

26 CompositesManufacturing Photo Credit: Purdue Research Foundation

Using SwiftComp composite simulation sofware developed at Purdue University are, from left, Bo Peng, a graduate research assistant; Wenbin Yu, associate professor; and Ernesto Camarena, a graduate research assistant. one contains so much material and that material is consistent – used for simulation, however the intricacy of a composite part typically a combination of structural balsa wood, resin and glass makes it more difficult to deliver accurate results. Wenbin Yu, fibers, with the bulk of the weight in glass fibers. associate professor of aeronautics and astronautics at Purdue Englund believes this research may first lead to “low hanging University, has developed a high-fidelity simulation tool for fruit” commercial products, such as panels for residential use modeling of composite parts that is designed to unify structural or other applications that will add value or replace wood-based and micromechanics modeling. products. Meanwhile, GFSI, which plans to open its first plant in Initial research into the theory behind a general-purpose Bothell, Wash., this fall, is in pre-production stage with some of its composites-specific computer simulation system was funded products and is partnering with other manufacturers to produce by the U.S. Army Vertical Lift Center of Excellence. The railroad and subway ties, decorative bases for utility poles, utility technology was further developed with funding from the U.S. poles, manhole covers, jersey barriers and roof cladding. Air Force Office of Scientific Research. Yu’s initial systems As the collaboration continues, neither side will run out of FRP analyzed narrow categories of structural parts – slender blade material anytime soon. GFSI has more than 125 wind composite structures and composite plates and shells. A third blades on hand, while Englund simply laughs when asked how system conducted micromechanical modeling of composites. many blades he is working with. “It will probably take me the rest In 2012, Yu began to consolidate the three predecessor of my life to finish working on one!” systems to develop a unified modeling system. The result is a new approach to high-fidelity modeling of composites based on Modeling Tool Comes of Age a unified theory for multiscale constitutive modeling, as well as Project: Composite simulation software the development of a general purpose micromechanics code for School: Purdue University heterogeneous materials. According to Yu, SwiftComp is based Location: West Lafayette, Ind. on a theory which maximizes accuracy in the modeling process Principle Investigator: Wenbin Yu at a given level of efficiency. Until now, the complexity of composite structures required SwiftComp homogenizes composites of an arbitrary cumbersome simulation programs to model their performance microstructure using the variational asymptotic method to characteristics. Finite element analysis (FEA) has often been calculate effective properties, such as thermal, elastic, electric

CompositesManufacturing 27 and magnetic characteristics for beams, plates, shells and structures, continuous fiber-reinforced composites, short fiber 3-D bodies. According to Yu, the analysis implements a true composites, textile composites and more. multiscale theory, which guarantees the best models at the The composites simulation program is commercially speed of engineering design capture both anisotropy and available, with exclusive licensing rights held by AnalySwift. heterogeneity of composite constituents at the microscopic The engineering software also will be available through scale. SwiftComp is based on a new concept called the technology provider Altair as part of its Altair Partner Alliance. Mechanics of Structure Genome, which fills the gap between Yu says the program “could change the industrial practice of materials genome and structural analysis. “It enables engineers computer simulation of composites to accelerate innovation by to model composites as black aluminum, capturing details as shortening the design period, reducing experiments and further needed, which not only saves computing time and resources adjustments, and ultimately, reducing the costs associated with without sacrificing the accuracy, but also enables engineers to composites.” tackle complex problems impossible with other tools,” says Yu. SwiftComp can be used independently as a tool for virtual Patrice Aylward is a communications consultant based in testing of composites or as a plugin to power conventional FEA Cleveland. Email comments to [email protected]. Melissa codes with high-fidelity multiscale modeling for composites. O’Leary is a freelance writer based in Cleveland. Email comments “It’s a general purpose system and is not restricted to a specific to [email protected]. manufacturing technique,” says Yu. It can be used to model a variety of applications, including rotor blades, wind turbine blades, composite panels, corrugated structures, sandwich

Want to Hear About More Research? CAMX 2015 will feature a Poster Session where the next generation of researchers, engineers and industry professionals share innovations in material science and composites. Last year, more than 30 posters were on display. For more information on CAMX, which will be held Oct. 26-29 in Dallas, visit thecamx.org.

28 CompositesManufacturing Photo Credit: PlastiComp

Thermoplastics Are on the Rise Topping the reasons why thermoplastics are gaining momentum are their processing capabilities, recyclability and short cycle times. By Susan Keen Flynn

f you’ve ever gazed out of the airplane window while waiting each year on fuel costs, he adds. to push back from the gate, you’ve probably seen large cargo “Airlines are waking up to the cost associated with ULDs,” Icontainers – or unit load devices (ULDs), as they’re called in says Pherson. “For years, aluminum was fine until they started the industry – being placed onto the aircraft. For 30 years, ULDs looking at the economics behind the containers. Now they were made from aluminum. But 12 years ago, CargoComposites are more conscious about fuels costs and carbon dioxide introduced a new option. “We developed and patented a design emissions and looking for unique opportunities to save using a thermoplastic fiberglass polypropylene composite,” money.” Thermoplastic composites offer that savings: Pherson says Tom Pherson, president and CEO of CargoComposites in says his company’s ULDs provide “aerospace properties at Charleston, S.C. industrial economics.” The body of the ULDs are made from ½-inch thick panels ULDs are just one niche product within the aerospace market comprising two fiberglass polypropylene skins that are that rely on thermoplastic composites. The materials also are continuously laminated onto a polypropylene honeycomb core. found in airplane interiors and primary and secondary structures They are pressure formed to shape the edges, then machined, of aircraft. Other major industries that use thermoplastic trimmed and drilled on a CNC machine. The containers feature composites include electrical and electronics as well as consumer a fabric door constructed of an ultra-high molecular weight products. In addition, thermoplastic composites are making polyethylene composite – the same material used in bullet-proof headway in the automotive market. vests – with a special coating. The global marketplace for thermoplastic composites is Thermoplastic ULDs are lightweight, durable and cost- growing thanks to high demand from end users backed by new effective, three important characteristics for the airlines that industrial applications, according to a report released in June utilize them. Pherson says the average aluminum ULD weighs by Research and Markets, a Dublin-based business intelligence 180 pounds, while a thermoplastic ULD hits the scales at 127 and market research provider. The report predicts that the global pounds. That saves airlines more than $1,000 per container thermoplastic composites end product market will reach $9.9 CompositesManufacturing 29 Photo Credit: Copyright 2015 TenCate

A4000 Wrightlon® 5200 The TAPAS2 consortium is developing a 39-foot thermoplastic torsion box for a tail structure for Airbus. BENEFITS Excellent elongation and billion in 2020, with a compound annual growth rate of 6.5 strength reduces bridging in percent between 2015 and 2020. corners, avoiding scrap or rework. High visibility colors can reduce risk of Processing Possibilities FOD and leaving film on cured parts. Thermoplastic resins are all around us in unreinforced Color options help differentiate perforation applications. They’re in water bottles, toys, grocery bags, window styles. frames and more. Combining them with reinforcing fibers Easy release off cured parts, leaving increases mechanical properties, just like with thermoset resins. excellent finish. However, there are differences between the two types of resins. Widths up to 160 inches (4 m) without heat seams. Thermosets are converted from a liquid to a solid through a chemical reaction that causes the polymer to cross-link. When used to manufacture products, thermosetting resins are Wrightlon® 5200 cured with a catalyst, heat or a combination of the two. Once Elongation: 350% cured, they can’t convert back to their original liquid form. Use Temperature: Thermoplastic resins are shaped or molded while in a heated, 500°F (260°C) semi-fluid state and become rigid when cooled. There are no chemical reactions during processing, and thermplastics can be remelted after solidification. The majority of FRP composites use thermoset resins, but A4000 thermoplastics are gaining a foothold. “Thermoplastics have two characteristics that make them attractive,” says Arnt Offringa, Elongation: 300% director of research and development for Fokker Aerostructures in Use Temperature: Hoogeveen, Netherlands. “One is the toughness of the resin. You 500°F (260°C) can design parts with less plies of material to make them lighter in -Available in Bonded One Side (BOS) weight and lower in cost. The other is the processing possibilities. You can remelt the resin and do things like welding or melting Airpad Rubber Fabrication bonds well with A4000 BOS‐ together of things like simple preforms to make a single shape.” These two advantages are key to many aircraft parts manufactured by Fokker Aerostructures, such as the rudder Watch a video on and two elevators for the Gulfstream G650, a twin-engine Scan this Wrightlon® 5200 business jet airplane. They were originally constructed of & A4000! aluminum, then later thermoset composites. A few years ago, Fokker Aerostructures began making the parts from continuous www.airtechonline.com fiber-reinforced thermoplastics (CFRT), using a carbon/ polyphenylene sulfide (PPS) prepreg supplied by TenCate Advanced Composites. The parts of the rudder and elevator, INTERNATIONAL INC. EUROPE Sarl ADVANCED MATERIALS LTD ASIA LTD including ribs and beams, were press formed, then joined together via induction welding. The G650 rudder and elevators require high torsional stiffness and little bending stiffness. They are designed to allow buckling at 70 percent limit load, which provides a weight advantage over a honeycomb sandwich design. The transition to thermoplastic 30 CompositesManufacturing composites yielded a 10 percent reduction in weight and 20 percent cost savings.

Recyclability and Other Benefits Another benefit of thermoplastic composites is tied to an industry hot topic – sustainability. “We can recycle thermoplastics and give them a second life,” says Ed Pilpel, president of Polystrand, a provider of CFRT materials based in Englewood, Colo. “There’s a significant financial impact associated with being able to either reprocess waste or bring material back to use at end of life.” Thermoplastic material can be shredded and compounded into pellets for injection molding of new products. Polystrand is currently developing a product called Random Oriented Polystrand (ROP) which will utilize the plant’s secondary material and thermoplastic composite end-of- CargoComposites sells unit loading devices, which feature life products. They will be shredded into pieces resembling Polystrand sandwich panels, to most of the major airlines. cornflakes, dispersed on a continuous belt, and then fused together with heat and pressure to form a structural panel with • Long shelf-life mechanical properties similar in all directions. “When that panel • High material toughness and impact resistance comes out, we can use it as an impact panel inside a truck or • Excellent fire, smoke and toxicity properties freight train box car,” says Pilpel. The polypropylene fiberglass panels will be about 65 percent fiber by weight. Pilpel anticipates • Fast, low-cost processing and short cycle times the first application will be truck skirts – long panels attached to the sides of the trailers between the front and back wheels to “You can pump out a part every 30 to 60 seconds via injection improve efficiency and reduce drag. molding, where with a thermoset it will take many minutes – or Aside from processing options and recyclability, other even hours, in some cases,” says Eric Wollan, technical director advantages of thermoplastics include: at PlastiComp, a provider of long fiber-reinforced thermoplastic (LFT) composite technologies.

CompositesManufacturing 31 An Introduction to Thermoplastic Matrices There are many options for thermoplastic resins, including those listed below. Commodity thermoplastics are the most common and least expensive. Engineering thermoplastics are used for high-performance applications that require heat resistance, chemical resistance, fire retardancy, impact resistance and other specific requirements.

Thermoplastic polymers also can be classified into two primary categories – semi-crystalline and amorphous – based on differences in their molecular structure. Semi-crystalline polymers feature a highly-ordered molecular structure. They are generally opaque, extremely tough, offer excellent chemical resistance and are capable of withstanding mechanical loads above the glass transition temperature. The molecule chains of amorphous polymers are randomly arranged and tangled. They are mostly translucent, soften gradually as the temperature rises, have a low tendency to creep and warp and offer good dimensional stability.

Resin Type Category Polyethylene (PE) Commodity thermoplastic Semi-crystalline Polypropylene (PP) Commodity thermoplastic Semi-crystalline Polyamide (PA) [nylons] Engineering thermoplastic Semi-crystalline Polysulfones (PSU) Engineering thermoplastic Amorphous Polyphenylene sulfide (PPS) Engineering thermoplastic Semi-crystalline Polyethersulfone (PES) Engineering thermoplastic Amorphous Polyetherimide (PEI) Engineering thermoplastic Amorphous Polyetherketone (PEK) Engineering thermoplastic Semi-crystalline Polyetheretherketone (PEEK) Engineering thermoplastic Semi-crystalline Polyetherketoneketone (PEKK) Engineering thermoplastic Semi-crystalline Thermoplastic polyimide (TPI) Engineering thermoplastic Semi-crystalline

Market Advances fiber was cost prohibitive. “They were able to boost stiffness Recent innovations within thermoplastics range from new and still maintain cost targets by using the blended approach,” material formulations to expanded applications. Last fall, says Bowen. PlastiComp introduced hybrid thermoplastic composite Among those on the cutting edge on the application front is the pellets that combine long glass fiber and long carbon fiber Thermoplastic Affordable Primary Aircraft Structure consortium reinforcements. According to the company, this allows for more (TAPAS). Originally launched in 2009, the consortium is now in uniform dispersion of fiber during injection molding than its second phase. The TAPAS2 program partners 11 companies post blending of glass and carbon fiber pellets manufactured and research institutes in the Dutch aerospace industry with separately, where the difference in bulk density can lead to aircraft manufacturer Airbus to advance material, production and separation. connection technology and develop thermoplastic applications, PlastiComp tailors the levels of carbon fiber and glass fiber including primary structural components. to meet end use needs. “If the customer is more concerned TAPAS2 is moving forward two full-scale demonstrator about impact strength, but wants some carbon in the material, components begun in the first phase of the program – a then we can push more glass into the composite,” says Wollan. fuselage (built in 2012) and torsion box (built in 2013). Both “If they are interested in stiffness, then we add more carbon.” components include unidirectional carbon fiber prepreg from Hybrid LFTs have another benefit, too – lower cost entry into TenCate, HexTow® AS4 carbon fibers from Hexcel and a carbon fiber. polyetherketoneketone (PEKK) matrix from Arkema. Processes “The hybrid fills in the gap between GFRP and CFRP. That’s used include automated fiber placement, press forming and a huge step – and a very expensive one,” says Steve Bowen, welding. CEO of PlastiComp. “Our technology enables us to offer a The torsion box demonstrator has been successfully subjected gradation of fiber ratios, all the way from 100 percent glass fiber to a full-certification test program. Offringa, whose company to 100 percent carbon fiber. You pick what works to optimize leads TAPAS2, anticipates that the technology for thermoplastic both performance and economics.” skin fields of the torsion box will be brought to technology level During the first quarter of 2015, a leading sports and readiness (TRL) 6 this year and the entire torsion box to TRL recreation company adopted the hybrid LFT technology for a 6 in 2017. (TRL measures maturity of a technology: TRL 6 very thin-walled part. A fiberglass reinforcement wouldn’t have has a fully functional prototype, while the highest level – TRL met the structural demands of the part, but using only carbon 9 – indicates the technology is “flight proven.”) The consortium 32 CompositesManufacturing “Thermoplastics enable automobile manufacturers to produce affordable structural components to substitute conventional metal solutions.” expects the fuselage technology to hit TRL 4 (multiple hybrid carbon fiber composites for automotive,” says Bowen of components tested with one another) in 2017. Ultimately, the PlastiComp. “These parts are going into development vehicles consortium hopes that Airbus and other aircraft manufacturers in China and around the world, and production vehicles will will feature thermoplastic components in new narrow-body be the next wave. It finally seems to be within the three- to five- aircraft. year horizon.” As with any material, thermoplastic composites have their Expanding into Automotive share of shortcomings: It’s difficult to achieve high fiber While aerospace has been a leader in adopting thermoplastic loading, the high-temperature tooling materials require an composites, automotive manufacturers are taking note investment and the technology is newer than thermoset, of the possibilities. “Thermoplastics enable automobile so the knowledge base is limited. But thermoplastics may manufacturers to produce affordable structural components prevail in many markets because of the overall cost benefits. to substitute conventional metal solutions,” says Frank Meurs, “Thermoplastics are not the best solution for everything,” says group director of TenCate Advanced Composites EMEA in Offringa, “but if you can find the right application, you can Nijverdal, Netherlands. “Shorter cycle times are just around the reduce costs.” corner, and overall production costs can be reduced through automated volume production.” While most composites used in automotive rely on CFRP with a thermoset epoxy resin, Susan Keen Flynn is managing editor of Composites companies are developing thermoplastic structural components Manufacturing magazine. Email comments to sflynn@ to make vehicles lighter and more efficient. keenconcepts.net. “The big wave of commercial growth is carbon fiber or

Thermoplastics AUTOMOTIVE AIRCRAFT RAIL on the Move Wheel Helicopter Tail Liners for Rims Plane Refrigerated Cars Transportation is the Continuous Fokker Aero- Miles Fiberglass largest market for carbon fiber- structures & Composites thermoplastic composites, reinforced developed in Portland, with weight savings, thermoplastic the horizontal Ore., uses rolls fuel economy and other materials from TenCate tail – a main load-bearing of Polystrand reinforcing performance benefits Advanced Composites are primary structure – for the material to fabricate fueling consumption. Here used in all-thermoplastic AgustaWestland AW169 corrugated panels for are just three applications and hybrid (composite helicopter. Designed as railroad freight cars that within the transportation and aluminum) rims. a co-consolidated, multi- transport frozen and sector: “This solution aims for spar torsion box, the perishable products. reduction of rotating mass 3-meter-long horizontal Polystrand’s ThermoPro™ through a lightweight tail weighs 15 percent X-Ply™ reinforcement structure,” says Frank less than previous com- tapes are made from Meurs, group director posite designs. It’s made continuous E-glass fibers of TenCate Advanced from Fortron® polyphen- that are impregnated with Composites EMEA in ylene sulfide (PPS) from polypropylene thermoplastic Nijverdal, Netherlands. Celanese and carbon/PPS resin. The company ships “Inherent impact resistance semi-prepreg and plate the materials in rolls that combined with a high material from TenCate Ad- are 60 percent continuous service temperature make vanced Composites. fiber by weight, aligned in a this wheel suitable for 0°/90° orientation. use in demanding driving conditions.”

CompositesManufacturing 33 Deep in the Heart of CAMX Deep in the Heart of CAMX Industry leaders from all over the world will come to Dallas to collaborate, learn and display products at CAMX.

The Exhibit Hall The CAMX exhibit hall features 100 categories of products, By Evan Milberg from thermoplastics, prepregs and adhesives to carbon fibers, tooling and reinforcements. Many of the products can be applied in growing market sectors such as aerospace, automotive, energy and marine, in addition to other market CMA has teamed up with the Society for the segments that use composites and advanced materials such Advancement of Material and Process Engineering as transportation, sports and leisure, construction and A (SAMPE) to produce the second annual Composites infrastructure, and kitchen and bath. and Advanced Materials Expo (CAMX) – the biggest and most “The exhibit hall will certainly be buzzing with people looking comprehensive event in North America for the composites to discover all the cutting-edge products being developed in industry – in Dallas from Oct. 26-29. This year, CAMX expects our industry,” says Tom Haulik, carbon fiber sales manager at to feature around 550 exhibitors and 300 conference sessions. Hexcel Corporation. “CAMX is a big opportunity to unite composites professionals One of the exhibitors this year will be AOC, a leading from all over the world and provide them with the resources manufacturer of resins, gel coats and colorants. The company they need,” says ACMA president Tom Dobbins. “Through will be displaying a diverse range of products, including low- product displays, live manufacturing demonstrations and a robust conference program, we believe attendees will come away from CAMX with the tools necessary to continue driving Keynote Speaker innovation in our industry.” On October 27, CAMX SAMPE CEO Gregg Balko adds that CAMX participants officially kicks off with a also want an event where they can see the future of our keynote address from Dr. industry and meet with other key decision makers who will J. Gary Smyth, executive help shape that future. “Last year at our inaugural CAMX, director of global research over 7,100 composites and advanced material practitioners and development at from 44 countries came to CAMX to discover new industry General Motors. For the developments, develop industry skills and grow business past five years, Smyth opportunities,” says Balko. “CAMX will continue to grow as the has identified global venue in North America to network with the critical players in automotive energy trends the composite industry.” and addressed energy One company that benefited from the business opportunities challenges facing the at CAMX and saw its business improve was Global Composites. automotive industry. Some “CAMX allows us to not only meet new potential customers, of those solutions include but also meet new suppliers and current suppliers in a social advanced carbon fiber and green composites. and business atmosphere to discuss new, unique products which Smyth’s CAMX 2015 address will provide a high- help us to produce in a more efficient manner,” says Gary Beck, level perspective on transformational changes in president of Global Composites. “Even if you don’t pick up a the automotive industry and include what GM has new customer, the exposure to what is going on in other parts of learned about composites from the evolution of the the country can kick start your management team into thinking Corvette. what might be possible.”

CompositesManufacturing 35 density sheet molding compound for the automotive industry. Norwegian University of Science & Technology and a look Fletcher Lindberg, vice president of marketing for AOC, believes at the state of bio-based materials by Louis Pilato of Pilato it’s vital for companies to attend and display products at CAMX, Consulting. not only for the benefits they receive, but the benefits to the “The educational sessions and technical paper presentations at composites industry as a whole. “This is a very important event CAMX will leave you thinking about ways you can implement for AOC to attend, exhibit and sponsor,” Lindberg explains. new ideas and energy into your business plans,” says Marcy Offner, “CAMX allows us to showcase our technology, meet with director of marketing communications at Composites One. customers and support the industry.” Awards and Innovation Showcase Conference Programming The CAMX Awards honor developments in two categories. CAMX will offer the largest conference program on The Unsurpassed Innovation Award recognizes a product composites and advanced materials anywhere. This year, CAMX or process that will significantly impact composites and will include several types of educational events, including advanced materials in the marketplace. Last year, Composite general sessions, featured sessions, pre-conference tutorials, Panel Systems LLC won the award for its Epitome composite technical paper presentations and a poster session. In total, these foundation wall system, fabricated by Fiber-Tech Industries Inc. sessions will offer industry expertise in over 250 topics. and made with fire-retardant resins from Ashland Performance Some interesting general sessions this year include Owens Materials. Cornings’ Dhruv Raina’s insights on using green composites The Combined Strength Award celebrates visionary concepts to reduce vehicle weight, UCSI Group’s Scott Holmes’ and products that show strength through collaboration, while presentation on FRP composite utility poles and Dr. Richard bridging low-cost materials/high-volume applications with high Ryden’s techniques for achieving a fast and reliable return on performance applications/low-volume materials. Last year, the investment with reusable vacuum bags. award went to NASA and Boeing for their collaboration on the Featured sessions, which are developed by a joint team of Composite Cryogenic Technology Demonstration (CCTD) ACMA and SAMPE members, will cover trending hot topics project, which utilized innovative manufacturing and design in the industry, including sustainability, market growth, techniques to build the largest composite liquid hydrogen fuel workforce training and consumer markets. With sessions on tank out-of-autoclave. additive manufacturing, thermoset and thermoplastic resins The Awards for Composites Excellence (ACE) is a prestigious and advances in natural fiber technology and automation, they composites industry competition that recognizes outstanding are an ideal opportunity to learn about new topics and enhance achievement and innovation in the categories of design, your knowledge in your own market segment. market growth and manufacturing. The ACE display will Some featured sessions this year include insights on offshore showcase new products and present awards for innovations in market applications by Professor Andreas Echtermeyer of the creative design, manufacturing and market growth. ACMA

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CompositesManufacturing 37 COMBINED STRENGTH. UNSURPASSED INNOVATION.

Produced by GENERAL SESSION DON’T MISS THESE & KEYNOTE ADDRESS FEATURED SESSIONS ON CAMX 2015 will kick off with Dr. Gary Smyth, CUTTING EDGE TOPICS: Executive Director of Global Research and Advances in OCTOBER 26–29, 2015: CONFERENCE / OCTOBER 27–29, 2015: EXHIBITS Development at General Motors Company, with a Traditional Materials DALLAS CONVENTION CENTER / DALLAS, TX keynote address providing a high-level perspective Sponsored by: on the transformational change now ■ Structural Parts for Automotive: going on in the automotive industry and Why Carbon Fiber Composites? lessons learned from the Corvette’s use Dr Gary Smyth, An International Overview of composites. General Motors Company ■ Thermoplastic Composites CAMX IS MORE THAN A TRADE SHOW Keynote Speaker Green & Sustainability CAMX is the one source for connecting and advancing all aspects of the world’s Composites and Advanced Materials Bio-Based Materials – Now and communities: R&D, engineering, manufacturing, service providers, and end-users. Regardless of the application – transportation, ■ CONFERENCE PROGRAM Into the Future aerospace, marine, wind energy, software, construction and infrastructure, medical, academics, sports and leisure – CAMX is Designed by leading experts, the CAMX Conference Program provides the most robust America’s go to event for products, solutions, networking, and advanced industry thinking. ■ Composites Sustainability/ Life education anywhere for the composites and advanced materials industries. Featuring Cycle Assessment detailed Technical Papers and Education Sessions, the CAMX conference program Register Now - www.theCAMX.org delivers timely topics and industry thought leaders. Manufacturing Rates Increase Oct. 2 ■ High Speed Automation in Automotive Manufacturing ■ Joint Programs for National PRE-CONFERENCE TUTORIALS Network for Manufacturing Arrive a day early and participate in Pre-conference Tutorials! These 3 hour courses are Innovation (NNMI) CAMX Schedule At-A-Glance* EXPERIENCE THE FUTURE OF THE held on Monday, October 26, and fully immerse participants in a specific area of focus. See the full Conference Program and tutorials at www.theCAMX.org. MONDAY, OCT. 26 INDUSTRY Market Applications (Industrial/Consumer) 9:00 AM – 12:00 PM Pre-conference Tutorials At CAMX, you’ll find the best of ACMA and SAMPE – game- Challenges Using Composite 2:00 – 5:00 PM Pre-conference Tutorials changing products and applications, research highlighting ■ uncharted uses for composites and advanced materials, AWARDS & INNOVATIONS Materials Offshore Find the newest, most innovative products, applications, and research on display at ways to improve tried and true technologies, as well as ■ Opportunities in Architecture CAMX. TUESDAY, OCT. 27 trends and market analysis. CAMX gives you the unique ■ Pressure Vessel Tanks for CNG, LPG and Other Gas/Liquids 8:00 – 8:55 AM Conference Programming opportunity to engage with all the experts – as well as the The CAMX Award recognizes cutting-edge innovations that are shaping Sponsored by: (Transportation Distribution and 9:00 – 10:15 AM Opening General Session, next generation of experts – who are shaping the future of the future of composites and advanced materials in the marketplace. Consumer Use) Keynote & CAMX Award composites and advanced materials... all in one place. 10:30 AM – 5:00 PM Exhibit Hall Open Hosted by ACMA, the Awards for Composites Excellence (ACE) offers ■ Processes and Materials for Sponsored by: Mass Production Markets 2:00 – 5:00 PM Conference Programming six total awards recognizing excellence in Design, Manufacturing, 5:00 – 6:00 PM Welcome Reception and Market Growth. ■ Success Stories on Lighter Weight Applications The 2015 Poster Session will feature the latest industry research WEDNESDAY, OCT. 28 conducted by students, universities, and companies. Sponsored by: 8:00 – 11:00 AM Conference Programming 9:00 AM – 6:00 PM Exhibit Hall Open Adapt Laser Systems Alpha Professional Tools 2:00 – 5:00 PM Conference Programming Choose from 300+ Network with 7,100+ Conference Sessions attendees CAMX EXHIBITORS Addcomp North America Alphacam 5:30 – 7:00 PM Specialized Market Segment Reception As of August 14, 2015* Adhesive Systems, Inc. Altair 21st Century Chemical Advacam AMAMCO Tool 3A Composites/Baltek Inc. Advanced Composites, Inc. American Chemistry Council THURSDAY, OCT. 29 3M Aerospace Advanced Plastics American Colors Inc. A&P Technology 8:00 AM – 12:00 PM Conference Programming Advanced Processing Technology, Inc. (AvPro) American GFM Corporation A.B. Carter, Inc Advantic ANF Technology Limited 9:00 AM – 1:00 PM Exhibit Hall Open A.P.C.M. Manufacturing LLC Adventure Power (Pty) Ltd AOC Resins 1:00 – 2:15 PM Closing Luncheons AAF International Aeron Composite Pvt. Ltd. Aonix 2:30 – 4:30 PM Conference Programming ABARIS Training Resources Inc Agilent Technologies Applied Aerospace Structures Corporation Accudyne Engineering & Equipment Co. AGY Holding Corp. Applied Graphene Materials *Subject to change. Accudyne Systems AIM Aerospace, Inc Aramicore Composite Co., Ltd. ACE Awards AIM Supply Arkema Inc. Visit www.theCAMX.org and connect with CAMX on ACG Materials Airtech Advanced Materials Group Armacell Benelux S.A. social media. ACMA, American Composites Manufacturers Airtech Vacuum, Inc. Arno Seyfert CC Association AKPA Organik Peroksit Kimya San. ve Dis Tic. Ltd. Sti. ASC Process Systems Acmos Inc. Akzo Nobel Functional Chemicals Ascent Aerospace View products and services from 550+ exhibitors ACS International, Inc. Allnex USA Inc. Exhibtors Continued on next page COMBINED STRENGTH. UNSURPASSED INNOVATION.

GENERAL SESSION DON’T MISS THESE & KEYNOTE ADDRESS FEATURED SESSIONS ON CAMX 2015 will kick off with Dr. Gary Smyth, CUTTING EDGE TOPICS: Executive Director of Global Research and Development at General Motors Company, with a Advances in keynote address providing a high-level perspective Traditional Materials Sponsored by: on the transformational change now ■ Structural Parts for Automotive: going on in the automotive industry and Why Carbon Fiber Composites? lessons learned from the Corvette’s use Dr Gary Smyth, An International Overview of composites. General Motors Company ■ Thermoplastic Composites Keynote Speaker Green & Sustainability ■ Bio-Based Materials – Now and CONFERENCE PROGRAM Into the Future Designed by leading experts, the CAMX Conference Program provides the most robust ■ Composites Sustainability/ Life education anywhere for the composites and advanced materials industries. Featuring Cycle Assessment detailed Technical Papers and Education Sessions, the CAMX conference program delivers timely topics and industry thought leaders. Manufacturing ■ High Speed Automation in Automotive Manufacturing ■ Joint Programs for National PRE-CONFERENCE TUTORIALS Network for Manufacturing Arrive a day early and participate in Pre-conference Tutorials! These 3 hour courses are Innovation (NNMI) held on Monday, October 26, and fully immerse participants in a specific area of focus. See the full Conference Program and tutorials at www.theCAMX.org. Market Applications (Industrial/Consumer) ■ Challenges Using Composite AWARDS & INNOVATIONS Materials Offshore Find the newest, most innovative products, applications, and research on display at ■ Opportunities in Architecture CAMX. ■ Pressure Vessel Tanks for CNG, LPG and Other Gas/Liquids The CAMX Award recognizes cutting-edge innovations that are shaping Sponsored by: (Transportation Distribution and the future of composites and advanced materials in the marketplace. Consumer Use) Hosted by ACMA, the Awards for Composites Excellence (ACE) offers ■ Processes and Materials for Sponsored by: Mass Production Markets six total awards recognizing excellence in Design, Manufacturing, and Market Growth. ■ Success Stories on Lighter Weight Applications The 2015 Poster Session will feature the latest industry research conducted by students, universities, and companies. Sponsored by:

Adapt Laser Systems Alpha Professional Tools CAMX EXHIBITORS Addcomp North America Alphacam As of August 14, 2015* Adhesive Systems, Inc. Altair 21st Century Chemical Advacam AMAMCO Tool 3A Composites/Baltek Inc. Advanced Composites, Inc. American Chemistry Council 3M Aerospace Advanced Plastics American Colors Inc. A&P Technology Advanced Processing Technology, Inc. (AvPro) American GFM Corporation A.B. Carter, Inc Advantic ANF Technology Limited A.P.C.M. Manufacturing LLC Adventure Power (Pty) Ltd AOC Resins AAF International Aeron Composite Pvt. Ltd. Aonix ABARIS Training Resources Inc Agilent Technologies Applied Aerospace Structures Corporation Accudyne Engineering & Equipment Co. AGY Holding Corp. Applied Graphene Materials Accudyne Systems AIM Aerospace, Inc Aramicore Composite Co., Ltd. ACE Awards AIM Supply Arkema Inc. ACG Materials Airtech Advanced Materials Group Armacell Benelux S.A. ACMA, American Composites Manufacturers Airtech Vacuum, Inc. Arno Seyfert CC Association AKPA Organik Peroksit Kimya San. ve Dis Tic. Ltd. Sti. ASC Process Systems Acmos Inc. Akzo Nobel Functional Chemicals Ascent Aerospace ACS International, Inc. Allnex USA Inc. Exhibtors Continued on next page Jensen Industries Inc CAMX EXHIBITORS Fabric Development JG&A Metrology Center Continued from Factocode t/a Microfinish (Pty) Ltd Jiangsu Jiuding New Material Co., Ltd. previous page Composites Horizons Fiber Dynamics, Inc Jiaxing Sunny FRP Industries Co., Ltd. Composites One Fiber Materials, Inc Jinan Gold Lead Machinery Co., Ltd. Composites One-The Lean Mean Closed Fiberglass Coatings, Inc. Johns Manville Ashland Mold Machine Fiberite Products (Pty) Ltd JPS Composite Materials Assembly Guidance Systems, Inc Composites Washington Fiberlay, Inc. JRL Ventures, Inc. Associated Industries Inc CompositesWorld Fiber-Line LLC Jushi USA Associated Technologies Weld Mount CompositeTechs, LLC Fibrtec Inc Kaneka North America LLC ATI dba SCRA Applied R&D Compotool Fives Machining Systems Kayco Composites Autodesk Concordia Fibers FlackTek, Inc Knowlton Technologies, LLC Automated Dynamics Conductive Composites Company Florida State University - High-Performance Komo Machine, Inc. Automated Solutions, LLC. Con-Tek Machine, Inc. Materials Institute Krayden Autometrix Precision Cutting Solutions Controx Neuhauser FloTex L & L Products AXEL Plastics Research Lab Convergent Manufacturing Technologies Flow Waterjet Lanxess Corporation Axia Materials Co., Ltd. Cool Clean Technologies, LLC Formosa Plastics Corporation LAP Laser, LLC Axiom Materials, Inc. Coosa Composites LLC Fraunhoffer Project Center Laser Projection Technologies, Inc (LPT) Axson Technologies US COREHOG Freeman Manufacturing & Supply Company Laser Technology, Inc. B/E Aerospace CoreLite, Inc Freeman Service Desk Leadgo American Ltd. Bally Ribbon Mills Coriolis Composites Canada Inc Freudenberg Performance Materials LEUCO Telcon Barrday Composite Solutions CPIC North America, Inc. Gelvenor Consolidated Fabrics (Pty) Ltd LEWCO, Inc. BASF Corporation Crane Composites General Dynamics Armament and Technical Products Liaoyang Yimeng Carpet Manufacturing Bayer Material Science LLC Creative Foam Composite Systems, LLC General Plastics Manufacturing Co. Co., Ltd. Becker Pumps Corp. Creative Pultrusions, Inc. Genesis Systems Group Lindau Chemicals, Inc Beijing Composite Material Co., Ltd. CRG, Inc Gerber Technology & Virtek Vision International Lingrove Benecor, Inc CTG International (N.A.) Inc. Germany Trade and Invest Litek Composites Corp. Bercella USA, Inc., U.S. Partner of Axia Current, Inc. Gibco Flex-Mold Inc. LMG Materials, Co. CVC Thermoset Specialties Global Specialty Products USA, Inc. Lucas Industries BGF Industries, Inc Cytec Industries Globe Machine Manufacturing Company Lucintel Blueshift Daicel (U.S.A.), Inc. Gordon Composites, Inc Luna Bondtech Corporation Dantec Dynamics Inc Graco Inc Luoyang Prince Fiberglass Co., Ltd. Bostik, Inc. David H Sutherland & Co., Inc GS Manufacturing Mafic Brenntag Specialties, Inc. DCM Clean-Air Products, Inc GTI Technologies Magnolia Advanced Materials, Inc BriskHeat Corporation De-Comp Composites Inc Gurit Magnum Venus Products Brookhaven Instruments Corporation DelStar Technologies, Inc Hall Composites Mahogany Company Burnham Composite Structures, Inc DeltaTrak Inc Harper International Maine Composites Alliance BYK USA Inc Dexmet Corporation Harris Corporation Mar-Bal C&D Zodiac Inc dba Zodiac Advanced DIAB Americas Hawkeye Industries, Inc. Composites & Engineered Materials Marietta Nondestructive Testing LLC Dia-Stron Ltd HEATCON Composite Systems C.A. Litzler Co., Inc. MarkForged Diatrim Tools HELD Technologies GmbH C.R. Onsrud, Inc. MARU HACHI Corporation Dino-Lite Scopes (BigC) Henkel Corporation CAMX Awards MasterWorks Inc Diversified Machine Systems Hennecke Inc. CAMX Lounge Matec Instrument Companies, Inc. Dixie Chemical Company Hexcel Corporation Carbon Flight LLC Materials Sciences Corporation DowAksa Hexion Inc. Carbon-Core Corp Matrix Composites, Inc. DPSS Lasers Inc Highland Composites Cardolite Corporation Maverick Abrasives Duna USA HK Research Carl Zeiss Microscopy, LLC Maverick Corporation Dunstone Company Inc Hollingsworth & Vose Carolina Narrow Fabric MB Superabrasives DWA Aluminum Composites USA, Inc. HORN Century Design Inc McCausey Specialty Products E.V. Roberts HOS-Technik GmbH CGTech McClean Anderson LLC Eagle Technologies, LLC Huber Engineered Materials Changzhou Pro-Tech Industry Co., Ltd. McCoy Machinery Corp. Eastman Machine Company Huntingdon Fiberglass Products Changzhou Sunlight Pharmaceutical Co., Ltd. McLube Division of McGee Industries Inc EconCore Huntsman Advanced Materials Chemique Adhesives Mektech Composites Inc Eco-Wolf Inc HyperSizer - Collier Research Chemir - EAG Melco Steel Inc EFI Composites, LLC IDI Composites International Chem-Trend LP METYX Composites - Telateks Tekstil Ekasi IT Solutions (Pty) Ltd IKONICS Advanced Material Solutions Urunleri San. Tic. A.S. Chesapeake Testing Services, Inc. Electrolock, Inc. Imetrum Ltd. Miki Sangyo USA Inc Chomarat North America LLC Element Materials Technology Impact Composites Miller-Stephenson Chemical Chromaflo Technologies Elliott Company of Indianapolis Impossible Objects LLC MISTRAS Group, Inc Cincinnati Testing Laboratories Endurance Technologies IMR Test Labs Mitsubishi Rayon Carbon Fiber and City of Hampton - Economic Development Engineered Bonding Solutions, LLC InChem Corporation Composites Clayton Associates Inc Engineered Solutions Ingersoll Machine Tools, Inc. Mokon Clear Carbon and Components, Inc Engineering Technology Corporation In-House Solutions Montalvo Click Bond, Inc. Entropy Resins Innegra Technologies LLC Multiax America, Inc CMS North America Inc. Epcon Industrial Systems, LP Instron MultiCam Inc CNC Technics Pvt Ltd ES Manufacturing Integrated Technologies, Inc - INTEC Myers Mixers Coastal Enterprises Company ESI North America Interplastic Corporation N12 Technologies, Inc Coats plc Euro-Composites Corp. Intertape Polymer Group Nabertherm Cobham Composite Products Eurovac Inc. Intertek Nammo Composite Solutions Composite Alliance Corp Evonik IST - Industrial Summit Technology Corporation Nanjing Union Silicon Chemical Co., Ltd. / Composite Essential Materials, LLC Exel Composites Plc ITW Insulation Systems USI Chemical America LLC(USA) Composite Fabrications, Inc. e-Xstream engineering SA J6 Polymers NASA Composite Fabrics of America Extramet Janicki Industries National Diamond Lab of Texas Inc. COMPOSITES EUROPE Lounge National Research Council of Canada Powerblanket Shandong Shuangyi Technology Co., Ltd. TCR Composites ND Industries / Vibra-Tite PPG Industries, Inc. SHIMADZU SCIENTIFIC INSTRUMENTS, INC. TE Wire & Cable NDE Labs, Inc. Precision Fabrics Group, Inc. Sicomin Technical Fibre Products, Inc. NDT Systems, Inc Precision Measurements and Instruments Sigmatex Technology Marketing, Inc. Nederman LLC Corporation Sika Corporation TEI Composites Corporation Netzsch Instruments North America PRO-SET Epoxy Siltech Corporation Teijin Aramid USA, Inc. New Hampshire Division of Economic PTM&W SINGLE Temperature Controls, Inc. Tempco Electric Heater Corporation Development Pultrex Ltd Sino Composite Company Limited TenCate Advanced Composites Nippon Graphite Fiber Quintax SL Laser Systems Tesco-Italmatic LLC NMG USA, INC. R2M Engineering, LLC Smart Tooling Texonic NONA Composites RAMPF Group, Inc Socomore Textile Products, Inc Nordson Sealant Equipment RAPTOR Composite Fasteners Sogel Inc. TeXtreme® North American Composites Reed Industrial Systems, Inc Solvay Specialty Polymers Textum Carbon Solutions North Coast Reichhold LLC2 Specialty Materials, Inc TFB Composites Group North Star Imaging, Inc. Reliant Machinery USA / BHP Armor Starfire Systems The Boeing Company North Thin Ply Technology Renegade Materials Corporation StateMix Ltd The Department of Trade and Industry Northern Composites, Inc. Reno Machine Company Inc Steelman Industries, Inc The Dow Chemical Company Northwood Machine Manufacturing Company Resodyn Acoustic Mixers Stelmack & Associates The R.J. Marshall Company Norton Revchem Composites, Inc Stiles Machinery Inc The United Soap Factory OCSiAl LLC REXCO Stoner Molding Solutions Thermacore Materials Technology Division OEM Press Systems Reynolds Advanced Materials Storm Tight Windows Thermal Equipment Corporation Olympus Rhode Island Composites Alliance Strand7 Pty Ltd Thermal Wave Imaging, Inc. Omya RobbJack Corporation Stratasys Thermoset Resin Formulators Onyx Specialty Papers, Inc. Robotmaster Stratasys Direct Manufacturing Association Orbital ATK Aerospace Structures Rock West Composites Structural Composites Thermwood Corporation Owens Corning Composite Solutions Business Rosenthal Manufacturing Co. Inc Structural Design and Analysis Inc. Tiger-Vac Inc. Pacific Coast Composites Royce International Structured Composites Tinius Olsen Park Electrochemical Corp RT Instruments, Inc. with Hitachi High Tech Sunstrand, LLC Tiodize Co., Inc. Parson Adhesives, Inc. America SURAGUS GmbH TMP, A Division of French Pathfinder Rubbercraft Surface Generation America Toho Tenax America Patz Materials and Technolgies SAATI Surfx Technologies Tong Xiang Aisen Composites Co., Ltd. PCM Innovation SAERTEX USA, LLC SWORL (div. of Prairie Technology) TOR Minerals PEI Pinette USA Saint-Gobain ADFORS Symmetrix Composite Tooling TR Industries Performance Minerals Corp. Saint-Gobain Vetrotex Synasia Inc Tricel Honeycomb Plascore, Inc SAMPE System Three Resins Trilion Quality Systems Plexus - ITW Polymers Adhesives North America Sandvik Process Systems TA Instruments Tri-Mack Plastics Manufacturing Corp Poco Graphite Schroeder Wooden Furniture and Motorhomes Taconic CC UHT Unitech Co., Ltd. Polynt Composites Taizhou Huangyan Dasheng Mould Plastics Ultracor Polystrand Inc. SCIGrip Smarter Adhesives Solutions Co., Ltd. Unicomposite Technology Co., Ltd Polyumac USA Scott Bader - ATC Taizhou Jiadebao Technology Co., Ltd. Uni-ram Corporation Poraver North America Inc. Sensitech, Inc Taricco Corporation Potters Industries LLC SGL Technologies Gmbh United Initiators Inc.

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Entrance Entrance WichiTech Industries, Inc. United Testing Systems, Inc Verisurf Software, Inc Wickert Hydraulic Presses USA Universal Trim Supply Co., Ltd. Victrex Wisconsin Oven Corporation University of Alabama at Birmingham Volume Graphics Wm. T. Burnett & Co. University of Delaware Center for Wabash MPI / Carver, Inc. Xamax Industries, Inc. Composite Materials Walton Process Technologies XTX Composites, Inc. University of Massachusetts Lowell Waukesha Foundry Inc YXLON University of Southern Mississippi Web Industries Zeus, Inc Utah Composites Industry Weber Manufacturing Technologies Inc Zibo Hongjia Aluminum Stock Vaupell Weibo International Co., Ltd. Vectorply Corporation Weihai Guangwei Composites Co., Ltd. Zotefoams Inc. Venango Machine Company, Inc Wells Advanced Materials Co., Ltd. Zund America, Inc As of August 14, 2015* Ventilation Solutions Wetzel Engineering Inc. Zwick USA Inside ACMA

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Pantone 376 C Pantone 3025 C Pantone 180 C Pantone 376 C Pantone 3025 C Pantone 180 C

c - 50 c - 100 c - 0 r - 141 r - 0 r - 217 m - 0 m - 17 m - 79 g - 198 g - 89 g - 83 y - 100 y - 0 y - 100 b - 63 b - 132 b - 30 and durability. k - 0 k - 51 k - 11 • Comparisons of composites with steel, aluminum, wood and granite. • Case studies detailing the use of composites in several different applications, including automotive, architecture, and infrastructure. • Detailed explanations of the many different materials and processes used to make composites.

ACMA will continue to add to this CompositesLab is • An in-depth explanation of the website over the next months, building science behind composites, the out the sections to include additional Live! applications and other information. isit CompositesLab (compositeslab.com) history of composites and an industry overview. Please link to this site from your company V– ACMA’s new and comprehensive websites or from your social media sites online guide to composites – written • Information about the benefits of composites, such as strength, weight, to help us inform more potential users of for design professionals, other specifiers and composites on their benefits. students. CompositesLab features: corrosion resistance, design flexibility FRP Pole and Cross Arm Manufacturers Advance Federal Policy n July 22, ACMA’s Utility and OCommunications Structures Council (UCSC) met in Washington Vacuum Infusion with Congressional offices and federal agencies and secured support from key policymakers for new federal policies encouraging electric utilities companies to consider FRP. Later this year, ACMA expects Congress to consider legislation that includes requirements supporting the use of FRP products by utilities seeking to improve electric grid resilience.

Hexion Inc. ACMA Calls for Updated FHWA Distributor for Hexion Inc. Bridge Database rom 1991 through 2004, the Federal FHighway Administration provided www.hexion.com funding for 324 bridge projects across the Hexion Inc. country that were built with composites. These projects are no longer being

42 CompositesManufacturing tracked, which makes it difficult to assess • Does my bulk storage tank comply frequently. Requests for additional the performance of the bridges. ACMA’s with NPFA standards? information can be sent to jschweitzer@ legislative team is currently lobbying acmanet.org. Congress to reword the Senate highway All the information is kept up to date reauthorization bill to require the DOT to by ACMA, and new topics are added commission a follow-up study of the long- term performance of the bridges. Online Access to Regulatory SMC Information REQUIRES or almost 30 years, ACMA has Faccumulated a trove of information, guidance and tools for composites manufacturers to efficiently provide safe CME workplaces and comply with regulatory requirements. And all of this is but a few clicks away. Visit ACMA’s website at acmanet.org, and click on the Member Resources tab at the top. Scroll down the page until you see Regulatory & Compliance, and then click on Index of Tools and Resources.

ACMA provides answers to many common questions, including: Innovative • Automotive • How much styrene do I report on Hydraulic • Aerospace TRI Form R? Compression • Medical • What packaging complies with the • Marine DOT standards for bulk shipment of Molding • Industrial molding compound? Solutions • How do I comply with OSHA requirements to provide warnings to customers on combustible dust American hazards? Made

• Is there a risk from exposure to BPA Today’s SMC challenges require the utmost Compression Molding Expertise. associated with vinyl ester resin? Greenerd has the engineered application solutions you need to succeed.

• What’s the lowest concentration that styrene odor can be detected? Scan to visit our Pressing for the best solution Compression Molding • What’s a VOC? Is it the same as a 800-877-9110 • www.greenerd.com Applications Showroom! HAP? How much of it is in my resin?

CompositesManufacturing 43 ADVANCED ADHESIVES AND SEALANTS A PIONEER AND LEADING MANUFACTURER FOR BONDING COMPOSITES, OF INNOVATIVE SPRAYABLE SYNTACTIC CMYK RGB THERMOPLASTICS, METALS AND MATERIALS AND SPRAYABLE

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c - 50 c - 100 c - 0 r - 141 r - 0 r - 217 DISSIMILAR SUBSTRATES INDUSTRIAL COATINGS m - 0 m - 17 m - 79 g - 198 g - 89 g - 83 y - 100 y - 0 y - 100 b - 63 b - 132 b - 30 k - 0 k - 51 k - 11 · Over 30 years of application experience · Sprayable coring materials and barrier coats ACMA Activity Under · High impact resistanceñH[LELlity, · Sprayable ðller/primers for use on and durability many substrates Way with IACMI · Ease of use · Polyester adhesive putties for ðlling he Institute for Advanced Composites · Reduced cycle times and bonding · Sprayable mold and plug building materials TManufacturing and Innovation · Patented MMA technology and service (IACMI) is off to a fast start. The Visit us at CAMX - Booth #K47. · Brushable and sprayable radius materials Automotive Composites Alliance (ACA) is developing four concepts for collaborative projects with IACMI. ACMA’s recycling collaboration with IACMI began in August, and a face-to-face meeting is planned for the end of September. The CCT program recently signed an Plexus® and SprayCore® adhesives, sealants and sprayable syntactics... improve product quality/durability while increasing manufacturing efficiencies and reducing VOC emissions!!! agreement with IACMI to develop some training videos that can be used to help individuals prepare for the VIP CCT Plexus® brand is proud to be certLðHG by... www.itwadhesives.com designation. There also will be several featured IACMI speakers at CAMX, including IACMI’s CEO Craig Blue. If

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44 CompositesManufacturing Find out more at CAMX • BOOTH K99 • Dallas TX • Oct 27-29 you would like to know about IACMI or how to become a part of these programs, ADVANCED NONWOVENS contact Dan Coughlin at dcoughlin@ acmanet.org. FOR COMPOSITES ACMA Begins FROM TECHNICAL FIBRE PRODUCTS Exposures Testing CMA’s Government Affairs MULTIPLE BENEFITS FROM USING A SINGLE MATERIAL! ACommittee recently started testing a number of typical composite products to characterize the amount of styrene SURFACE FINISH and ethylbenzene people may be exposed High quality resin rich surface finish to as a result of using the products. This testing program will provide data ACMA members can use to comply with California’s Prop 65 regulation, which FABRICATION AID requires toxicity warning labels for any Adhesive carrier • Resin flow media • Fracture toughness improvement product sold in the state if using the product may result in unsafe exposures to certain listed chemicals. For more information, contact John Schweitzer at SURFACE FUNCTIONALITY [email protected]. EMI shielding • Electrical conductivity • Abrasion resistance Galvanic corrosion protection • Corrosion resistance • Fire protection OSHA’s HAZCOM Policy a Challenge t CAMX, a panel consisting of Asenior OSHA leadership will break down how members of the composites industry can comply with OSHA’s recent implementation of the newest version of WWW.TFPGLOBAL.COM • [email protected] • 1 518 280 8500 its Hazard Communications Standard TFP is part of James Cropper plc, a specialist paper & advanced materials group (HAZCOM). Composites manufacturers and other employers are likely to be cited and fined if they fail to fully recognize Industry Calendar of Events all hazards and implement all safety recommendations identified by their For more information regarding Oct. 26-29, 2015 suppliers on the Safety Data Sheets for ACMA’s upcoming events and CAMX - The Composites and the materials they use. Also, suppliers will education, visit acmanet.org/ Advanced Materials Expo likely come under OSHA scrutiny if they meetings. Co-Produced by ACMA and employ their own weight-of-evidence SAMPE assessment to characterize hazards on SDS Sept. 29-30, 2015 Dallas, Texas instead of referring to recognized references CCT Instructor Course such as the Report on Carcinogens. More Ashland, Inc. - Dublin, Ohio April 5-6, 2016 information on HAZCOM compliance is Composites Executive Forum available acmanet.org/regulatory-compliance/ Washington, D.C. workers-regulatory.

CompositesManufacturing 45 Inside ACMA

CMYK RGB

Pantone 376 C Pantone 3025 C Pantone 180 C Pantone 376 C Pantone 3025 C Pantone 180 C

c - 50 c - 100 c - 0 r - 141 r - 0 r - 217 m - 0 m - 17 m - 79 g - 198 g - 89 g - 83 y - 100 y - 0 y - 100 b - 63 b - 132 b - 30 k - 0 k - 51 k - 11

46 CompositesManufacturing Advertising Index Advertiser Page

New Members Airtech International ...... 30 BASF Polyurethane Solutions AOC Resins ...... BC Wyandotte, Mich. Ashland, Inc...... 3 BGF Industries, Inc...... 7 Citadel Plastics CAMX ...... 38 Conneaut, Ohio Composites One ...... IFC Don Lipp ...... 37 Equisplast S.A. Elliot Company of Indianapolis, Inc...... 31 Cuenca, Ecuador Greenerd Press & Machine Company, Inc...... 43 Nova Scotia Boatbuilders GS Manufacturing ...... 37 Association ITW Plexus ...... 44 Halifax, Nova Scotia, Canada Janicki Industries ...... 24 JRL Ventures, Inc...... 44 Poly-Tec Products, Inc. Magnum Venus Products ...... 24 Tullytown, Pa. Master Bond, Inc...... 47 Mektech Composites, Inc...... 42 RSP Composites North American Composites ...... 28 Santiago, Chile Polynt Composites ...... 12, 19 R.S. Hughes Company ...... IBC University of Massachusetts Lowell SAERTEX ...... 5 Lowell, Mass. TFP Global ...... 45 The R.J. Marshall Company ...... 47 Weibo International Composite Thermwood Corporation ...... 22 Materials U.S. Polychemical ...... 13 Houston, Texas Web Industries, Inc...... 11 Weibo International Composite For more information on becoming Materials ...... 46 a member of ACMA, email [email protected] or call BC=Back Cover 703-682-1665. IFC=Inside Front Cover IBC=Inside Back Cover

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CompositesManufacturing 47 1056LK_3.25x2.5_12AOHT-LO.indd 1 7/20/15 4:46 PM Postcure Chatter

Molding Music with Carbon Fiber

ompanies have been using carbon fiber for a long time the tone, giving more freedom of sound modulation to the Cto make guitars, flutes and violin bows. However, until player.” recently, composites had not been widely accepted for brass instruments. A Swiss company, known as daCarbo, Nägeli Swiss AG considered several processing options is producing trumpets with CFRP bells for musicians for manufacturing the trumpet bell before choosing resin all over the world, including famous jazz artists Arturo transfer molding. RTM was the best option for fabricating Sandoval and Roy Hargrove. the precise shape of the bell, which is later connected with a U-bend to the metal valve engine. “The inner geometry Werner Spiri and Dr. Andreas Keller, the founders of of the bell [must be] highly precise and show an optimal daCarbo, teamed up with Nägeli Swiss AG to manufacture surface quality,” explains Niklaus Nägeli, a board member the trumpet. Unlike other companies that use carbon of Nägeli Swiss AG. fiber to make products lighter, daCarbo wanted to use it to reduce the amount of physical effort required by the RTM offers another advantage: Because it is largely musician. automated, the process yields a consistent quality trumpet bell. And the composite materials are corrosion-resistant, “We use the design freedom of composite materials which prevents problems from condensation common in to suppress the most energy taking vibrations of the brass instruments. instrument’s wall,” Dr. Keller explains. “This leads to instruments that are remarkably easy to play. The tone The daCarbo CFRP trumpet is now in serial production in will appear, even if you play out of the so-called center of three versions to meet varying requirements of players.

Resin Fibers

Nägeli Swiss AG chose Araldite® LY 564, a low The trumpet bell features dry carbon fibers in viscosity epoxy resin, and XB 3458, an amine preformed braided tapes. They are placed in the hardener, from Huntsman Advanced Materials. The mold and vacuum is applied. Next, the resin is resin is suitable for injection under temperature. In injected at high pressure. After the curing cycle, the addition, the curing cycle had to be considered: A finished part is demolded. melting core is used, so the temperature range is limited.

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