Compositesmanufacturing the Official Magazine of the American Composites Manufacturers Association
Total Page：16
File Type：pdf, Size：1020Kb
omposites anufacturing CNovember/December 2017 The OfficialM Magazine of the American Composites Manufacturers Association Real-World 3-D Printing Applications Auto Market Update Disruptive Technologies November/December 2017 CompositesManufacturing The Official Magazine of the American Composites Manufacturers Association 12 Photo Credit: Virginia Tech Features Photo Credit: General Motors 2017 Transformative Technologies ………. .................................... 12 24 Disruptive technologies are sweeping the composites industry, changing the Photo Credit: Penske Racing way products are made – and the products themselves. Take a look at five Market Segments innovations, ranging from an RTM process to make structural automotive parts Architecture ………. ........................ 6 in less than two minutes to carbon nanotubes for space applications. Bathroom Renovations By Susan Keen Flynn and Evan Milberg Renewable Energy ………. ............... 9 Recycling Turbine Blades A Moving Target ………. .........................................................20 Predictions on widespread use of composites in the automotive industry Departments & Columns always seem to be “five years out.” With advances in technology, processes and From the ACMA Chair ………. ....... 2 materials, is that forecast finally accurate? Experts cite several reasons why it looks hopeful. Best Practices ……… ........................ 4 By Megan Headley Inside ACMA ………. ......................29 The 3-D Printing Boom ………. ..............................................24 Ad Index ………. .............................31 Additive manufacturing has garnered a lot of attention in the past few years Postcure Chatter ...............................32 with the introduction of new equipment and materials. Companies are showing off the possibilities of the technology with 3-D printed tooling, yachts, race car parts and more. By Mary Lou Jay About the Cover: Oak Ridge National Laboratory used biocomposite materials to 3-D print this pavilion for the 2016 Design Miami showcase for architects and design professionals. Photo courtesy of SHoP Architects; Photography by Robin Hill From the ACMA Chair Composites Manufacturing Disruption by Disaster Volume 33 | Number 6 | November/December 2017 Official Magazine of the and Design American Composites Manufacturers Association Publisher Tom Dobbins f I could sum up the year the composites industry has had in [email protected] one word, it would be “disruptive.” Throughout the south, Gulf Editorial Iand the Caribbean, hurricanes have devastated communities Managing Editor and disrupted the way of life of many residents and businesses, Susan Keen Flynn [email protected] including ones in our industry. Senior Manager Marketing and Communications However, much like the composite materials we manufacture Barbara Sadowy and supply, our industry is incredibly resilient and can weather [email protected] any storm. At Core, we activated our contingency plans at our Senior Vice President of Events and Information facilities in Mexico and South Carolina. Fortunately, we were not Heather Rhoderick, CAE, CMP impacted by the storms. I know many of you had similar plans [email protected] in place and had to experience the impacts of the weather. I hope Communications Coordinator that everyone was safe and you are back in production! Evan Milberg [email protected] Hurricane Irma also forced ACMA to postpone CAMX. However, the rescheduled Editorial Design & Production event (Dec. 11-14, 2017, in Orlando, Fla.) will contain much of the same exhibitors, Keane Design, Inc. [email protected] networking and programming, including a general session panel focused on a more keanedesign.com positive form of disruption: market innovation. Advertising Sales The YGS Group While natural disasters like hurricanes are not something anyone hopes for, they do 717-430-2357 provide the opportunity to shine the spotlight on what composites deliver, especially [email protected] in infrastructure. Strong, durable and corrosion-resistant composites can serve as a 717-430-2212 replacement to traditional materials in bridges, water structures, electric utility poles and other building structures. Creative Pultrusions’ President/CEO Shane Weyant (page 29) discusses how ACMA is helping grow the infrastructure and construction market for members, and why we as an industry need to advocate for using better materials when American Composites Manufacturers Association 2000 N. 15th Street, Ste. 250 our country rebuilds after disasters or replaces structures due to age. The CAMX general Arlington, VA 22201 session also provides some innovative ways to do this. Phone: 703-525-0511 Fax: 703-525-0743 Email: [email protected] Our materials’ potential for market disruption isn’t limited to infrastructure, though. Online: www.acmanet.org Five end use applications that will change the way we look at everything from wind Composites Manufacturing (ISSN 1084-841X) is pub- blades to high-performance aerostructures are highlighted in our lead article (page 12). lished bi-monthly by the American Composites Manu- facturers Association (ACMA), ACMA Headquarters, 2000 N. 15th Street, Ste. 250, Arlington, VA 22201 USA. I’m thankful that our industry and its employees survived the recent natural disaster Subscription rates: Free for members and non-members in the U.S., Canada and Mexico; $55 for international non- disruptions, and I’m sure that all of us – and especially those in areas directly impacted members. A free online subscription is available at cm- – are ready to get back to business. I’m looking forward to CAMX to help us do this magazineonline.org. Periodical postage paid at Arlington, VA and additional mail offices. and to learn more about some ways to benefit from disruptive innovation ideas. I look POSTMASTER: Send address changes to Composites forward to seeing you there. Manufacturing, ACMA Headquarters, 2000 N. 15th Street, Ste. 250, Arlington, VA 22201. The magazine is mailed to ACMA members and is also available by sub- scription. Canada Agreement number: PM40063731 Return Undeliverable Canadian Addresses to: Station A, PO Box 54, Windsor, ON N9A 6J5, Email: returnsil@imex. pb.com. Copyright© 2017 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 Kevin Barnett Composites Manufacturing, circulation 9,000, as a service to Core Molding Technologies its members and other subscribers. Opinions or statements of authors and advertisers appearing in Composites Manu- ACMA Chairman of the Board facturing are their own and don’t necessarily represent that [email protected] of ACMA, its Board of Directors or its staff. Information is considered accurate at the time of publication, however ac- curacy is not warranted. 2 CompositesManufacturing Best Practices Composite Molds: Choices and Considerations Manufacturing magazine, we will examine • Durability – This is often tied to By Rick Pauer mold building, mold maintenance and required volumes, but simple design and Andrew Pokelwaldt up-and-coming mold innovations. modifications (like higher draft angles) can reduce wear and damage omposite molds vary widely, Composite Production of the mold surface. depending on the industry and C Processes • Speed to build – The time it takes application. For instance, high-end, nickel- Prior to starting the mold-making to make one or multiple molds. iron alloy tooling is commonly used in the process, it’s imperative to consider the • Cost and budget aerospace industry, while boat and wind expected production method for the blade manufacturers typically use GFRP Design, plug making, mold final application. The method you use molds. This column will focus on traditional construction, surface preparation, influences the mold you will build, composite molds that utilize glass fiber as framing, maintenance and demolding can and, conversely, the mold impacts the reinforcement and will provide guidance vary significantly depending on what type production method. Here’s an example for manufacturers striving to invest in of composite manufacturing process the illustrating the symbiotic relationship cost-effective molds that meet the required mold will ultimately be used for. between the two: If you only require a few volume and quality standards, using the parts, then you wouldn’t build a mold for best-suited process for manufacturing. Mold Design a heated resin transfer molding (RTM) Best practices for mold making vary The mold-making process typically process. The mold and process would based on many factors, including the starts with a plug (a representation of the simply be too costly. But if you plan on following: final part) and the initial mold (the mirror fabricating a dozen or so parts per day, image that is “pulled off” the plug to make • Number of parts to be made with then you would likely utilize heated RTM production parts). It’s important to start a mold molds, which can turn out two to three projects off right with a solid design. By • Mold service life parts per hour. investing time, energy and money in the • Cost These are some of the factors to consider design stage, you can avoid or minimize • Final product specifications, as you think about both your anticipated production issues later. Your return on tolerances and surface finish production process and the mold: capital – realized only after production • Material