Composites January/February 2012 Manufacturing The Official Magazine of the American Composites Manufacturers Association Industry Segments Automotive...... 4 NASCAR Infrastructure...... 8 Seal Observatory Marine...... 10 Military Technology Sports & Recreation...... 12 X-Games Departments & Columns President’s Message ...... 2 Inside ACMA...... 38 Ad Index...... 39 Features Marketplace...... 39 Postcure Chatter...... 44 Welcome to the Composites 2012 Show Issue See our Show Guide on page 18 Cover photo courtesy of NASCAR/Getty Images Defining Green...... 15 Correction: Focused on Life Cycle Inventory (LCI), ACMA’s Green Composites Committee has been In the article “Battlefield Ready” helping the composites industry understand, compile and report critical, missing information (p 27) of our Nov/Dec issue, needed to make a credible green case for composites. By John Busel, Gary Jakubcin, Goodrich was credited for creating David J. Lipiro and Cheryl Richards submarine components for over 35 years and for manufacturing the new Virginia-class submarines State of the Industry...... 27 using the patented RHO-COR Staying alive and profitable in a V-shaped business cycle has been challenging for most technology. Goodrich has only been companies in the composites industry. Survivors, take a well-deserved deep breath as making submarine sonar domes indicators suggest the worst is behind you. By Ray MacNeil since 2002 and uses RHO-COR in sonar domes for frigates and Taking Art to the Streets...... 32 destroyers without fire resistant Artist Walter Geiger built functional sculptures to inspire Orlando citizens in his composite materials. For more information, visit Goodrich.com. outdoor bus stop exhibit. His collection, named the Cascade series, provides color and cooling to public transportation. By Angie McPherson Structure, Sport and Style...... 34 Recent advances with short fiber technology have led to innovative composite implementations in the Boeing 787 Dreamliner, Callaway Golf RAZR driver and the Lamborghini Sesto Elemento. By Angie McPherson Online Exclusives www.compositesmanufacturingblog.com Composites are everywhere. So is Composites Manufacturing. Visit www.compositesmanufacturingblog.com for exclusive content, including Q&As with industry leaders, new product round-ups and up-to-date news. C Beyond the University Gate M Our September/October issue featured research projects underway at universities worldwide. We also received an update on a 2010 project, the bike-manufacturing IsoTruss technology. Catch up with BYU alumnus and IsoTruss manufacturer Altus Poles CEO Mark Jensen to see what successes a year can bring. In the News Composites Manufacturing magazine highlights industry breaking news and delivers it daily straight to you. Q&A Interviews Read what leaders of Altaeros, Recreational Boat Group, the National Science Engineering Research Chair and more view as the strengths, weaknesses, areas of growth potential and factors affecting the composites industry.Composites Manufacturing 1 President’s Composites Message Manufacturing Volume 28 | Number 1 | January/February 2012 Opportunities for

Composites Official Magazine of the American Composites Manufacturers Association s we start the New Year I think, “What a great time to be in the composite industry!” There will be many new Publisher A Tom Dobbins advances in composite products developed around energy [email protected] efficiency and more opportunities for expansion. For example, UPS trucks, U.S. Director of Marketing & Communications streetcars, wind turbines and more. The growing demand for light weight, high Mary E. Johnson strength-to-weight ratio and longevity make composites a great answer. [email protected]

Editorial Here at Miles Fiberglass, we are currently developing a prototype electric car Associate Director, Communications with an all-composite body shell. I know of a company in Hawaii developing Melinda Skea [email protected] composite sole inserts for shoes. Even wave energy buoys use composite materials for their non-corrosive properties in salt water. Communications Coordinator Angie McPherson [email protected] However, more can be done to ensure that composites get their fair share of the market with competing materials. As an association, ACMA is supporting Advertising Sales CM Magazine Advertising Department proposed legislation that would require life cycle costing for federally funded 3033 Wilson Blvd., Suite 420 construction projects. The 599-page bill includes several provisions that will Arlington, Va 22201 spur increased use of composites. Life Cycle Costs Analysis (LCCA) is a P: 703-525-0511 • F: 703-525-0743 process for evaluating the total economic worth of a project by analyzing initial Editorial Design & Production costs and discounting future costs. In the short term analysis composites are Keane Design, Inc. [email protected] often more expensive compared to competing materials, but under LCCA, keanedesign.com composites shine. Eliminating the “lowest cost only” factor from government All reprint requests should be directed to selection bids will help composites compete on a more level playing field. Reprint Management Services at 717-399-1900.

If you would like to get involved in this process, contact John Schweitzer, American Composites Manufacturers Association ACMA’s senior director of Government Affairs. John has been working 3033 Wilson Blvd., Suite 420 diligently on this and other legislative matters. Many members have already Arlington, Va 22201 Phone: 703-525-0511 Fax: 703-525-0743 encouraged their Congressmen (or Congressional representatives) to support Auto attendant: 703-525-0659 this effort. Meanwhile John Busel, ACMA’s director of Composite Growth Email: [email protected] Online: www.acmanet.org Initiative (CGI), has been gathering data in collaboration with the Federal Composites Manufacturing (ISSN 1084-841X) is Highway Administration and other agencies and universities to build the case published bi-monthly by the American Composites Manufacturers Association (ACMA), 3033 Wilson Blvd., of composites service life longevity and its cost effect on infrastructure. Suite 420, Arlington, Va 22201 USA. Subscription rates: Free for members and non-members in the U.S., Canada The Senate Highway Bill is another of the many opportunities this industry and Mexico; $85 for international non-members. A free online subscription is available at cmmagazine.org. Pe- has to increase the use of composites. Many of the CGI committees have been riodical postage paid at Arlington, VA and additional working tirelessly to develop codes and standards that will help architects mail offices. specify composite materials. The Green Composite Committee is currently POSTMASTER: Send address changes to Composites working on the Composites Life Cycle Inventory (LCI) Project aimed at Manufacturing, P.O. Box 336, Congers, NY 10920. The magazine is mailed to ACMA members and is also developing data for certain materials and manufacturing processes so that a available by subscription. Canada Agreement number: Life Cycle Assessment (LCA) can be readily conducted allowing manufacturers PM40063731 to compare composites to competing materials. To read more about it, turn Return Undeliverable Canadian Addresses to: Station to page 15 of this issue. If you want to be involved in this very important, A, PO Box 54, Windsor, ON N9A 6J5, Email: returnsil@ imex.pb.com. Copyright© 2012 by the ACMA. All rights ground breaking work or learn more about what is going on, visit www. reserved. No part of this publication may be reprinted acmanet.org or call them directly at 703-525-0511. Remember, we are a member without permission from the publisher. The ACMA, a driven organization and that means we need your help! If you’re not already a nonprofit organization representing the composites industry worldwide, publishes Composites Manufactur- member of ACMA, join today. ing, circulation 10,000, as a service to its members and other subscribers. The reader should note that opinions or statements of authors and advertisers appearing in Lori Luchak Composites Manufacturing are their own and do not Miles Fiberglass & Composites, ACMA President C necessarily represent the opinions of statements of the [email protected] M ACMA, its Board of Directors or ACMA staff. 2 Composites Manufacturing Composites Manufacturing 3 Industry Auto Segments Gentlemen, Start Your Engines Photo: NASCAR/Getty Images he opening day for the 54th overflow tanks, mirrors and other National Association for Stock non-structural components. Teams TCar Racing (NASCAR) season such as Joe Gibbs Racing (JGR) is February 26, 2012 at Daytona have even brought composite International Speedway in Daytona, manufacturing in-house to get Fla. Hundreds of thousands of concepts built on the car faster and viewers will pack into the 2.5 mile increase the team’s competitive edge. arena while millions more will tune in at home to watch 42 cars battle, The Joe Gibbs engineering team crash and roar past the black and Opening day at Daytona International On a tour of the JGR headquarters, white checkered flag. Speedway. based in Charlotte, N.C., Technical To an engineer, this sport may Sponsorship and Marketing Director look a little different than to a engineers focusing on composite Mark Bringle showed Composites NASCAR fan. For example, what concepts in approved areas of the Manufacturing how 50 plus are the different ways to make a cars. engineers, including a composites stock car capable of producing 190- Race cars could employ expensive department, create parts for 11 racing mph speeds? Exactly what types of techniques to lightweight and design teams. Bringle was previously in materials and techniques are teams an impressive racing machine, but charge of the vehicle designs and has using to build a machine capable of NASCAR is intent on keeping the a background in manufacturing. withstanding hours of high-speed cost down to allow small teams “Seeing the car on the track is one racing? The short answer is: Sheet to compete in the growing sport. of my favorite parts of the job,” says metal, powerful engines and good That’s not to say that composites Bringle. “It’s good to see something tires. However, composites are have been opted out of the racing you’ve built on a worldwide arena.” slowly integrating into NASCAR arena; composite parts are heavily Bringle reflects on the 2005 Sprint manufacturing designs thanks to integrated into the nose, tail, interior Cup Championship win as one of faster prototyping tools and more seats, dash panels, fan housing, his favorite experiences with the company and mentions that Gibbs’ leadership is the driving force that JGR driver Denny Hamlin #11 and pushes the entire organization to do Kyle Busch #18 in track-ready, its best. NASCAR approved cars. JGR only recently brought its composite manufacturing in-house in early 2000 when the team realized the benefits of shorter and cheaper production time. “Everything I’ve learned about composites manufacturing I’ve done here with JGR,” says Engineer Mike Bright, one of the main composite engineers at the facility. “The learning curve for manufacturing was pretty steep. But after playing around with some of the composite prototypes, the team quickly saw the advantages of manufacturing its own composite parts.” JGR uses both vacuum processes and hand lay-up on all of the parts it manufactures in-house. “We don’t have an autoclave, so we 4 Composites Manufacturing Kyle Busch’s pit crew fueling up his #18 Toyota Camry. outsource most of our ducting in NASCAR Fast Facts order to manufacture those parts,” adds Bringle. For JGR, the benefit • NASCAR started implementing composites into cars in the 1980s of using vacuum processes is • Officials do a “magnet test” to ensure parts are steel that the expense for equipment is • The nose and tail are the only approved composites body parts considerably lower. However, the • Aluminum and CFRP are the only two approved materials for racing seats surface quality is not as fine as the parts cured in an autoclave. Most of the composite parts were only racecars. “We were having difficulty probably the best example of how recently implemented into NASCAR with tires blowing out during races bringing composite manufacturing designs such as the dash board and and needed to find a way to cool in-house has provided cost and time the tank. The team has prototyped the rubber. We concept designed a solutions for our design processes,” several designs to include composite cooling duct to distribute air around says Bringle. parts to lightweight the car in the tires,” says Bright. NASCAR approved areas. The JGR The prototype part is designed in The checkered flag team uses a variety of different the Fortus 3D computer software, After the parts are completed, they building materials depending on and then a thermoplastic model is are tested for strength and durability the application, including composite built in the machine in one day by onsite. They are then attached onto prepegs, Kevlar and epoxy resins. layering the material one at a time the chassis. It takes eight days to put to fit the design specifications. This the entire car together and when we From concept to production new process significantly reduces visited mid-November, the team was JGR recently invested in new the time from concept to prototype, already building cars for February’s prototyping technology to get enabling the team to get new designs Daytona 500. After the car is built, concept parts from the CAD into a to the cars before the next race. Once it goes through a number of tests on plastic prototype part and finally the part is installed on the vehicle and off the track to assess the wheel into a shape for a mold. This way and accepted, the machine builds a placement, shocks, springs, etc. It the engineers take less time per mold for the part so the designers then goes to the officials to verify week to produce parts for 70 JGR can manufacture the part. “This is that the properties of the vehicle Composites Manufacturing 5 Teams such as Joe Gibbs Racing (JGR) have brought composite manufacturing in-house to get concepts built on the car faster and increase the team’s competitive edge.

meet NASCAR standards. Then it’s to ensure that the parts won’t break retired race cars are recycled in the off to the races where the car goes during the race. back of the manufacturing facility through35632 MSO several 4.75x7.25_Res tests on Infusn the track Gnrl half Final 11/16/11Most of 2:16the metalPM Page parts 1 from and the composite parts are ground and thrown away. If a part is only slightly damaged, Bright will cut away the damaged part and patch it using wet lay-up. “None of the parts are structural, so we can just fix the part and reuse it in another car,” says EXCELLENCE IN Bright. After a crash at the racetrack CORE SOLUTIONS (or during prototyping), composite and metal parts will travel to the

failure lab at the JGR facility to test the durability of the product. “We’ll push a product until it breaks. This For today’s vacuum infusion, use is how we know the threshold of a today’s choice cores. specific product,” says Bringle. Some of the retired cars are sold to fans in order to raise money and the team begins building again for the next race. So, how are teams building speed- hungry, doorless, windowless cars? From scratch—building­ from the chassis up with a team of engineers following NASCAR standards and prototyping with new designs to help the cars perform better under high speeds. This February, in the midst of thousands of cheering NASCAR fans, it will be up to the driver, crew chief and pit crew to determine how the 190-mph mass Innovative building methods infusion applications. The result: of moving sheet metal, rubber, contribute to a cleaner environment, No voids and highly-efficient use of higher-quality laminates and faster materials. composites and all will cross the production. Our advanced GPS-type For detailed information on resin finish line. AIREX® foams and BALTEK® balsa infusion methods and compatible cores ® cores, as well as Lantor SORIC and as well as technical support, contact Angie McPherson is the communications FINISHMAT® materials have been the experts at 3A Composites specifically designed to enhance all Core Materials. coordinator at ACMA. Email comments to [email protected].

North America / S. America: Europe / Middle East / Africa: Asia / Australia / New Zealand: Baltek Inc. Airex AG 3A Composites (China) Ltd. High Point, N. Carolina 27261 U.S.A. 5643 Sins, Switzerland 201201 Shanghai, P.R. China Tel. +1 336 398 1900 Tel. +41 41 789 66 00 Tel: +86 21 585 86 006 [email protected] [email protected] [email protected] For more stories like this, visit compositesmanufacturingblog. com and search using keyword www.corematerials.3AComposites.com “racing.” C M Come see us at COMPOSITES 2012, Booth #747 6 Composites Manufacturing High Performance Materials.

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saertex_ad09_windcraft_USA_RZ.indd 1 11.05.2009 16:52:52 Uhr Industry Segments Cast Polymer Percentages Can Be Misleading Nationwide housing starts rose for a third consecutive so the real growth isn’t as large as it would have been a month in March to a seasonally adjusted annual rate of few years ago.” 626,000 units, according to a report from the National As- Todd Loebel, owner of Wisconsin-based Custom Marble sociation of Home Builders (NAHB) that relies on U.S. Products, agrees, saying local homebuilders in the area Commerce Department data. The report also indicates that who were once building 70 to 80 homes per year now the rate of permit issuance for new housing construction struggle to build about 15. “I view percentages with a grain rose by 7.5 percent in the month, to a seasonally adjusted of salt. Ten percent growth sounds good, until you realize annual rate of 685,000 units. But how is this affecting the that because it comes from the lower number, you’re look- cast polymer market, which relies heavily on the housing ing at essentially one extra home per year. That’s good, but industry for its business? not anywhere close to what the typical levels would be,” Composites Manufacturing talked to three manufacturers he says. who have experienced modest growth in their business. Even with the modest increase in new housing over the Southern Cultured Marble, Custom Marble Products and previous year, Bishop says the cost factor will continue to Formatop have seen increases ranging from 10 to 25 per- inhibit cultured marble. “The houses themselves are worth cent over the past two months. less, and feature less-expensive materials to match,” he So what’s accounting for this growth? According to says. “Unfortunately for us, the price of the raw materials Mark Buehner, president of South Dakota-based For- hasn’t dropped. In fact, they’ve only increased, so we’re matop, part of it may be psychology. “For too long, the still at their mercy.” news was too negative, and the way people feel has a Though the housing levels continue to be a fraction of strong influence on their purchasing habits,” he says. what they were even a few years ago, these men say the Buehner hopes the positive news galvanizes spending. industry will continue to focus on innovations and devel- However, these companies still can’t fully shake the re- opments to make the recent growth even larger. “The in- ality of their situation. “I tend to disregard percentages dustry has to look at the aesthetics of the product. For and focus on real numbers,” says Scott Bishop, vice presi- example, color trends change much faster than what they dent of South Carolina-based Southern Cultured Marble, used to, so companies must always be thinking about what Inc. “I think in this case, the percentage aspect is slightly they can do to make things newer,” says Buehner. misleading. It’s a percentage of a much smaller number,

Industry Infrastructure/ConstructionInfrastructure Segments The Role of Composites in Disaster Relief When Haiti’s recent earthquakes left InnoVida is donating 1,000 composite houses to the people of Haiti. residents without shelter and ex- NOAA Alaskan posed the need for better infrastruc- ture, one composites manufacturer found a way to do good…and good business. Seal Observatory InnoVida manufactures composite panels and assembles structures for housing applications in the residen- tial and defense markets. The Miami- based company has pledged to donate 1,000 homes to Haitians. The implementation of such a large sam- ple of composite homes is a charita- ble act,Photos courtesy of Wade Construction and Strongwell. Perrow but it will also demonstrate the role composites can play in reha- continued...

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aint Paul Island is located in NOAA specified This was the first project that Sousie the middle of the Bering Sea constructed using FRP composite Sand is home to the largest composites to ensure materials. Northern Fur Seal breeding ground To research more about the ma- the in the world. American scientists the product life would terial he would be working with, have been conducting research at the Sousie searched the Internet for site since 1911, counting the colony’s reach 50 years. “composite materials” and found population and observing new-born Strongwell Corporation, Bristol, Va. seal behavior. To stay aloof from the -Jason Sousie “The small island population seldom marine mammals, scientists make Project Manager, WPC uses heavy construction equipment their observations from a series of Seattle, Wash. and the installation was manhandled wooden planks connecting seven using a forklift and pulley system,” towers on a remote part of the island only would the building material says Randy Montgomery, project that is surrounded by rocks and ice. need to be transportable, but contrac- manager at Strongwell who coor- When the National Oceanic and At- tor Wade Perrow Construction LLC dinated the material provided for mospheric Administration (NOAA) (WPC), Gig Harbor, Wash., needed the Seal Observation project. This needed to replace the long-standing materials that were strong enough to required non-traditional planning wooden observatory deck at a re- withstand the 20-60 mph winds and from WPC to ensure project success search facility in Saint Paul Island, light enough to install with limited with the available tools. Logistics Alaska, the U.S. government speci- construction equipment. Chiefly, continued to challenge Strongwell fied pultruded composites as the NOAA wanted to extend the obser- and WPC to complete the observa- material of choice. vatory lifespan. “NOAA specified tory before June and remain within The location of the observatory composites to ensure the product life the budget. is difficult to reach via traditional would reach 50 years,” says Jason The Northern Fur Seal is an en- methods like trucks and ships. Not Sousie, project manager at WPC. dangered species and the colony 8 Composites Manufacturing occupies the island during the projects with unique composite appli- For more stories like this, visit summer months, leaving only the cations in the coming year. compositesmanufacturingblog.com winter available for construction. and search keyword “pultrusion.” Angie McPherson is the communications Therefore, the timeline for shipping C the building materials to the island coordinator at ACMA. Email comments to M was imperative to the success of this [email protected]. project. “We put a lot of energy into the coordination of this project. Ev- erything they needed to complete the project had to ship on one boat to the island,” says Montgomery. The composite handrails, platforms and ladders were manufactured in ALL NEW September and delivered to Wash- DESIGN ington state via trucks by Novem-

Photos courtesy of Wade Construction and Strongwell. Perrow ber. The product departed Seattle Harbor on a 300-foot coastal boat to Saint Paul Island in December where WPC employees installed Strongwell pultruded composites in blizzard- like conditions during a four month timeframe. If the building materials missed the last western Alaskan boat to Saint Paul for the year, the team would have to hire a charter vessel, which costs upwards of $30,000. “During transportation, some of the fiberglass parts were crushed in the shipping trucks. Fortunately, we were able to contact Montgomery at Strongwell and ordered extra spare parts. There aren’t any hardware stores on the island, we only had the tools we brought,” says Sousie. “I was really impressed with the level of responsiveness from Strongwell and the durability of the product. I know NOAA was extremely pleased with the outcome as well. If the right opportunity came up, I would defi- nitely work with the material again.” The Alaskan Observatory Project was recently named the Best Federal Heavy Renovation Project of 2010 at the Aon Build America Awards in Las Vegas. The composite observa- tory provided NOAA and WPC with material more durable than wood, corrosion resistant and easy to install in the field. Montgomery predicts that the observatory will last much longer ® than the previous wood installation, based on his experience with current Strongwell products in the field, and Come see us at COMPOSITES 2012, Booth #935 looks forward to completing more Composites Manufacturing 9 Industry Marine Segments Structural Composites was one of Venore, Tenn., approximately five three teams accepted in Phase I, each years ago to lightweight recreational was awarded $75,000. The company boats, which offered a 10 percent Technology teamed with Zodiac Boats, an inflat- weight reduction. “But the problem able and rigid-hull boat company with the previous single skin system Lowering based in Stephensville, Md., to help was that it wasted a lot of material,” with the rigid boat design. The team says Lewit. “They were buying core More than completed Phase I in December 2009 kits, which are expensive due to and was the only team to pass into core material cost and the volume Boat Prices Phase II, where they were awarded lost during knitting.” The Prism SST $750,000. In Phase II of the project, Navy boats are sandwich-free de- Structural Composites will produce signs where the hull, deck, and even n late 2008, Structural Composites one low-risk, low-cost boat approxi- the transom is a single skin construc- based in Melbourne, Fla., submitted mately 21-feet long with the option tion. Ia proposal to the Navy Small Business to build another more advanced The laminates are manufactured Innovation Research (SBIR) to solve boat using higher quality fibers to using resin infusion on Prisma pre- project number N091-049, Advanced improve shock mitigation, but also to forms created at Structural Compos- Combatant Craft for Increased Afford- further lightweight the boat design. ite’s manufacturing sister company ability and Mission Performance. The Elements of the Prisma Single Skin CompSys, also in Melbourne, Fla. purpose of the project was to reduce Technology (SST) were modeled off The company can manufacture one the lifecycle cost and improve shock a similar single skin system that was mile of beams in four hours, this mitigation protection on small combat- used by Maverick Boats, Fort Pierce, reduces the labor cost and ensures ant crafts in difficult environments. Fla., and MasterCraft Boat Company, ample supply.

10 Composites Manufacturing Lewit believes the composite skin tant step for the industry. “If you industry to move towards, particu- technology can impact the future start building flatter bottom boats larly the boating industry. Especially of the marine industry by reduc- and suspend the cockpit, you can since I don’t see the marine market ing weight and labor cost using change the hydrodynamics of the going back to where it was and preforms for both open mold and boat to the point where you can put the boat industry is well suited to vacuum assisted resin transfer mold- a smaller engine on it,” says Lewit. bridge deck technology.” While the ing (VARTM). The thin, single-skin “That starts a spiral towards fuel- boat and aerospace industry remain membrane uses significantly less efficiency and overall cost-savings. somewhat stagnate in Florida, Struc- material and could bring the cost of Put in a smaller engine, smaller fuel tural Composites continues to move boats down for the marine industry. tank, pull an axel of the trailer, drop forward into a rich and rewarding “In 2006 we were able to make a horsepower, you’re looking at po- new realm for composite innovation, $32,000 boat cost $25,000. But that tentially 40-50 percent savings in the using its new Prisma SST technology was five years ago; imagine what we price of the boat, making them af- to lower weight and cost. could do with this new technology,” fordable again.” says Lewit. Additionally, Lewit and his team Angie McPherson is the communications Lewit recently received a Congres- are working with the Florida DOT to coordinator at ACMA. Email comments to sional Medal of Merit for developing implement composite material into [email protected]. this new technology in partnership movable bridge decks, a huge need with the U.S. Navy. His company in the state. “We have a coalition of is focused on bringing this military boat builders that are interested in For more stories like this, visit technology back to the marine indus- producing bridge decks. There are a compositesmanufacturingblog.com try. He believes that applying Prisma lot of people out of work and there and search keyword “reduction.” SST technology on recreational boats are over 150,000 structurally defi- C could significantly reduce the weight cient bridges in the U.S.,” says Lewit. M and price, which could be an impor- “This could be a good area for the ACMA: Your Education Connection 2012 Events Calendar

February 21-23 COMPOSITES 2012, Las Vegas, NV

May 8 - 9 CCT Instructors Course, Arlington, VA May 16 - 17 Composites Build America Lobby Day, Washington, DC May 23-24 Chemical Processing Workshop, Houston, TX

June 19-20 Green Composites Workshop, Chicago, IL (tentative)

October 9 -10 CCT Instructors Course, Arlington, VA

Unless otherwise noted, all events are open to members and nonmembers. For more information, visit www.acmanet.org/meetings

Composites Manufacturing 11 Industry Sports/RecreationSports/Recreation Segments Composites Aid in Aquatic Maneuverability

Rodrigo Silveira has been designing Uphill custom jet skis for the past eight years. The Samba XRS is the work of designer-turned-manufacturer Rodrigo Silveira. Now, he’s branching out and using composites to make his own line of per- Progress sonal watercraft. Silveira’s company, Silveira Group, for Downhill has developed the Samba XRS, a water- craft made largely from carbon fiber. Sil- Sports veira notes the composite material is exactly what he needed to achieve his main goal: maneuverability. “Personal ompetitive snowboarders watercrafts are getting bigger, and are more about going resulted in prototyping a new machine from start to fin- rely on a slim piece of from point A to B. If you want maneuverability, it’s tougher ish in about two weeks,” he says. Cfiberglass and some plastic to achieve with big watercraft,” he says. “You see a lot of Doing all the work in-house has also aided the stream- strapping to ride down the sleek, riders trying to do stunts or tricks, but because of their mas- lining process. “From the design to the routing to the fabric often precarious slopes like the sive weight, the rider doesn’t have the control they need. cutting to the mold-making in the actual part being made, Colorado Rocky Mountains. In stiff Having a machine that is so small and so lightweight gives doing everything in-house really does make the process competition, snowboarders must the rider more instinctive body control.” quicker,” says Silveira. Though this current edition of the trust the equipment they bring to Carbon fiber has helped achieve that control and as a XRS is gas-powered, the company also hopes to make a the slopes to keep from breaking in result, the XRS comes in at about 34 pounds. “We wanted splash with an electric-powered version this fall. harsh conditions. Especially when the rider to really have the most control of the machine, the boards are tested in extreme and we knew we had to make it as light as we could to do conditions like the high intensity that. That’s why we turned to making it out of carbon rides, the Superpipe, BigAir and K2 Snowboards manufactures thousands of quality snowboards featuring top-of-the-line fiber,” Silveira says. Snowboarding X events, during the technology developed at their new research facility. This includes implementing the high-strength compos- ESPN Winter X-Games. This year’s ite into unusual parts. The ride plate, which is the equiv- events will take place in Aspen, years ago in November 1961. Bill manufacturer of fiberglass cages, alent of an automotive chassis, is usually made from Colo., January 26-29, 2012, and new Kirshner is the original founder knew that composites would be the aluminum. Silveira cites the increased costs of mass pro- snowboard advances, thanks to of the company and a pioneer future of winter sports equipment duction with carbon fiber have been the main reason for composites, are expected to raise the in the market for fiberglass design because the use of fiberglass this, and he hopes this is one way to buck the trend. level of competition. manufacturing in winter sports could prevent wood rot and other The manufacturing process begins with creating a 3D K2 Sports based in Seattle equipment. Previous to his work in corrosion issues associated with model, then a wet lay-up for the mold. For the part itself, has been engineering snow skis the 1960’s, most ski manufacturers traditional winter gear. the company used prepreg and five layers of carbon fiber with composite materials since were making components out Today, K2 Snowboards, a branch material, which Silveira says makes for a straightforward, the company was founded 50 of wood or metal. Kirshner, a of K2 Sports exclusively focused easy lay-up. The mold is then heated in an autoclave for about an hour at 180 degrees and another hour at 250 de- grees to cure it. “The first hour is used to soften the resin Not Offso it will Your flow into Rocker the right places in the material. The sec- K2 has one snowboard team member potentially competing in the Women’s Superpipe at the 2012ond Winter hour X-Games, is curing Gretchen that resin,” Bleiler, Silveira who has says. won four gold medals at the Winter X-Games andAfter silver the in initial the Winter two Olympics.hours has Bleiler passed, uses the the finished K2 Eco part Pop 152, a lighter board constructioncan beshe pulled helped from design the and mold. promote The incompany 2010. It is uses built two for women au- snowboarders and nowtoclaves the rocker, for a thissnowboard process. shaped A 10-ft. with diameter a small upward model curveis used rather than the traditionalfor camber the larger design, parts is for and all aterrains. 5-ft. diameter model is used for smaller parts such as hood components and plates. Doug Sanders,Silveira global credits product his director background of snowboards as a 3D at designer K2, believes for athat the recent industry smoothtrend towards manufacturing more rocker process, shaped whichsnowboards was accomplished is a result of the R&D efforts from the byresearch designing facility a developingmodel in 3Dthe androcker extracting design. “We’ve the patterns made tons of ineffectual snowboardsfrom at that K2 to model develop in ourthe rockerCNC routingboards but process. they never “Tradition- make it to the customer. All of our advances come from concepts that occur when you experiment,” he says. He ally, you have people drawing out and manually cutting Olympic medalist expects that the future will bring more advances for the rocker design, which has only Gretchen Bleiler on her recently patternsgripped the for industry, the lay-up. and Wemore streamlined interesting competitionthis process thanks which to the advances of award winning board, snowboard engineering. the K2 Eco Pop. Subscribe for free at cmmagazine.org Composites Manufacturing 17 12 Composites Manufacturing on manufacturing composite snowboards, still uses hand lay-up The flatline rocker, a flattened rocker to handcraft high-performance winter sporting equipment. It stays arch, uses hybrilight technology to ahead of the curve by investing in snowboard technology research minimize material during construction. and development at a state-of-the- art facility capable of building 100 says Sanders. “When it comes you need sheer layers to allow the percent production level snowboards to manufacturing snowboards, product to flex and stay together in four business days. “We can there’s only so much engineering under the enormous stresses our concept a design on Monday, have you can design in the board before products go through; especially the board ready on Thursday, test you have to just go out and test since we have to perform at it out on Friday and potentially it. Our research facility gives us cold temperatures. A lot of little tweak it on Monday if we want to,” that opportunity.” Some of the components need to be put into the says Doug Sanders, global product low end snowboards have started board and the only way to do that director of snowboards at K2. to implement closed molding is with a skilled craftsman and not K2 manufactures thousands of technology like compression an assembly line. It’s the only way snowboards a year and prototypes molding on preforms to increase the to get the quality we want,” says approximately 200 boards. “That production speed, but hand lay-up Sanders. mathematically works out to be is a must for the high performance The snowboard team sponsored about one board a day that we mold boards. “In composites, you can’t by K2 is used as a research group to to ride, break and make it better,” just have all hard structural layers, develop competitive snowboards

Composites Manufacturing 13 for their personal use. The athletes The recent downhill economy has typically use the boards they help not impacted the popular downhill to develop during competitions. sport manufacturer. “We took the One composite component that has opportunity to capitalize on research recently undergone considerable and development opportunities amounts of testing is the material at the height of the U.S. economic used in snowboard cores. In high- depression. We saw the dip coming performance snowboards, K2 uses but we didn’t take our foot off the a mixture of different woods and pedal,” says Sanders. “Our new bamboo to strengthen the board. designs started coming out around “We use three different trees in that time. The entire time I’ve been the core to increase strength and involved in the snowboard industry durability on the outsides and down I’ve never seen new technology move the center of the board. Then we mix faster than it is now. It feels like it’s in some bamboo for flexibility and the first five years that snowboarding strength,” says Sanders. Just this ever existed. Honestly, if you have a year, K2 developed a board using a board older than three years, you’re laminated bamboo wood core that riding old technology.” has been termed “unbreakable.” The snowboard has gone through Angie McPherson is the communications multiple extreme tests and riders coordinator at ACMA. Email comments to and has never broken. Bamboo [email protected]. is not the lightest of woods but it For more stories like this, visit is easily available for snowboard compositesmanufacturingblog construction. “Bamboo has huge .com and search using Inside the K2 research facility, an employee weight to strength properties. In keyword “sports.” Asia people are using it to build removes excess material from a prototype C scaffolding.” says Sanders. board. M

FREE CCT Tutorials Offered at COMPOSITES 2012! Las Vegas ■ February 21, 2012

Don’t miss this once-a-year opportunity! Increase productivity. Reduce production cost. Enhance product quality. Take your CCT exam When you attend COMPOSITES, you Space is limited. at the show! can participate in these full-length Register at www.acmashow.org CCT tutorials FREE February 23, 2012 Come to ACMA’s booth #665 at Open Molding COMPOSITES 2012 and receive a You must be enrolled Wind Blade Repair 10% discount when you sign up for in the CCT program other CCT programs (both individual and registered for Vacuum Infusion and group enrollments). COMPOSITES 2012 to take the exam. Register for the exam To sign up or for more information, please contact session by [email protected] or call 703-525-0511 January 28, 2012.

14 Composites Manufacturing Legislative and Regulatory

Defining Green An update on the Composites LCI project

By John Busel, Gary Jakubcin, David J. Lipiro and Cheryl Richards

hat is the environmental What is Life Cycle Inventory? LCA involving the compilation and footprint of my products? There are environmentally im- quantification of inputs and outputs, WHow green or sustainable portant inputs (e.g., energy, water, for a given product system through- are they relative to competing prod- materials and other resources) and out its life cycle. Once LCI data is ucts made of different materials? outputs (e.g., discharges to air, land available, an LCA can be conducted What information is out there for my and water) at every step of the life on products using the materials and company to use? How do I develop cycle of a product. processes covered in a national LCI quantifiable data to support my Life Cycle Assessment (LCA) is database, maintained by the U.S. claim? As the composites industry the formal method by which the en- Department of Energy’s National Re- works to meet the needs of a world vironmental life cycle impacts of a newable Energy Laboratory (NREL). that is more environmentally aware, product are compiled and evaluated. The NREL LCI database includes in- these and many other questions are An LCI is the front-end phase of formation on materials such as steel, being asked by composites manufac- turers each day. Figure 1: Generalized Product Life Cycle These questions have been largely answered in many applications for “CRADLE” OUTPUT competing materials such as steel, INPUT wood and aluminum, but the same Raw Material Acquisition cannot be said for composites. How- Materials Air Emissions ever, that is about to change. Since Production 2009, ACMA’s Green Composites Energy Wastewater Discharges Committee (GCC) has been helping Water Solid/Hazardous Waste the composites industry understand, Other Use/Reuse/Maintenance compile and report the critical missing Resources Coproducts/Byproducts information needed to make a cred- Recycle/Waste ible green case for composites. That Management missing information comprises the Life Cycle Inventory (LCI) for com- “GRAVE” posites. Composites Manufacturing 15 aluminum, concrete and wood, but Science Foundation. Future phases LCI Project by Company very little on composites. Without are planned and will include other Participation readily available LCI data, LCAs on materials and processes, but are de- UP Resin Task Grp composite products will be very dif- pendent on company participation in ficult and costly to conduct. supporting the required materials and AOC, LLC The GCC is addressing this by processes, as well as funding. Ashland Performance Materials developing the missing LCI data. In total, 25 ACMA corporate mem- CCP Composites In June 2011, at the ACMA’s Inau- bers have volunteered to work with Interplastic Corporation gural Green Composites Workshop Franklin Associates to collect the nec- PCCR USA, Inc. in Chicago, the GCC launched the essary information. These companies Reichhold, Inc. Composites LCI Project. ACMA se- have been working for more than lected Franklin Associates, a Division three months collecting the raw data E-Glass Fiber Reinforcement Task Grp of Eastern Research Group Inc., to that were needed to comprehensively Johns Manville help conduct this important project. complete the project task, including Owens Corning Franklin Associates has more than 35 general information, material inputs/ PPG Industries, Inc. years of experience conducting LCAs outputs, water use/consumption, for private companies and industry energy use, solid waste and air/water Open Molding Task Grp associations and has completed nu- emissions. The shared data was con- Alaglass Pools merous material LCAs and submit- fidentially analyzed and averaged by Best Bath Systems ted LCI process data modules for Franklin Associates, generating repre- fuels, plastics and other materials to sentative information for each mate- Ershigs, Inc. the U.S. LCI Database. rial and manufacturing process that Lifestyle, LLC will be shared with the industry. Xerxes Corporation Overall, the two main objectives Compression Molding Task Grp of Phase 1 are to provide individual ACMA members with LCI data on Mar-Bal, Inc. the materials and composite produc- MFG Tray Company tion processes that are specific to their Molded Fiber Glass - North Carolina The nuts and bolts operations for internal benchmarking Premix Inc. In the composites industry, there and decision-making, and to provide Stahlin Enclosures are thousands of composites materi- ACMA as a whole with aggregated als and more than a dozen manu- LCI data representative of the average Vacuum Infusion Processing Task Grp facturing processes. Developing LCI production on those same materials Ershigs, Inc. data for all these materials and pro- and processes in a format suitable for Fiber-Tech Industries, Inc. cesses is a daunting prospect. The submission to the U.S. Department Plasti-Fab, Inc GCC decided to maximize value by of Energy NREL’s LCI database. This focusing the Composites LCI Project information will be used by public Casting – Open/Closed Mold Task Grp on the most commonly used materi- and private stakeholders in preparing Bradley Corporation als and manufacturing processes. LCAs. Classic Cultured Marble Further, the project was divided into Not an easy task by any means, Hoffman Fixtures Company three separate tasks of collecting/ but the results will greatly benefit compiling fundamental data, devel- the industry, especially participating International Marble Industries, Inc. oping a report and developing NREL companies. Not only will these 25 Secondary Bonding Task Grp LCI templates that will be used to companies be able to gauge how their Ershigs, Inc. submit the final data into the registry. materials and processes compare to To begin, the Committee agreed in the aggregated (averaged) data, but Molded Fiber Glass Companies Phase 1 to evaluate two materials, un- their participation provides them the Stahlin Enclosures saturated polyester resin and E-glass opportunity to take a close look at reinforcement materials, and five their manufacturing process flow, the processes, open molding, compres- decisions they make and the waste sion molding, casting-open molding, they produce. This top-to-bottom, in- vacuum infusion processing and sec- depth review can help them redefine ondary bonding processes. Originally, their business and marketing plans, pultrusion was on the Phase 1 list; identify ways to gain production sav- The Next Steps however, evaluation was completed ings, and better comply with environ- The GCC is committed to provid- separately under the leadership of mental regulations. ing ACMA members with the most Dr. Michael Lepech at Stanford Uni- transparent LCI data available for the versity and funded by the National materials and processes under study. 16 Composites Manufacturing At COMPOSITES 2012 in Las Vegas, process needs to be repeated with Take a Vested Interest an educational session titled, “Big many products in different markets. The LCI Project is a complex under- Steps Towards a Small Footprint – Devel- The Committee expects manufactur- taking that requires qualified LCA/ opment of Life Cycle Inventory Data for ers of composites products will con- LCI experts to successfully complete. U.S. Composites” will be presented by duct individual LCAs modeled on This could not happen without fund- Melissa Huff, senior chemical Engi- this test case on their own and at their ing. In addition to ACMA, the follow- neer and project manager at Franklin expense to determine how well their ing composites industry leaders have Associates. The presentation will products stack up environmentally provided critical funds to execute focus on the process to develop the against the competition. None of this Phase 1 of this project: data and the results of this project in- would be feasible without a solid AOC, LLC cluding the data submitted to the U.S. foundation – the Composites LCI • LCI Database. Project. • Ashland Performance Materials As previously mentioned, a pri- • CCP Composites mary objective of the Composites John Busel is the project principal • Interplastic Corporation LCI Project is to enable companies to investigator and director, Composites conduct—at a relatively manageable Growth Initiative at ACMA. Gary • PCCR USA, Inc. expense—green product comparisons Jakubcin is the co-chair of the GCC • Reichhold, Inc. LCI Subcommittee and manager Green via the formal methodology of LCA. • Ershigs, Inc. The GCC will carefully evaluate the Products and Life Cycle Assessment at many products and markets served Owens Corning-Corporate Sustainability. The entire composites industry has by composites and select a few prod- David J. Lipiro is the co-chair of the a vested interest in this work and its GCC LCI Subcommittee and president ucts as a test case for a comparative results. There is more work to do be- of ECRM, Inc. Cheryl Richards is the LCA. From those comparisons, we yond Phase 1 and we ask that many will finally understand and be able chairperson of the ACMA GCC and more companies commit to becom- to quantitatively document the sus- global market development manager of ing involved and support this critical tainability of composites relative to wind energy at PPG Industries Inc. industry endeavor. competing materials. However, this

is recognizing the Industry’s BEST

Who is a leader in the composites industry? TIC SKILLE GE D T ER R Whose accomplishments do you most admire? N A IL E B T L A H Z G Top choices will be featured in our July/August issue I E

R

R S

B Whether an up-and-comer Nominations or an established leader, will begin at share your pick with CM! COMPOSITES 2012

Visit us in the ACMA booth #665 to cast your vote

Won’t be at COMPOSITES? Make your BEST choice known online at: www.compositesmanufacturingblog.com

Composites Manufacturing 17 Composites 2012 Network Your Way to Success

Get Involved In Person and Online Opening Welcome Reception on Tuesday at 5:00 pm Awards Luncheon on Wednesday at 12:00 pm Specialized Networking Sessions on Wednesday at 5:00 pm

Join us for COMPOSITES 2012 in person or online. This year FEBRUARY 4, 2011 Available throughout the convention center, The official

brought to you by Show Daily Official Magazine of the American Composites Manufacturers Association there will be several ways to get up-to-the-minute news, schedul- Attendees Find Solutions Composites Manufacturing is providing COM- on Show Floor In front of John Hoskinson, people walked up on a stage and talked about their new projects and discoveries. Somewhere behind him, the folks from Composites One worked on closed mold work cells live on the floor, separated from the crowd by little more than a makeshift viewing wall.

Hoskinson leaned back in his seat, his nine ribbons ing and read the latest stories on COMPOSITES 2012. cascading down his chest, from his badge to his belt buckle. POSITES attendees with a Show Daily. Each “I wanted to see what’s happening in the marketplace,” of what other opportunities are out there and, at the same said Hoskinson, president and CEO of Gruber Systems Inc., time, what’s happening in the market we’re serving.” Valencia, Calif. “This is a good place to come to get a flavor continued on page 2

Futurist: Vision and Collaboration Will Shape Future Renowned futurist Daniel Burrus encouraged attendees old control 80 percent of the wealth. As they hit retirement, of the General Session to set aside the standard “I’m too where will they spend their money and how can your morning pick up a copy, which will include busy” excuse and help shape the future. “We are at the base company capitalize on this? Perhaps you can build easy- of a mountain of not just change, but transformation,” said launch trailers for boats to make them more accessible for Burrus, founder and CEO of Burrus Research and author older people. Once again, Composites Manufacturing will be the official Show of the best-seller Technotrends. “There’s more opportunity in the composites market than at any other time. You ain’t Another area of certainty is technology. There will be seen nothin’ yet!” more processing power, storage and bandwidth that will accelerate change. They will “transform how we sell, In his presentation “Using Innovation and Trends to Drive market, communicate, collaborate, innovate, train and Growth,” sponsored by Owens Corning, Burrus stressed educate,” said Burrus. One idea he gave for harnessing the Schedule-at-a-Glance, the day’s Can’t-Miss the importance of focusing on “the visible future”—trends power of technology is to make smart composites. Imagine you know will happen. “In a world of uncertainty, start with the possibilities of adding a sensor to composite materials Blog. Go online to compositesmanufacturingblog.com, where certainty,” he said. “What am I certain about?” so you know when they chip or crack? As an example, he talked about demographics. The U.S. “You and I can invent the future right now,” said Burrus. But has 78 million Baby Boomers, and people over 55 years he added that you can’t do it alone. It will require teamwork from all generations—the young techies in your company Stay Posted on the Go with Inside Reporting and the experienced vanguard. “We need to collaborate in this industry—manufacturers, distributors and suppliers.” Before, during and after the show, Composites spots, and a recap of the day’s top sessions and Manufacturing editors and writers will post interviews Burrus ended his presentation with a challenge to the with education presenters, exhibitors and attendees at audience: “Spend at least one hour a week where you www.compositesmanufacturingblog.com. Or follow unplug from the present and plug into the future. I think you’ll find speaker interviews, news, event information and up- the conversation on Twitter @cmmagazine. your business will take off.” continued on page 2 to-the minute educational session wrap-ups. 1 speakers. Follow us on Twitter! @cmmagazine On Facebook, we’ll post daily photos and top stories. Con- We’ll be tweeting breaking news, schedule changes, raffle sider it a Daily Digest for Facebook lovers. prizes, show floor news and more. Is there a session you really liked or a networking event you enjoyed? Tweet about it using #COMPOSITES2012. Follow our COMPOSITES LinkedIn group for discussions and show updates. 18 Composites Manufacturing EXHIBITS | DEMONSTRATIONS

EDUCATION | NETWORKING

BUSINESS MEETINGS | AWARDS

SHOWCASE | PRODUCT LAUNCHES

ARCHITECTURAL | AEROSPACE AUTOMOTIVE | BATH It’s All About Tomorrow’s Business BUILDING/CONSTRUCTION | CORROSION COMPOSITES 2012 is a diverse forum providing one-stop access to POWER GENERATION | KITCHEN experts, vendors and innovations from all segments of the industry – MARINE | MASS TRANSPORTATION an unparalleled opportunity to network with and learn from the best in the business. This is your event, with a 30+ year track record of MILITARY | SPORTS & LEISURE results, backed by the industry’s association. Attend COMPOSITES

TRUCK & RV and you’ll understand why decades of experience delivers positive results. FABRICATORS/MANUFACTURERS

END USERS | SUPPLIERS Choose THE COMPOSITES opportunity.

DISTRIBUTORS | GOVERNMENT REGISTER NOW.

UNIVERSITIES | MILITARY

“COMPOSITES is the only show where you can see the latest technology, meet industry experts and network with your peers to make your business stronger.” — 2011 Attendee

www.acmashow.org

ACMA CM 8pgs insert.indd 1 12/19/11 9:15 PM Unparalleled Opportunities Schedule-at-a-Glance

It’s All About Tomorrow’s Business Tuesday, February 21, 2012 9:00 AM – 12:00 PM COMPOSITES 2012 provides all the tools you need to stay competitive in current markets Education Sessions and Technical Papers Join COMPOSITES 2012 on Facebook, Twitter and and take advantage of emerging ones. You’ll fi nd everything from basic materials and 12:00 PM – 1:30 PM LinkedIn to easily connect with other composites processes to cutting edge, high-tech products and equipment, as well as an unmatched University Poster Session industry professionals. Go to www.acmashow.org selection of educational presentations and hands-on demonstrations. The emphasis is to sign up and receive special announcements on real-life applications that will help build your business and enhance your bottom-line. 1:30 PM – 2:45 PM and discounts! General Session – Open to All COMPOSITES Opportunity: World-Class Learning ■ Enjoy some Vegas-style excitement at the not-to-be 3:00 PM – 4:55 PM missed Opening Welcome Reception. Key industry professionals and expert speakers from Education Sessions and Technical Papers around the globe offer information and insights on a broad Sponsored by range of topics. Whether you’re new to the industry or a 5:00 PM – 6:30 PM seasoned professional, there’s something for you! ■ Celebrate industry achievements at the Awards Luncheon Opening Welcome Reception and recognize the ACE (Awards in Composites Excellence) General sessions are open to all attendees Competition winners. Sponsored by and exhibitors Sponsored by Wednesday, February 22, 2012 Tuesday, February 21 CCT Tutorials and Exam NASCAR legend and ABC/ESPN commentator ■ Take advantage of Specialized Networking Receptions 8:00 AM – 9:15 AM Rusty Wallace is in the keynote spotlight, sharing for the following areas: Emerging Markets; Pultrusion; General Session – Open To All offered at the Show his compelling perspectives on teamwork, high Corrosion/Construction/Architecture; High Performance; Have you been enrolled for one of the International and ICPA (Cast Polymer). 9:30 AM – 5:30 PM performance achievement and composites in racing. CCT exams but just haven’t found the time Exhibit Hall Open to take the exam? Enroll now and take your Wednesday, February 22 Sponsored by 12:00 PM – 1:30 PM certifi cation exam at COMPOSITES 2012 Composites on the move! A distinguished panel Awards Luncheon or attend one of the free tutorials on VIP, focuses on transportation trends and technologies COMPOSITES Opportunity: Exhibits, Open Molding or Wind Blade Repair. Get and what developments in this dynamic sector mean Sponsored by for our industry. Demonstrations and Displays ahead of your peers and start preparing now for this once-a-year opportunity! With the broadest range of composites industry 2:00 PM – 4:45 PM ■ More than 100 peer-reviewed technical papers and companies coming together in one location at one time, Tutorials are offered Tuesday, Education Sessions and Technical Papers education breakout sessions – developed by ACMA, the COMPOSITES exhibit hall is the best place to fi nd the SAMPE and SPE. February 21 and are open to all attendees newest innovations, products and services in 2012. 5:00 PM – 6:30 PM and exhibitors. ■ In-depth sessions on green composites, materials, Don’t miss: Specialized Networking Sessions manufacturing, design and engineering, innovation, The exam is Thursday, February 23, regulation and legislation, traditional and emerging ■ Over 220 exhibitors. ■ Special pavilions for Adhesives and Sealants, and is only open to those already enrolled markets plus business strategy and operations. Sponsored by International (Europe and China), University and First- in a CCT program. ■ Special sessions on the latest information pertaining to Time exhibitors. Remember to indicate your intent to styrene and what this means for your business. ■ Real-time manufacturing demos on the Show Floor. take the CCT exam on the COMPOSITES ■ Free CCT (Certifi ed Composites Technician) ■ ACE and Pinnacle Competition Showcase highlighting Thursday, February 23, 2012 Tutorials on VIP, Open Molding and Wind market potential, innovation and creativity. registration form! 9:00 AM – 11:45 AM Blade Repair. ■ Increased education on the Innovation Stage – hear from ACE and Pinnacle Award submitters and exhibitors. Education Sessions and Technical Papers ■ Exciting product/service announcements and launches COMPOSITES Opportunity: Connections from leading companies. 9:30 AM – 3:30 PM Register by February 20, 2012, to The industry’s premier event provides plenty of time ■ A fabulous closing raffl e valued at more than $5,000. Exhibit Hall Open avoid higher onsite rates! to network with the best in the composites business – 1:00 PM – 2:45 PM Register Now at www.acmashow.org including your colleagues, customers and competitors. Sponsored by Education Sessions and Technical Papers

COMPOSITES 2012: February 21-23, 2012 • Mandalay Bay Convention Center, Las Vegas, NV For a current list of exhibitors, program information and to register, visit: www.acmashow.org

ACMA CM 8pgs insert.indd 2 12/19/11 9:15 PM ACMA CM 8pgs insert.indd 3 12/19/11 9:15 PM Unparalleled Opportunities Schedule-at-a-Glance

Tuesday, February 21, 2012 9:00 AM – 12:00 PM Education Sessions and Technical Papers Join COMPOSITES 2012 on Facebook, Twitter and 12:00 PM – 1:30 PM LinkedIn to easily connect with other composites University Poster Session industry professionals. Go to www.acmashow.org to sign up and receive special announcements 1:30 PM – 2:45 PM and discounts! General Session – Open to All 3:00 PM – 4:55 PM Education Sessions and Technical Papers 5:00 PM – 6:30 PM Opening Welcome Reception

Sponsored by

Wednesday, February 22, 2012 CCT Tutorials and Exam 8:00 AM – 9:15 AM General Session – Open To All offered at the Show Have you been enrolled for one of the 9:30 AM – 5:30 PM CCT exams but just haven’t found the time Exhibit Hall Open to take the exam? Enroll now and take your 12:00 PM – 1:30 PM certifi cation exam at COMPOSITES 2012 Awards Luncheon or attend one of the free tutorials on VIP, Open Molding or Wind Blade Repair. Get Sponsored by ahead of your peers and start preparing now for this once-a-year opportunity! 2:00 PM – 4:45 PM Tutorials are offered Tuesday, Education Sessions and Technical Papers February 21 and are open to all attendees 5:00 PM – 6:30 PM and exhibitors. Specialized Networking Sessions The exam is Thursday, February 23, and is only open to those already enrolled Sponsored by in a CCT program. Remember to indicate your intent to Thursday, February 23, 2012 take the CCT exam on the COMPOSITES registration form! 9:00 AM – 11:45 AM Education Sessions and Technical Papers 9:30 AM – 3:30 PM Register by February 20, 2012, to Exhibit Hall Open avoid higher onsite rates! 1:00 PM – 2:45 PM Register Now at www.acmashow.org Education Sessions and Technical Papers

For a current list of exhibitors, program information and to register, visit: www.acmashow.org

ACMA CM 8pgs insert.indd 3 12/19/11 9:15 PM Exhibitors Exhibitors

Link-up with current suppliers, locate the products you need and learn about new vendors in the Exhibit Hall. Plus, see product displays and the ACE Showcase!

Exhibit Hall Hours Wednesday, February 22, 2012 9:30 a.m. – 5:30 p.m. Thursday, February 23, 2012 9:30 a.m. – 3:30 p.m.

Exhibitor Listing

A C D 21st Century Chemical CCP Composites Dassault Systems Americas Corp. A.P.C.M. Manufacturing LLC Cerex Advanced Fabrics, Inc. De-Comp Composites, Inc. ACMA Central Changzhou Topweaving New Material DIAB Sales, Inc. ACS International, Inc. Tech Co. Ltd. Diatrim Tools Ltd. Advanced Plastics, Inc. Chemique Adhesives Inc. Diocel (U.S.A.) Inc. Airtech Advanced Materials Group Chem-Trend LP Diversifi ed Machine Systems Akzo Nobel Polymer Chemicals China National Building Material & Dixie Chemical Company Albion Engineering Company Equipement Import & Export Co. DuraPlate Products Group Allied Custom Gypsum CHOMARAT North America E American Colors, Inc. CMS North America, Inc. AOC, LLC Colbond, Inc. Eastman Machine Company Arkema, Inc. COMPOSITES EUROPE Lounge Elliott Company of Indianapolis, Inc. Ashland Composites Innovation Centre Endurance Technologies ATC Formulated Polymers, Inc. Manitoba, Inc. Engineered Fillers International Auburn University Composites One Engineered Syntactic Systems Axel Plastics Research Composites One – Learn the Secrets Entec Composite Machines Laboratories, Inc. of the Lean Mean Closed Mold Entropy Resins Machine Experts Eurovac, Inc. B Composites World F B/E Aerospace Continental Diamond Tool Baltek, Inc., a division of 3A Controx - Neuhauser Inc Fiber Glass Industries Composites CPIC Fiberlay Bayer Material Science Crane Composites Fiber-Line, Inc. Beijing Partnerworld International Creative Pultrusions, Inc. FLOW INTERNATIONAL CORP Exhibition Co. Ltd. CTG International (North America), Inc. Frees, Inc. BYK USA, Inc. Cutting Edge Composites Freudenberg Nonwovens

COMPOSITES 2012: February 21-23, 2012 • Mandalay Bay Convention Center, Las Vegas, NV For a current list of exhibitors, program information and to register, visit: www.acmashow.org

ACMA CM 8pgs insert.indd 4 12/19/11 9:15 PM Exhibitors Exhibitors

G M Specialty Products Co. Geis Companies Magnum Venus Plastech Spheretex America, Inc. General Plastics Manufacturing Martin Pultrusion Group Stiles Machinery, Inc. Company MCC Equipment & Service Center Structural Composites, Inc. Gibco Flex-mold, Inc. McClean Anderson Sworl Div. Of Prairie Technology GIE Media McLube Division/McGee Industries Inc. Group, Inc. Gruber Systems MDC Mould & Plastic Co., Ltd. Syrgis Performance Products GS Manufacturing Mektech Composites, Inc. System Three Resins, Inc. Gurit Micro Air T MIT-RCF, LLC H MultiCam, Inc. Taconic Hawkeye Industries, Inc. Myers Engineering, Inc. TCR Composites, Inc. Henkel Corporation Tech Systems, LLC Hennecke Inc. N Technical Fibre Products, Inc. HK Research Corporation Nantong Power Plastic & Teijin Aramid USA Hodogaya Chemical (USA), Inc. Rubber Co., Ltd Telateks A.S. Hollingsworth & Vose Co. Nederman, Inc. - Headquarters The Adhesive & Sealant Council Horn Nexeo Solutions The R. J. Marshall Company HTS Pipe Consultants Norton Tiodize Co., Inc. Huber Engineered Materials NRC Automotive Toho Tenax America, Inc. TR Industries I O Tricel Honeycomb Corporation Tyvarian International LLC INOAC Olympus NDT InnoVoc Solutions Owens Corning U Interplastic Corporation/NAC Intertape Polymer Group P Unicomposite Technology Co., Ltd. United Soybean Board Intertek Parabeam BV Universal Star Group Limited IPS Weld On Corporation Parson Adhesives University of Alabama at Birmingham ITW Finishing Equipment Americas PCCR USA (UAB) ITW Insulation Systems Performance Minerals Corp. University of Mississippi ITW Plexus Plascore, Inc. ITW SprayCore Plasticolors Incorporated V ITW WindGroup PPG Industries, Inc. PPG-Devold LLC Valspar Corporation J Precision Drive Systems Vectorply Corporation Jensen Industries Inc. Precision Quincy Corporation Ventilation Solutions Jiaxing Sunny FRP Industries Co., LTD Pro-Set, Inc. Virginia Economic Development JRL Ventures, Inc. Partnership R Jushi USA W Reichhold, Inc. K Rexco Mold Care Products Warm Industrial Nonwovens Kenrich Petrochemicals, Inc. RS Hughes Co. Watkins & Associates, Inc. KMT Robotic Solutions Westech Aerosol Corporation KNF FLEXPAK Corporation S Winona State University Wisconsin Oven Corporation Knowlton Technologies SAERTEX USA, LLC Wm. T. Burnett & Co. Krauss Maffei Corporation Saint-Gobain ADFORS Scott Bader, Inc. X L Sika Corporation Lindau Chemicals, Inc. Smart Tooling Xamax Industries, Inc. Litek Composites Corporation Sogel Inc

Current as of December 9, 2011. See new exhibitors and the fl oor plan at www.acmashow.org.

For a current list of exhibitors, program information and to register, visit: www.acmashow.org

ACMA CM 8pgs insert.indd 5 12/19/11 9:15 PM World Class Education

Education is key at COMPOSITES. For descriptions and speaker information, check the Conference Program online at www.acmashow.org. New sessions will be posted online.

Tuesday, February 21 toward Testing Parameters that Give 3:00 PM - 5:30 PM Meaningful Results CCT-Open Molding Tutorial 10:30 AM - 10:55 AM 9:00 AM - 12:00 PM 3:00 PM - 3:45 PM Technical Papers ■ CCT- Vacuum Infusion Process Tutorial Education Sessions ■ CCT- Wind Blade Repair Tutorial ■ Advantages of Polyurethane ■ Making Sense of the Green Product Composites made by Vacuum Infusion 9:00 AM - 9:45 AM Marketplace: How to Use “Green” to and VARTM Boost Profi ts Education Session ■ Experimental and Numerical Analyses ■ Styrene Communications for ■ High Performance Glass Fibers: From of Glued FRP and Wood by Epoxy Resin Employees and Plant Neighbors Lab to Market Scale - 10 Years Trend ■ Probabilistic Development and ■ Design and Construction of the First Application of a Life Cycle Inventory 9:00 AM - 9:25 AM Worldwide Two-Way Flat Slab Parking (LCI) Dataset for Pultruded Fiber Garage Reinforced with GFRP Bars Technical Papers Reinforced Polymer (FRP) Composites ■ Comparison of Cycloaliphatic and ■ Fracture Toughness of Thermoset 3:00 PM - 3:25 PM Linear Aliphatic Glycols in Corrosion Polymers Technical Papers Resistant Unsaturated Polyester ■ Monomer Free Pultrusion Resin ■ Fire Resistance Cellulosic Fibers for Resins System Polymer Composites ■ Thin Surface Coatings to Provide Abrasive Waterjet Trimming of Low Cost EMI Shielding and Surface 11:00 AM - 11:45 AM ■ Composites and Various Materials Conductivity in Composite Structures Education Sessions Using 5 & 6 Axis Robots ■ Investigation of Process Improvements ■ Big Steps Towards a Small Footprint– on PHBV-based Composites Using Development of Life Cycle Inventory 3:30 PM - 3:55 PM Multi-criteria Selection Data for U.S. Composites Technical Papers ■ Advances in Polyurethane Pultrusion: ■ Calculating Your Break-Even Point Flame Spray Deposition of Electrically Cure Modeling and “Second ■ Conductive Traces on Polymer Generation” Resin Systems 11:00 AM - 11:25 AM Technical Papers Substrates for System Integrated 9:30 AM - 9:55 AM Composite Structures ■ Titanates and Zirconates– Why they ■ Comparison of Fiber Reinforced Poly- Technical Papers are Different than Silanes mers in Global Fire Performance Tests ■ Immersion Effects on FRP Composites ■ Development of Fiber Reinforced for Underwater Applications Thermoplastic Composites Using in 4:00 PM - 4:45 PM ■ A Novel Approach to Manufacturing situ Polymerizable Polyamide6 as Education Sessions Foam-Filled Honeycomb Sandwich Matrix in RTM Process New Styrene Occupational Exposure Structures ■ ■ GFRP Reinforced Stay-in-Place (SIP) Level (OEL) Update ■ Creep Behavior and Modeling of PHBV- Formwork for Concrete Seawalls ■ Choosing the Right Catalyst based Composites for Construction Urethane Resins Increase ■ ■ High Performance Session Applications Opportunities for Pultruders ■ Recycling Glass Fiber Reinforced ■ Hardware Considerations When Polymer Thermoset Composites Processing Urethane Resins 11:30 AM - 11:55 AM A National Perspective on the Use of Technical Papers ■ 10:00 AM - 10:25 AM Prefabricated Bridge Elements and Sys- ■ High Performance Monomer Free Technical Papers tems from the Transportation Industry Resin Systems ■ Glass Fiber Corrosion Study: Some ■ Continuous Fiber Tapes and Metal Cord 4:00 PM - 4:25 PM Unexpected Results Reinforcement of LFT Composites for Technical Papers ■ Examination of Exposure Procedures Enhanced Damage Resistance and Effects of Thermal Mass on the Curing for Moisture Conditioning of Pultruded ■ Crashworthiness of Thin and Thick Laminates Composites ■ Coating Polyurethane Pultrusion: ■ New Halogen-Free Fire Retardant Integrating Novel Exterior Durable 4:30 PM - 4:55 PM Resin for Mass Transportation Coating with State of the Art Technical Papers Applications Application Methods ■ Thermal Press Curing of Advanced ■ Development of Hybrid Composites Composite Parts Made From Glass and Natural Fibers 1:30 PM - 2:45 PM ■ Composite Mechanical Testing- General Session with Keynote Speaker, Starting from a Standard and Working Rusty Wallace — Open to All

COMPOSITES 2012: February 21-23, 2012 • Mandalay Bay Convention Center, Las Vegas, NV For a current list of exhibitors, program information and to register, visit: www.acmashow.org

ACMA CM 8pgs insert.indd 6 12/19/11 9:15 PM World Class Education

5:00 PM - 6:30 PM Optimize Wind Blade and Component 9:30 AM - 3:30 PM Opening Welcome Reception Performance– A Panel Discussion Exhibit Hall Open ■ Panel Discussion on Compliance Topics Sponsored by 3:00 PM - 3:45 PM 9:30 AM - 9:55 AM Technical Paper Education Sessions ■ Long Fiber Polypropylene Growth in ■ Packaging and Delivery Systems for Wednesday, February 22 Automotive Applications Adhesive and Sealant Applications 8:00 AM - 9:15 AM ■ Low/No Styrene Resin Technologies for 10:00 AM - 10:45 AM Composite Applications Education Sessions General Session on Transportation and ■ Composite Tooling Materials and ■ Improving Your Measurement System: Composites — Open to All Fabrication Critical Factors to Consider ■ SAMPE Session 9:30 AM ■ Natural Fibers 101: When, Why and ■ Business Issues and Trends Global How to Replace Fiberglass Exhibit Hall Ribbon Cutting Composites Industry ■ ICPA Technical Forum 9:30 AM - 5:30 PM 4:00 PM - 4:45 PM ■ A Racing Win-Win: Composite High- Exhibit Hall Open Education Sessions Speed Press Cure 12:00 PM - 1:30 PM ■ FRP Mold Making Methods: Current 11:00 AM - 11:45 AM Trends and State-of-the-Art Infusion Education Sessions Awards Luncheon ■ SAMPE Session ■ USDA’s New Certifi ed Biobased Label ■ Composites from Plant Oil-based Resin Sponsored by and the BioPreferred Program and Fatty Acid Reactive Diluents ■ Resin Vaporization in Vacuum Infusion ■ Business Issues and Trends - Lean ■ Methods of Building Self-heated 2:00 PM - 2:45 PM Manufacturing Tooling with Thermal Image Analysis ■ Innovations in Additives Education Sessions ■ The Impact of Shifting Housing ■ European Initiatives for Sustainability – 5:00 PM - 6:30 PM Demographics on the Cast Polymer LCA and Recycling Approaches Specialized Industry Networking Industry ■ Styrene Toxicity Research, Regulatory Receptions ■ Process and Equipment Breakthroughs Status and Advocacy in Long-Fiber Technology ■ Color Trends- Decorative Surfaces Sponsored by ■ SAMPE Session 11:30 AM - 1:00 PM ■ Choosing Lightweight Materials for Lunch in the Exhibit Hall Heavy Duty Machines 1:00 PM - 1:45 PM ■ Robotic Integration to Your Composites Thursday, February 23 Process Education Sessions 2:00 PM - 2:25 PM 7:00 AM - 9:00 AM ■ The Future Use of Peroxides, Today ■ Vacuum Infusion Processing Problems Technical Papers Become a CCT, Take Your Exam Now! and Solutions ■ The Composites Manufacturing HUB – 9:00 AM - 10:45 AM ■ Correlation of Formulation and Crowd Sourcing as the Norm Manufacturing Parameters in ■ A Study of Novel Alternatives to Cobalt Education Sessions Innovative Direct SMC Technology Metal Complexes in Unsaturated ■ Thermoplastic Composites and Polyester Resin Systems Processes 2:00 PM - 3:00 PM Exhibit Hall Raffl e 2:30 PM - 2:55 PM 9:00 AM - 9:45 AM Technical Papers Education Sessions Sponsored by ■ Polyurethane Adhesives for Productivity ■ FRP Rebar is No Longer an Emerging and Performance Technology but Building a Successful ■ High Temperature Performance and History 2:00 PM - 2:45 PM High Mechanical Strength Composite ■ Understanding Resin Chemistry for Education Session Material Development Successful LRTM Production ■ Reducing Styrene Emissions in ■ Nanomaterials from Trees– Harnessing 3:00 PM - 4:45 PM Composites Using Fatty Acid the Power of Nature’s Basic Elements Monomers Education Session ■ Casting New Filler Materials ■ Developments in Composite ■ ICPA General Session 9:00 AM - 9:25 AM Manufacturing Technologies for the Auto Industry 3:00 PM - 4:25 PM Technical Paper Education Sessions ■ Development of the High Performance Schedule and topics subject to change. ■ Using Repair and Maintenance to GFRP with Multiwall Carbon Nanotubes

For a current list of exhibitors, program information and to register, visit: www.acmashow.org

ACMA CM 8pgs insert.indd 7 12/19/11 9:15 PM Registration and Housing

Register Now at www.acmashow.org! Register by February 20, 2012, to avoid higher onsite rates!

Full Registration Exhibit Hall Only Show Sampler Full conference includes access to all Access to exhibit hall and two general Access to general sessions, exhibit events, networking, education and the sessions. Tickets to receptions hall, welcome reception, and 3 exhibit hall. and luncheon must be purchased educational or technical paper Regular separately. breakouts. ACMA Member: $659 Regular Regular Non-member: $869 ACMA Member: $35 ACMA Member: $359 Government: $379 Non-member: $55 Non-member: $479

For ticket prices, onsite rates, and student, spouse/guest and press registration information, see the Registration section at www.acmashow.org

Housing Information

Lock in the lowest hotel rate available Make your reservation at www.acmashow.org! to COMPOSITES 2012 attendees now Mandalay Bay by reserving your room today. Hotel COMPOSITES 2012 Headquarters Hotel rates are based on availability. Room Rate: $165/per night Luxor Room Rate: $75/per night

Thank you to our Sponsors! PLATINUM GOLD SILVER

Safe Bathing for people  all abilities since 1971

If you are interested in sponsoring or exhibiting, contact Ryan Brown, Sr. Manager Exhibit and Sponsor Sales, at 703-682-1673 or [email protected]. www.acmashow.org

ACMA CM 8pgs insert.indd 8 12/19/11 9:15 PM Registration and Housing Industry Report Register Now at www.acmashow.org! Register by February 20, 2012, to avoid higher onsite rates! State of the Industry Full Registration Exhibit Hall Only Show Sampler Full conference includes access to all Access to exhibit hall and two general Access to general sessions, exhibit events, networking, education and the sessions. Tickets to receptions hall, welcome reception, and 3 Key numbers and economic indicators for 2012 exhibit hall. and luncheon must be purchased educational or technical paper Regular separately. breakouts. By Ray MacNeil ACMA Member: $659 Regular Regular Non-member: $869 ACMA Member: $35 ACMA Member: $359 Government: $379 Non-member: $55 Non-member: $479

For ticket prices, onsite rates, and student, spouse/guest and press registration information, see the Registration section at www.acmashow.org

Housing Information

Lock in the lowest hotel rate available Make your reservation at www.acmashow.org! to COMPOSITES 2012 attendees now Mandalay Bay by reserving your room today. Hotel COMPOSITES 2012 Headquarters Hotel rates are based on availability. Room Rate: $165/per night Luxor was the second year of recovery for most Room Rate: $75/per night manufacturers, suppliers and distributors 2011serving the 5 billion pound U.S. composites industry. Hav- ing reached a volume of approximately 5.1 billion pounds Thank you to our Sponsors! in 2006, U.S. demand tumbled by an unprecedented 42 percent, or 2.1 billion pounds, over a 3-year period (2007- PLATINUM GOLD SILVER 2009), with the steepest decline in 2009. However, a strong rebound in 2010 enabled the industry to recover 1.2 bil- lion pounds. The estimated full-year shipments in 2011 restored another 350 million pounds of demand and posi- tioned the industry at 4.6 billion pounds or 89 percent of the previous peak year. Staying alive and profitable in a V- shaped business cycle as severe as our most recent one has Safe Bathing for people  all abilities since 1971 been challenging for most companies in the industry and the survivors can take a well-deserved deep breath as in- dicators suggest the worst is behind them. Looking ahead, the key economic indicators suggest 2012 will bring more tempered industry growth in the single digit range. the manufacturing economy is growing and any score above 42.5 percent indicates an expansion of the overall Purchasing Managers’ Index of Manufacturing economy in terms of gross domestic product (GDP). A popular indicator, the Purchasing Managers’ Index of Manufacturing is a data series published by the Institute • For the month of November 2011, the index was for Supply Management (ISM). Every month since 1931 it 52.7 percent, the 28th consecutive month the index If you are interested in sponsoring or exhibiting, contact Ryan Brown, Sr. Manager has published this report based on a survey of 400 indus- indicated expansion by U.S. Manufacturing and the trial companies. Any reading above 50 percent indicates 30th consecutive month it marked growth in U.S. Exhibit and Sponsor Sales, at 703-682-1673 or rbrown acmanet.org. @ Composites Manufacturing 27 www.acmashow.org

ACMA CM 8pgs insert.indd 8 12/19/11 9:15 PM GDP. The PMI for manufacturing turned negative U.S. automotive assembly companies experienced a few strong in February 2008 and did not return to positive ter- months of sales heading into the fourth quarter of 2011. Rough ritory until 19 months later in August 2009. After estimates state sales at least an 8 percent increase over 2010. the 28 months of positive growth the PMI peaked at 61.4 percent in February. Since then it slipped to the the earthquake and tsunami in Japan slowed U.S. sales low 50s but moved up nearly two percentage points because Japanese transplants encountered supply line from October to November of 2011. constraints and, anticipating shortages, many dealers • The PMI is considered a strong and reliable indica- stopped discounting prices of Japanese cars. Ford, GM tor because it captures 10 separate measures in its and Chrysler raised prices and dropped incentives at the monthly survey: new orders, backlog of orders, new same time, which caused sales to soften during the mid- export orders, imports, production, supplier deliver- dle months. Sales volumes regained momentum in Sep- ies, inventories, customer inventories, employment tember and October to an annualized rate of 13 million, and prices, each of which is scored and reported even though the prolonged flooding in Thailand reduced each month. The strongest factors last month and deliveries of electronic components needed in some ve- their respective scores were new orders (57 percent), hicle assemblies. In the fourth quarter of 2011, dealers production (57 percent) and exports (52 percent), a reported firmer prices and higher margins on sales. healthy combination of elements. The new orders Consumer confidence is still quite weak but the need index jumped 4.3 percent—an encouraging sign be- to replace aging vehicles has turned the auto industry cause it should convert into higher production and a into one of the economy’s bright spots. The average stronger overall PMI in future months. vehicle on America’s roads is 10.6 years old, up from • 8 of the 18 manufacturing industries in the survey 8.8 years in 2000. That’s helping drive sales, even with reported growth in November and the Plastics & the stock market and home prices slumping. The pent- Rubber Products segment reported business condi- up demand is not enough to push the industry to the tions were contracting. 15-16 million vehicle sales level of pre-recession years any time soon, but it is creating some new demand. It’s worth pointing out that a PMI reading of 53 per- cent correlates with GDP growth of 3.6 percent or nearly twice what the U.S. economy has delivered over the last few quarters. The rest of the U.S. economy simply has not matched the strong performance delivered by manufacturing. This is partly because manufacturing is a relatively small part of the U.S. economy, it employs only 9 percent of the work force and contributes about the same percentage of total GDP. So, while manufactur- ers can congratulate themselves on a decent recovery in 2011, they should worry that manufacturing strength isn’t spreading fast enough throughout the economy at large.

Automotive: Gaining Traction In the first four months of 2011, U.S. light vehicle sales were 20 percent greater than last year. However, 28 Composites Manufacturing Add to these conditions the recent reorganizations of contractors and lending institutions have been driven to Chrysler and GM, and the auto industry today is notice- bankruptcy. Nearly 2.3 million jobs were lost in construc- ably healthier. Balance sheets are in order, OEM’s are tion since 2006, and the rate of unemployment in con- no longer over-producing and selling at too-generous struction is 13.4 percent or 1.6 times the national average. discounts, and you have a genuine need to replace cars. The U.S. housing market is still bouncing along the These ingredients should be a good mix of business con- bottom with recent data showing no encouraging news. ditions in 2012 and many auto industry forecasters are Housing starts and permits data indicate no meaning- estimating an 8-12 percent growth in the year ahead. ful improvement and the same applies to existing home Specific to composites, the federal proposal to improve sales (starting to inch upwards) and home prices (still corporate average fuel efficiency standards (CAFE) will falling). There is still a large inventory of existing homes serve as a major stimulus to incorporate lightweight ma- for sale, due in part to weak demand and credit that re- terials like composites. The Obama Administration set mains tight in the wake of the mortgage crisis. This has new standards obliging light vehicles to achieve a CAFE led to the erosion in home prices, lenders further tighten- standard of 35.5 mpg by 2016 and the November 2011 ing lending standards and buyers sitting on the sidelines. proposal from the National Highway Traffic Safety Ad- Economists predict little improvement in housing be- ministration (NHTSA) and the EPA pushed the bar up to fore 2013. Global Insights estimates single family hous- 54.5 mpg by 2025. If a top-down mandate is not enough, ing starts declined 11 percent to 419,000 in 2011 and recent surges in the price of gasoline and the fear of more will grow only 5.3 percent in 2012. Only in 2013 will we fuel increases give car owners some real-world, bottom- see any meaningful gain—a 51 percent jump to 664,000 up incentive to select lighter weight, more fuel efficient single family starts followed by another 42 percent gain vehicles. Car makers will need to take several hundred in 2014 to 992,000 units. That still leaves a considerable pounds of weight out of their new vehicles if they wish gap to overcome before reaching the pre-recession level to comply with the new CAFE guidelines. While a daunt- of 1.7 million homes. Previous forecasts for improvement ing challenge, it is an opportunity for design engineers in 2012 had been dependent on stronger employment and composites fabricators to collaborate using new res- growth to revive housing formation and absorb excess ins, glass compositions, innovative reinforcements and supply. Pent-up demand for housing is accumulating as fabricating processes to solve problems. young adults remain at home but at some point will con- For heavy truck statistics, visit us online at tribute to a revival in housing activity. compositesmanufacturingblog.com, search “Industry Report.” Energy: Increased Momentum, Gaining Speed Construction: Building from the Ground, Up The wind energy sector experienced a sharp decline A traditional end-use market for composites, construc- in 2010 from 9,922 megawatts (MW) installed in 2009 to tion demand is mostly in the form of bath tubs, shower 5,217 MW in 2010. Experts state this was a delayed reac- stalls, flat, corrugated and architectural grade panels, tion to the global financial crisis and was compounded residential doors, garage door skins and window frames. by the absence of fresh capital, relatively low natural gas New housing starts and remodeling expenditures, the prices, softening wholesale electricity prices and slump- primary drivers of composites usage, have been miser- ing overall demand for energy. But it has shown strong ably weak the last few years. During October, the indus- recovery through the third quarter of 2011. 3,360 MW try built homes at a seasonalized rate of 628,000 per year, of new wind capacity was installed, up 74 percent from demonstrating the rate of builds has fallen 70 percent the first three quarters of 2010. Going into the fourth from its peak in 2005 but up from 598,000 last year. Many quarter, the American Wind Energy Association (AWEA)

Composites Manufacturing 29 The industry can take a well-deserved deep breath as indicators suggest the worst is behind them.

reported that over 90 projects were under construction incentives will stimulate a modest level of demand (4,000- amounting to 8,482 MW. If half of these open projects 6,000 MW) but certainly nothing close to the volume the are completed by year end, approximately 7,600 MW of industry has been gearing up for and aspired to sustain. new wind capacity will have been installed in 2011—a 46 As U.S. wind installations set records in recent years percent increase over 2010—but still short of the record and made the U.S. the 2005 global leader in annual in- 9,922 MW installed in 2009. stallations and cumulative capacity in 2008, China was Even though new installations fell sharply in 2010, the building even greater momentum. In 2009, China sur- industry enjoyed strong federal and state incentives to passed the U.S. volume of new installations with 13,804 invest in new wind facilities, which will keep the playing MW new capacity erected and became the overall leader field attractive through 2012 when the current Produc- in 2010 when it reached cumulative capacity of 44,733 tion Tax Credit (PTC) expires. The U.S. wind industry MW compared to 40,180 MW in place in the U.S. Overall, has frequently experienced sharp up-and-down cycles China’s average wind growth rate averaged 104 percent largely because of the lack of consistent policy. Europe per year over the last five years. In fact, four of the top has led in establishing renewable energy goals and it is 10 leading global suppliers of wind turbines now hail no accident that it has developed the most mature wind from China. This rapid growth in China is worth noting technologies and infrastructure. In the U.S., 29 states have because while its industry leaders have grown thanks to adopted renewable targets for utilities operating within very strong domestic growth, a few are now bidding on their boundaries but there is no federal equivalent. The projects in the U.S. Time will tell if they are successful U.S. wind industry has called for a national Renewable in affecting the dynamics of the U.S. wind market a few Energy Standard (RES) to provide long term investor years down the road. confidence in the sector. But a draft law was not approved by the Senate in 2010 and its prospects of passage appear Oil: No Longer a Pipe Dream unlikely. The closest thing it received was a 2008 technical Composites usage is thriving nowadays in one of the report issued by the U.S. Department of Energy that stud- more traditional forms of energy—crude oil production. ied and proposed a growth scenario for the U.S. to pursue Demand for glass-reinforced epoxy pipe in diameters a strategy where wind would provide 20 percent of the ranging from 2 to 40 inches is registering over 20 percent country’s energy requirements by 2030. To achieve that growth in 2011 thanks to an oil drilling boom in the U.S. 20 percent scenario, new wind power installations would Not only is the overall rig rate approaching a high, but have to increase to more than 16,000 MW per year by 2018 the number of drilling rigs searching for oil in the U.S. is and continue at that rate through 2030. the highest seen since 1987, according to Baker Hughes, The domestic content in U.S. wind installations was 35 Inc. percent in 2005 and is currently 60 percent. The number In early December 2011, there were 1,132 rigs em- of workers directly and indirectly employed by the wind ployed to search for crude oil compared to 856 rigs drill- energy industry is estimated at 75,000 and growing. It ing for natural gas. One year ago, there were 777 rigs seems legislators would be eager to support this rare drilling for oil in the U.S. and five years ago there were case of industrial insourcing and job creation, but un- fortunately it is more likely the U.S. Congress will again wait until the eleventh hour or later to renew or revamp the PTC. The current gridlock among Washington law- makers over so many substantive issues reinforces the argument that a PTC will not be passed by election year 2012. Even Vestas, the world’s largest wind turbine man- ufacturer, stated in its third quarter 2011 financial report that the industry will enter 2013 with no PTC extension and no federal RES. What does that mean for composites demand? Most likely there will be a very busy 2012 with developers at- tempting to complete construction on new wind farms before incentives expire at the end of the year. That could translate into wind projects of 6,000 to 10,000 MW in 2012, then demand in 2013 will probably decline sharply. Should the PTC disappear entirely, the remaining state 30 Composites Manufacturing just 279. U.S. exports of gasoline, diesel and other oil- based fuels are soaring, putting the nation on track to become a net exporter of petroleum products in 2011 for Learn the the first time in 62 years. This healthy jump in domestic exploration and production comes from “unconventional reservoirs” of crude oil that were deemed too hard to Secrets of crack until breakthroughs in drilling technology and high prices of oil led exploration companies to switch rigs from natural gas to oil. Lean Mean Filament wound or centrifugally wound epoxy pipe is used for onshore and offshore corrosion control in a va- riety of low to high pressure oilfield applications. It also provides improved flow capacity because of the resin- Closed Mold rich smooth interior and lowers installation costs because of the significant weight advantage versus steel tubing. Not only will it outlast competitive materials, composite Machine pipe is typically a quarter to an eighth the weight of com- parable steel pipe, making it easier, safer and less expen- sive to install. Forecasting the future price of oil is tricky at best, but Experts the long term price trend clearly seems to be upwards, giving a positive forecast and a robust outlook for com- posites demand in the oil patch. However, other end LIVE in Las Vegas at uses of composite pipe for civil construction and water transport are likely to see only sluggish demand until the ComposItEs 2012. economy strengthens and municipalities are able to fund more infrastructure projects. February 21-23,

A Year of Single-Digit Growth Booth #629 At the close of calendar year 2011, there was still specu- lation on how the U.S. economic recovery will proceed into 2012. It has been an exercise in patience waiting for Talk to closed mold experts. stronger numbers from the U.S. housing industry, vari- Get tips from more than 15 industry partners. ous consumer segments and the jobs market. The most Watch LIVE demos of 3 processes. recent government release of estimated GDP and indus- And find out how easy it is to take your trial production numbers suggest we are in for more operation to a whole new level. quarters of relatively soft growth. Third quarter GDP was revised down from 2.5 percent to 2.0 percent and See the LEAN MEAN CLOSED MOLD MACHINE – estimates of industrial production are 3.6 percent for the LIVE IN ACTION! full year 2011 and a mere 1.6 percent for 2012. Given this context of low expectations in the economic data, we are likely to see another year of single-digit growth in the U.S. composites industry as well. 800.621.8003 www.compositesone.com www.closedmoldalliance.com Ray MacNeil is a composite consultant based in Wexford, Pa. Email comments to [email protected].

To read an in- depth forecast on the aerospace, marine and sports

& recreation featuring new technologies from: visit us online at compositesmanufacturingblog.com. Presented LIVE by Composites One with the Closed Mold Alliance and more Search keyword “industry report.” than 15 partners at COMPOSITES 2012, Booth # 629, February 21-23.

Composites Manufacturing 31

CMP-323 LEAN MEAN DEMO CM halfPg Vert_R2.indd 1 12/14/11 11:45:26 AM Infrastructure Today

Taking Art to the Streets Composite structures along Orlando’s International Drive

By Angie McPherson

rtist Walter Geiger recently designed functional member, where he met Linda Watson, the former sculptures to inspire Orlando citizens in his executive director of LYNX (the central Florida regional Acomposite outdoor bus stop shelters. His transportation authority.) The two spoke about collection, named the Cascade series, was installed implementing art in public spaces, which Watson could in September 2011 after three years of development. provide in the form of bus stop shelters along popular Geiger wanted to put art in a public space and bring FRP Orlando routes. LYNX funded the group to build four composites into the limelight of a new market—art and bus stop shelters with art transit initiative funding. architecture. Geiger connected with engineering firm Entech Creative, An engineer, architect and sculptor, Geiger earned Orlando, Fla., to use technology the engineering firm his master’s degrees in Architecture and Landscape was developing for use in theme parks. Architecture from Harvard University’s Graduate School Geiger spent over 15 years working with Entech of Design and is a member of the American Institute Creative Chief Engineer John Marhoefer building of Architects and a fellow of the Society of American large composite structures at major theme parks like Registered Architects. In his projects, he applied three Universal Studios and Disney World. After working philosophies: People who prosper in communities with Marhoefer on a recent theme park project, he was should give back to the community, those who cannot intrigued by the process of forming composites into afford art are the ones who deserve it most, and through organic shapes where form and function come together. collaboration, engineers, architects and artists can move Geiger draws inspiration from natural forms and felt processes and materials from one industry into another. that the free flowing composite lamination process fit his vision for the nature-inspired sculptures. “The natural Prospering in communities forms represent free-flowing waterfalls,” says Geiger. In 2008, Geiger attended a benefit gala with his “The use of composites allowed us to maintain the pure wife, Anne, a former Orange County school board integrity of the shapes.” 32 Composites Manufacturing Geiger wanted to put art in a public space and bring FRP composites into the limelight of a new market— art and architecture.

specifically resins, to match his material needs. In order to find more information he contacted several composite industry members such as Pat Hery, sales representative at distributor company Fiberglass Coatings, Inc., in St. Petersburg, Fla., about spun fiberglass mats and how they mixed with certain resins. He collaborated Four Cascade series sculptures were installed along Orlando’s with Bill Karren, Jr., principal at Lochsa Engineering in International Drive, designed by artist Walter Geiger and Las Vegas, who performed advanced analysis on the manufactured by Entech Creative. composite materials. “It was a complicated process to get the composite information from Pat into a form that Bill Art for those who need it could use to analyze, and finally, numbers that could be The sculptures were strategically installed where used to manufacture the forms John was making.” says tourists and workers in the tourism industry could see Geiger. The team built four full-scale prototypes to test them. “I don’t want my sculptures in galleries; I want the tolerances of the composite materials to submit to them on the living, breathing streets. Central Florida LYNX and Orange County building department. is a huge tourist destination and thousands of people This process of research, testing and meeting building traverse it daily to see attractions and work in the specifications took nearly the entire three-year planning service industry,” says Geiger. The bus stops reinforce period. “In order to do all the testing required by the the surrounding landscape using artistic techniques that county for the design and installation of non-traditional keep it from competing with the surrounding buildings. structures, we had to go through empirical as well as For example, using the color white and curvilinear technical analysis,” says Geiger. “We even used FARO forms to enhance the buildings and integrate with the digital technology to assist in documentation. That way landscape. we could model complex shapes.” All the research was The Cascade series is composed of four different completed by Geiger, Entech and Lochsa without public shaped sculptures, each approximately 3 feet wide or industry funding. “Lochsa, Entech and I made the and 15 to 16 feet tall. The structures are laminated FRP investment, which really means that the bus stops were a panels using spun fiberglass, fire retardant resins and a technical gift to the city of Orlando and to the composite honeycomb core. “There were different thickness core industry.” and laminated skin materials needed on parts of the structures. Our main focus was on perfecting joining Angie McPherson is the communications coordinator at ACMA. techniques because this was a 100 percent laminated Email comments to [email protected]. structure and the seeming techniques had to be looked at carefully to ensure it would not take away from artistic To read this story in its entirety, visit us Composites expression,” says Marhoefer. Manufacturing online at compositesmanufacturingblog.com and search keyword “bus stop.” From one industry to another C The challenge for Geiger was determining the M tolerances and properties of composite materials, Did You Know? Entech Creative is known for building a giant piano for FAO Schwartz that could light up and play when you dance on it – later popularized in the motion picture Big, featuring actor Tom Hanks. More recently, Entech engineered and built the dragon in Harry Potter at Universal Studios, among many other technically challenging projects.

Composites Manufacturing 33 Automotive Advances

Structure, Sport and Style New material advances with Forged Composite designs By Angie McPherson

ecent manufacturing trends towards fuel-efficient The Lamborghini Sesto Elemento carbon fiber concept car was Rcars, sustainable infrastructure solutions and renew- developed at the Advanced Composites Structures Lab. able wind energy designs are forcing OEMs to look for reasonable alternatives to traditional metals. We know less time curing and less waste. As a result, it signifi- composite properties naturally provide these industries cantly reduces manufacturing costs and production time. with lightweight and durable parts. However, the key to bringing more composites into these markets is to find Cutting edge composite research more cost and time efficient solutions for manufacturing Forged Composite consolidates carbon fiber chips and techniques. The University of Washington’s Automo- a resin film into a sheet. The sheet is placed into a 1,000- bili Lamborghini Advanced Composite Structures Lab ton heated matched metallic mold where the material (ACSL) in Seattle, Wash., is working hard to develop cures in a short amount of time. The random arrange- such techniques. One of its biggest breakthroughs has ment of fibers creates a part stronger and lighter than been with Forged Composite, developed in collaboration aluminum. Once the part is cured it contains more than with the Automobili Lamborghini and Callaway Golf. 500,000 fibers per square inch, which is similar to other Inaugurated in 2009, ACSL is a composite research carbon fiber reinforced plastic (CFRP) parts, but the center co-sponsored by airline giant Boeing and luxury Forged Composite part is manufactured in significantly sports car manufacturer Lamborghini. The center acts as less time. It is currently being used in the structural a technology liaison for the two composite manufactur- window frames on the Boeing 787, the head of Callaway ers and focuses on providing short-term research and Golf club drivers and the tub and suspension arms in the collaboration on Lamborghini and Boeing projects as Lamborghini Sesto Elemento concept car. well as long-term research for composite innovation, focused on out-of-clave techniques. Forged technology Project #1: Boeing structural window frames builds on advanced com- In 2005, Professor Paolo Fe- pression molding pro- raboli, director at the ACSL, cesses using short fibers started working with Boeing and instead of continuous the Federal Aviation Administra- strands to create a stron- tion (FAA) to test the new com- ger material comparable posite parts on the Boeing 787 to metal. This new pro- Dreamliner. During this project, the ACSL tested several This is a sample of Forged cess for manufacturing 787 components produced using Hexcel’s HexMC, which Composite material. carbon fiber parts means is a new material derived from aerospace carbon fiber/ 34 Composites Manufacturing epoxy tape. After determining that the short fibers would work well on the new Dreamliner, Boeing contracted with Nordam Interiors and Structures Division in Tulsa, Okla., to manufacture the structural window frames and other parts using a process similar to compression mold- ing. Nordam implemented the Hexcel HexMC-based parts in the window frames and other small parts like brackets, fittings and gussets that are typically made from aluminum. “The main difference between Forged Composite and the Boeing structural window frames is the materials used to manufacture. The parts developed by Forged Composite were short fibers combined with a resin film as opposed to the Boeing carbon fiber/epoxy tape that was chopped and assembled into a sheet,” says Feraboli. The change resulted in higher damage tolerant parts The Lamborghini team building one of the 20 Sesto Elementos that will be released in 2013. that are cheaper to construct than other carbon fiber methods and lighter than the usual aluminum parts. Ac- cording to Boeing, the window frames are approximately In recognition of its ingenuity, Callaway Golf was 50 percent lighter than the aluminum counterpart. Nor- awarded the Award for Composites Excellence (ACE), dam continues to manufacture thousands of structural Most Creative Application Award at the American Com- window frames for the 787 and expects to yield more posites Manufacturers Association’s COMPOSITES Show than $200 million over the next 15 years. in 2011 for the use of Forged Composite in its RAZR Hawk driver. “We simply couldn’t have completed that Project #2: Callaway’s RAZR Hawk design with a laminated composite. Forged Composite In 2007, the ACSL joined with the Calla- proved to be a useful technology in our application.” way Golf Company, Carlsbad, Calif., in a collaborative effort to improve Callaway Project #3: Lamborghini Sesto Elemento tub drivers with similar short fiber technol- The Lamborghini Sesto Elemento concept car, literally ogy used during the Boeing structural named the “Sixth Element” to represent carbon on the window frames project. “We colloquially Periodic Table of Elements, was designed to be a test bed refer to the material as carbon fiber hard- for carbon fiber technology. The Sesto Elemento used the wood because it looks similar to cherry research conducted at the ACSL and Callaway to com- or walnut trees after manufacturing,” says Feraboli. plete carbon fiber testing in less than a year. The ACSL Callaway wanted to collaborate to improve its blad- began working with the project in 2009 and the Sesto El- der molded laminated construction on the Diablo Oc- emento debuted at the 2010 Paris Auto Show in October. tane driver. “The laminated composites were limited in The Sesto Elemento uses Forged Composite to lighten shaping and thickness variation and we were looking the car weight to approximately 2,200 pounds—which for a material that had more capability when it came to is 1,000 pounds lighter than the Lamborghini Gallardo shaping,” says Steve Ehlers, vice president of golf club Superleggera—and increase the power to weight ratio. innovation at Callaway Golf. Callaway uses Forged The Sesto Elemento is powered by the same V10 en- Composite to produce carbon fiber driver heads that gine as the Gallardo Superleggera, enabling the carbon meet the requirements for bending strength in the body fiber super car to accelerate from 0 to 62 mph in 2.5 and maintain low weight properties. seconds instead of 3.4 seconds. The car uses carbon fiber The RAZR Hawk driver, which was designed using the extensively throughout the vehicle, including Forged new technology, also takes advantage of the material’s in the tub and suspension arms. Lamborghini replaced shaping properties in the head, shaping an intricate pat- vacuum-assisted resin transfer (VARTM) molded parts to tern that improves the aerodynamics of the club and in- focus on testing Forged Composite technology and de- cludes shapes molded inside. This year’s new adjustable veloping CFRP parts at higher production volumes. driver, the RAZR Fit, which will be released at the end of “There were a couple of good surprises that came out January, uses Forged Composite in the head of an adapt- of the Sesto Elemento’s development. For example, we able club that can change loft, face angle and weight didn’t realize a Forged tub would work as well as it did. distribution. Previously, implementing composites in this The whole manufacturing process only took five min- location would skew the driver’s center of gravity. “After utes. That was a good confirmation that exceeded our further research with the material, we determined how hope and expectations,” says Feraboli. According to to use the weight savings and make an adjustable driver Lamborghini, the same part would normally take a full without sacrificing performance,” says Ehlers. day using VARTM, three to four days with a woven Composites Manufacturing 35 The Sesto Elemento features a Forged Composite tub that cures in five minutes.

prepeg, and four to five days with a prepeg. The next less rigid. For example, after already seeing an impact in step for further integration of this technology into other the sports industry, Callaway says it will continue to re- car designs is to develop a repair strategy for the car- search Forged Composite integration and expects to use bon fiber parts. “As you can imagine, if a plane on the it extensively in new drivers. runway gets hit by a servicing truck, or if a car gets hit Ehlers is also involved in helping the rest of the indus- on the highway, the repair technician will need to know try adapt to the new process into other sports equipment. exactly what kind of damage has occurred. So we have “I’ve been talking to a number of companies on how best developed a strategy with Boeing to conduct research on to use the material,” says Ehlers. “Without naming spe- the repair process,” says Feraboli. cifics, expect to see this material in many other parts such At the 2011 Frankfurt Auto Show, Lamborghini an- as crank sets for bicycles and derailer parts,” he says. nounced it will produce 20 Sesto Elementos by 2013 On the automotive front, Feraboli expects that future solely for track use. The Sesto Elemento concept is an Lamborghini designs will continue to see more power important technology development test bed and it will ratio increases through weight reduction from technol- push the integration of composites into other Lambo- ogy like Forged. “We need to continue to make produc- rghini family vehicles. Some of the carbon fiber parts de- tion more amenable for other cars that are less expensive veloped during the Sesto Elemento trial are anticipated than the Sesto Elemento,” he adds. The ACSL and to filter down to other Lamborghini car designs such as Lamborghini are still developing new out-of-autoclave the Volkswagen Group, Audi, Porsche and Buggati, and materials and processes for carbon fiber. “We’re going to it hopes to spread the use of the Forged Composite pro- continue our research. It has been a goal of Lamborghini cess to the rest of the automotive industry. and the ACSL over the last few years to improve and implement carbon fiber technology,” says Feraboli. The future of Forged All three manufacturers, Boeing, Callaway and Lambo- Angie McPherson is the communications coordinator at ACMA. rghini, agree that the new technology is “the way of the Email comments to [email protected]. future.” Parts are made faster, stronger and structurally 36 Composites Manufacturing WISCONSIN OVEN C O R P O R A T I O N

Composites Manufacturing 37 Come see us at COMPOSITES 2012, Booth #1147 Inside ACMA Log onto www.acmanet.org for more ACMA news Plan Strategically for a Prosperous Year

omposites manufacturers are try. Cworking in a highly competi- Regardless of how you compete, NASCAR driver tive environment. To compete, you Rusty Wallace and other featured speakers will give you either have to win on price, qual- new insights in taking on the competition and thriving. ity or value—a combination of the Finally, you will have the opportunity to learn from your two. No matter how you choose peers. With over 3,000 attendees, you will be able to con- to compete, COMPOSITES 2012 is nect with manufacturers around the country and around your best bet for improving com- the world who include the best and the brightest in the petitiveness. industry. If you are competing on cost, the educational sessions will teach Come to COMPOSITES and you too can be in the driv- you the most efficient way to er’s seat steering your company into the future. make your products, not to mention numerous oppor- tunities to work with exhibitors on cutting the costs of your materials and processes. If you are competing on quality you will learn about cutting-edge materials and processes to manufacture the highest quality products. Tom Dobbins, CAE You will also be inspired by the ACE and Pinnacle award winners who represent the best of the best in the indus-

Come see us at COMPOSITES 2012, Booth #412

38 Composites Manufacturing See the Lean Mean Closed Mold Machine More Ways to Plan for your Live at COMPOSITES ’12 Success February 21-23, Booth #629

NEW! Participate in ACMA’s Membership Call Get the latest news from ACMA headquarters and learn Presented by Composites One, the Closed Mold how to get the most out of your membership. Join ACMA Alliance and more than 15 industry partners. Chief Staff Executive Tom Dobbins in January or Febru- ary, for the new monthly membership webinars. Whether you’re a new member or a long-time member, you’ll learn something about your association. If you are interested in 3.25x2.5 CM market place ad_FINAL.indd 1 12/13/11 6:14:40 PM participating, contact ACMA Membership Manager Erin Lauria at 703-682-1674.

New Ways to Promote Your Company The Composites Manufacturing 2012 Media Kit is now available online on ACMA’s website. Inside you will find the editorial calendar as well as advertising rates. ACMA members receive a discounted rate to advertising in a magazine that reaches over 10,000 people. Advertising in online and e-communications like ACMA’s website, Insider and CM Interviews is also available. For more in- formation, visit contact Ryan Brown at rbrown@acmanet. org or 703-525-0511.

ACMA Holding Chemical Processing Symposium Finally, a fire retardant FRP with unmatched processability. ACMA’s first-ever Chemical Processing Symposium Finally, there’s a fire retardant, low smoke/low will be held on May 23-24, 2012, in Houston. This event smoke toxicity phenolic FRP that’s processed will focus on educating end-users and engineers in the as easily as polyester. It’s called Cellobond chemical industry about the benefits of FRP in highly FRP and it’s processed from phenolic resins corrosive environments. Stay tuned for more information available in a wide range of viscosities for: on registration, programming and sponsorship opportu- • Hand lay-up/spray-up* • RTM • Filament winding* • SCRIMP nities. • Press molding • Pultrusion *FM approved Gel coated Cellobond Phenolic FRP far Advertiser Index exceeds DOT and FAA requirements and meets all stringent European fire perfor- AOC...... Back Cover mance tests with ease. Baltek...... 6 The low density, high temperature resis- tance, low flame and low smoke / smoke CCP...... 3 toxicity properties make Cellobond the Composites One...... Inside Front Cover hottest new material for fire retardant applications. For the aircraft and aerospace Composites One-Demo...... 31 industries that require ablative materials, Elliott Company...... 10 we also offer Durite resins from Momentive. Call or write today for more information. Frees...... 38 ITW...... 9 Mektech Composites Inc. Mektech...... 39 Distributor for Momentive Specialty Chemicals, Inc. (Formerly Hexion) MVP...... 13 40 Strawberry Hill Rd. • Hillsdale, NJ 07642 Tel: (201) 666-4880 Fax: (201) 666-4303 NEXEO Solutions...... Inside Back Cover E-Mail: [email protected] Saertex...... 7 www.cellobond.com • www.momentive.com Wisconsin Oven...... 37 Cellobond and Durite are registered trademarks of Momentive Specialty Chemicals, Inc. Come see us at COMPOSITES 2012, Booth #1146 Composites Manufacturing 39 New Members Am-Liner East, Inc Paneltec LLC Frank Greco, CCT Wayne Radloff, CCT-VIP Berryville, Va. Lafayette, Colo. Eastport, Maine Aberdeen, S.D.

ATC Truck Covers, Inc Research Investment, Inc Gyedun Gyaltso, CCT Robert Richards, CCT Ottawa, Kan. Cleveland, Ohio Warren, Maine Mississauga, Ontario Canada Champion Fiberglass, Inc Utility Composites Intl. Ltd Jason Hebert, CCT Spring, Texas Dayton, Ohio Rangeley, Maine Mahendra Sinnarajah, CCT Mississauga, Ontario Crown Plastics Company W & W Fiberglass Tank, Co. Collin Heupel, CCT Canada Harrison, Ohio Pampa, Texas Eastport, Maine Jared Spiller, CCT Doug Frey Westech Aerosol Corp Robert Hildebrant, CCT Mississauga, Ontario Chapel Hill, N.C. Bremerton, Wash. Mississauga, Ontario Canada Canada Geis Companies New CCTs Jerehmi Stayner, CCT Streetsboro, Ohio George Barrios, CCT-I Stephanie Huber, CCT, CCT-I Mississauga, Ontario Aberdeen, S.D. Mississauga, Ontario Canada GrafTech International Canada Holdings Inc Michael Bryant, CCT-I Marek Szettel, CCT Parma, Ohio Huntersville, N.C. Thinh Huynh, CCT-VIP, CCT-I Mississauga, Ontario Aberdeen, S.D. Canada HZW Environmental Tshewang Dorsi, CCT Consultants LLC Eastport, Maine Jarret Morales, CCT-VIP Cameron Tedford, CCT Mentor, Ohio Aberdeen, S.D. Mississauga, Ontario Brian Duffy, CCT Canada Insituform Technologies, Inc Farmington, Maine Dorjee Namgyal, CCT-VIP Chesterfield, Mo. Aberdeen, S.D. Dorji Tshewang, CCT Patrick Fogg, CCT Mississauga, Ontario Lightsail Energy Eastport, Maine James Ng, CCT-WBR Canada Oakland, Calif. Savanah, Texas Damian Gomes, CCT Martin Pultrusion Groups, Inc Perry, Maine Patrick O’Donnell, CCT-VIP Bedford, Ohio Aberdeen, S.D.

40 Eye on 2012: Developing Technologies What was your favorite composite engineered product from 2011? Weigh-in now at compositesmanufacturingblog.com.

Vehicle Stronger Lightweighting Planes In 2011, the automotive Aerospace composites industry started dropping a soared when the Boeing 787 few thousand pounds off of passed aviation tests in Sep- compact cars and trucks to tember, putting composite increase fuel efficiency. materials on front page Expect this trend to news and more air- continue. planes.

Welcome to a new year filled with engineer- ing innovation! Last year was bursting with success stories that massively impacted the industry and spurred trends towards composite in- tegration in new markets. As we wave goodbye to 2011, here are some interesting developing technolo- Is that a gies that the industry can Cars with robot? Wings look forward to in 2012. Honda recently upgraded “It’s 2012, why don’t we its Asimo robot to run, pour have flying cars?” Well, soon drinks, communicate through you’ll have the opportunity to sign language and do other purchase one. The Terrafu- tricks, making it the most gia Transition is expected inundated robot ever to hit the roads late built. 2012.

Personal Space Travel Virgin Galactic will soon provide personal space travel in SpaceShipTwo vehicles by Scaled Composites. Even Bigelow Aerospace is build- ing space hotels for this growing industry.

Composites Manufacturing 41 CM In the News

“Once the bridge has completed its lifespan, the plastic can then be recycled again and used for other purposes; meaning it will never have to go to landfill.” William Mainwaring, CEO at Vertech Composites celebrating its recycled plastic bridge – now the longest in the world.

“Structural fiber doesn’t sound alluring, but we’re talking billions of dollars of potential market.” Larry Dickinson, founder at 3F, LLC in Raleigh, N.C., speaking to attendees of The Network at the Institute for Advanced Learning and Research about the potential of bio-based fibers.

“The roof crush and side impact strength is greatly improved on these bodies and I think this is a great new attribute for the DMC-EV.” Chris Anthony, founder of Epic Electrical Vehicles, on helping the new DeLorean move from a steel body to a one made from composites.

“This is GM going outside the four walls of the company to bring new technologies to customers.” Steve Girsky, vice chairman at General Motors, announcing the company’s partnership with Teijin to develop carbon-fiber parts.

“It’s gratifying for our development to be highlighted, particularly in light of the many wind turbine projects funded by the Department of Energy this year.” Mike Gallagher, director of public sector business at Bayer MaterialScience, LLC, talking about the success of its new polyurethane technology for stronger, longer wind blades.

To read these and other composites breaking news, visit compositesmanufacturingblog.com and click on “Composites in the News.” For daily composites updates, follow us on Twitter @cmmagazine

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42 Composites Manufacturing CM Online Exclusives Straight From the Source: Industry Leaders Speak Out

< Increase Demand by Investing Smartly Roch Lambert is president of the Recreational Boat Group, a portfolio company owned by Platinum Equity. He has global profit-and-loss responsibility over three historic boat brands: Four Winns, Glastron and Wellcraft, which were all acquired through the Genmar bankruptcy. Lambert is well versed in the consumer dynamics that motivate boat purchases and says he anticipates a profitable future looking ahead.

FRP’s Role in Rehabilitating Canada> Dr. Brahim Benmokrane is a National Science Engineering Research Chair (NSERC) and professor of Innovative FRP Composite Materials for Infrastructure in the Department of Civil Engineering at the University of Sherbrooke, located in Sherbrooke, Canada. He obtained his engineering degree from the Swiss Federal Institute of Technology of Lausanne, Switzerland and his Ph.D. in civil engineering from University of Sherbrooke.

Domino Effect in Bio-based Composites> Lane Segerstrom studied Business at Bethel College in St. Paul, Minn., before obtaining a degree in Entrepreneurship from Baylor University in Waco, Texas. In 2009, Segerstrom founded Carbon Stalk LLC and its subsidiary Corn Board Manufacturing, Inc., which holds an exclusive licensing agreement to a patented corn-based structural composite technology by the University of Illinois. .

To read the interviews with these and other leading members of the composites industry, visit compositesmanufacturingblog.com and click on “Q&A Interviews.” Composites Manufacturing 43 Postcure Chatter Confounded Composites! Take a second look and see if you can find the differences in these two pictures.

To an engineer, NASCAR looks a little different than it does to a fan. Engi- neers ask what types of materials and techniques will allow it to withstand hours of high-speed rac- ing. The short answer is: sheet metal, powerful engines and good tires. However, composites are slowly integrating into team designs.

Turn to page 4 for an inside look at one team’s journey to further inte- grate composites. Original 10

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