Advanced Composites - The Engine For Growt

Advanced Composites ‐ The Engine for Growth February 2013
Advanced Composites – The Engine for Growth
Presented by
Prof Mike Hinton
© National Composites Centre. All rights reserved. Confidential and proprietary document. NCC‐TMP‐038 v2
Contents
• The Composite Landscape
• Supply Chain Issues
• Technological Trends
• An Integrated Investment Strategy
• The National Composites Centre
• Technical Developments
• Future Advances
• Summary
Page 2
Contents
• Future Advances
• Summary
Page 3
Global Composites Market Growth
0.0% 5.0% 10.0% 15.0%
Creating the Equation for Growth
CAGR 2010 - 2016
Page 4
Market Opportunities
Creating the Equation for Growth
Source: Lucintel
Page 5
February 2013
The UK Composites Landscape: Large scale building composites

the Cumulative Demand demonstrators
Manufacture of large scale

demonstrators
Light-weighting rail carriage sub-

assemblies
Offshore renewables investment Wing of the Future Large Scale

in manufacturing technologies Demonstrator Manufacture
Footbridge design/ manufacture
Light-weighting rail carriage
doors
New boat hull tech. development Wing of the Future development
Development of new blade Samulet 3 Manufacture
manufacturing technologies
NGCW Prototype part New Capability demonstrators
Manufacture in ultra high rate low cost
Samulet 3 Engineering LCV Prototype development automation
LCV Design Development activity
activity
2012 2013 2014 2015 2016 2017 >
Page 6 Advanced Composites ‐ The Engine for Growth
The Aerospace Composites Landscape (1)
Page 7
Page 8
• UK Aerospace industry generated £22bn sales in 2010; 70% exported
• Next Generation Single Aisle requires Technology Readiness by 2018 latest
• Requires new capabilities for high rate , high performance, complex large structures
• Opportunities for UK to “leap‐frog” the competition
• Reasonable significant existing skilled workforce
• Strong UK supply chain that needs to remain integral part of OEM’s strategy
• Key challenges:
• New ground breaking architectures to deliver next gen weight, rate and cost targets
• UK retention/repatriation
• Current & Pending large research programmes
• Engines ‐ Samulet 2, Silhouette
• Airframes: NGCW; Wing of the Future
Wing of the Future Large Scale

Demonstrator Manufacture
Wing of the Future development
NGCW Prototype part Samulet 2 Manufacture
Manufacture
Samulet 2 Engineering
2012 2013 2014 2015 2016 2017 >
Page 9
The Composite Landscape ‐ Wind Turbines
Page 10
The Composite Landscape – Automotive
Automotive Council‐‐‐Provisional findings
For a medium sized family car :‐
• Save 200kg by 2020
• Save a further 200 Kg by 2030
Page 11
The Composites Landscape – Big Challenges
• Increasing demand for large components (aerospace, wind, construction..)
• Processes and costs that suit increased manufacturing rates (105/y not 102/y)
• Automated manufacture
• Growing the UK skills/expertise to compete with the world (supply chains)
Page 12
Contents
• Future Advances
• Summary
Page 13
Supply Chain issues
• Reduction of capital employed per part
• Creating resilient supply chains
―does the UK (or the West) have sufficient control on the supply chains ?
critical dependencies ?
Multi‐level supply chain management
―“pull” from competing & emerging sectors – e.g. automotive
―Labour cost vs emerging nations
• The impact of globalisation
• The impact of the emerging manufacturing nations
• UK People availability – volume & skills
Page 14
February 2013
UK Composites Supply Chain
• 1500 companies in UK composites sector
• £1.6bn turnover (2010)
― £1.1bn UK value add
― £0.9bn domestic market
• 85% in largest 38 companies
• Large OEM’s in Aerospace, Automotive and renewables
• More than 1400 SME’s
― Critical innovation source, yet often paranoid about IP leakage
― Need de‐risking service – Access to Experts
― Want Point of Use support
― No single service solution
― Financing often key issue
• Widespread critical shortfall of skilled people , particularly Technician and Graduate
― Need re‐skilling of existing metallic & low value composites resource
• Knowledge transfer opportunity from mature to emergent sectors
• UK weak on materials supply and manufacturing equipment development
Page 15 Advanced Composites ‐ The Engine for Growth
NCC Supply Chain Project Example
Next Generation Composite Wing
• TSB Funded
• Airbus Led
• >3years + 17 partners
• Developing future wing concepts and
associated supply chain capability
• NCC has supported “HiVol” part of
programme with involvement of
• Prime
• T1’s
• SME’s
• Material & Tooling providers
• Process Equipment Manufacturers
Page 16
August 2012
NCC Supply Chain Case Study
• Companies involved
• Rogers Yacht Design
• Sea Ventures
• Demon Yachts
• Full CAD Geometry/Ply lay‐ups
• Innovative Masters manufacture
• Portable 5 axis
• Infused Tooling utilising 3‐D Core
Page 17
Contents
• Future Advances
• Summary
Page 18
Technology Trends: Material
• Low cost materials!!
• Continuous enhancement of properties
―improved allowables,
―tightening tolerances
―properties tailored to application
• Composite material for arduous duty cycles
―damage tolerant, load bearing, heat resistant, etc –
• Faster cure cycles (105 parts/y not 102 parts/y)
• Enabling New & Improved Processes
• New surface treatments Can metal
―self cleaning, conductive fight back?
• New materials : ‐ natural fibres and bio resins?
Page 19
Technology Trends: Parts
• More extensive application:
― More 3D parts (complex ‘’integrated assemblies’’)
― High temperature applications – especially for engines
• Designed for automated fabrication
• Quality and repeatability
• Feature based improvements – eg around holes, or
integration of stiffeners
• Address regulatory requirements ‐ fire etc
• In service monitoring
• Robust, in‐field repair technologies
Page 20
Technology Trends: Assembled Products
• Increased penetration into Engines
• Multidisciplinary optimisation,
―taking advantage of functionality, and multifunctionality of composites
―High conformance structures – surface finish and tolerance
• New Architectures
• Mixed material assemblies
• New Joining technologies and solutions
• Multifunctional parts
―Data transmission and/or fluid transfer ducts
―Energy absorbing & storage
―Sensors (SHM, aero flow‐control)
―Smart surfaces Can metal
• Composites do more than save weight… fight back?
• Challenge design & certification rules
Page 21
Technology Trends: Processes
• Remove high cost low throughput equipment
―e.g Out of autoclave
• Process integration – end to end data usage
• End to End Process optimisation
―time, cost and quality improvements
―Data driven manufacture
―Process only as good as weakest link
• Machine & join mixed material assemblies
• Through thickness reinforcing processes
• Rapid, and smart NDT
• Manufacture complex, integrated parts.
• Automation…
Page 22
Technology Trends: Automation
• Reducing labour cost
• Increasing accuracy and repeatability
• Trends
• Automating wider range of operations
• Linking automated operations
• Increasing deposition rates
• increasing rate and reducing cost
• Enhanced product optimisation
• ply tailoring
• flexible automations systems
• Multiple robots
• Flexible, adaptable manufacturing processes
Page 23
Contents
• Future Advances
• Summary
Page 24
The Macro –Economic Drivers
• Technology Strategy Board role
• “Connect and Catalyse”
• “Concept to Commercialisation”
• Technology and Innovation Centres
• Hauser Report
• Dyson Report
• 2010 CSR
• High Value Manufacturing
• UK Manufacturing £168 bn and12% GDP
• Rebalancing the economy
• Innovation for competitiveness
• Innovation for growth
Page 25
Strategic Investment – Crossing the ‘‘Valley of Death’’
Align Research with Industry “Valley of Death” Technology

needs to Industry
Basic & Applied Technology Feasibility, Technology Launch &

Research Development & Demonstration Operations
Research
Product
TRL 1 TRL 2 TRL 3 TRL 4 TRL 5 TRL 6 TRL 7 TRL 8 TRL 9
Industry
Universities
Page 26
HVM Catapult Overview
The High Value
Manufacturing Catapult is
a consortium of 7 world‐
leading research centres
with £350M public &
private investment and
working with over 160
industrial partners. It will
receive grant funding of
around £25M pa,
securing sustainable
leading‐edge technology
Page 27
Aligning UK Strategic Investment
Government
Academia Industry
Page 28
Aligning UK Strategic Investment
Government
Academia Industry
Page 29
Strategic Investment – Crossing the ‘‘Valley of Death’’
Align Research with Industry “Valley of Death” Technology

needs to Industry

Research
Product
Industry
Universities Catapult Centres
CIMComp NCC Industry
Page 30
Contents
• Future Advances
• Summary
Page 31
NCC Overview
• Initiated by UK Composites Strategy (Nov 2009)
• Operational since June 2011
• Offers access to world class expertise and cutting edge industrial scale equipment
• Has more members and engagement than forecast
• 180 people on site plus c.40 visitors a day;
• Working on projects of utmost importance to UK
• Exercising a National Leadership Role through the “Composites Leadership Forum”
• Future Capability funded £4‐5m/annum by HVM Catapult
• Recent announcement of extension funding for growth
NCC Mission
To be the world leading centre of excellence for collaboration
and innovation in composite technology
• Deliver world‐class innovation in design and rapid manufacture of composites
• Validate design concepts and advanced manufacturing processes
• Develop prototypes & facilitate widespread industrial exploitation
Align Research with Industry NCC Technology

needs Focus to Industry

Research
Product
Industry
Universities HVM Catapult
Page 33
NCC Capabilities

• design and simulation Open Access
• prototype manufacture 
• process optimisation Confidentiality
• testing and inspection 
• manufacturing & test equipment Cross Sector
• expert resources 
Collaboration
40 + enquiries handled last 4 months, 18 from SMEs
Oil and Gas, Aerospace, Sporting Goods, Rail, Composite Materials, Medical, Automotive,
Consumer Electrical, Construction, Small Aircraft and Marine sectors.
~80 Engineers and Technicians
Page 34 Typical Background: 80% Industrial, 20% Research
NCC Facilities & Key Equipment
Page 35
NCC Current Membership
A Formula 1 Team
Page 36
Contents
• Future Advances
• Summary
Page 37
Core Research Programmes ‐ Overview
AFP Heating Technologies
Automated Fibre AFP In Process Inspection

Placement Technologies
Thermoplastic AFP – Curved

Panels
Flexible End Effector

Automation for
Composites
Automated Bonded Joints
Surface Treatment for Adhesive

Bonding
Bond Line Assembly
Bond-line Gap Measurement for
Adhesive Bonding
Modelling Toolbox
Composite Technology
Introduction Composite Technology State of
Art Review
Page 38
Core Programme
Page 39
Automation
• Tri‐robot cell acquisition and process patent application
• Novel end effectors developed
• Kinematic modelling & simulation
• Through Thickness Reinforcement cell installed & commissioned
Page 40
Automated Fibre Placement
Novel heating method patented
Thermoplastic “on the fly”
consolidation nearing maturity
A picture
Large integrated wingbox structure
manufactured
AFP FEA ‐ process simulation
Page 41
SME Demonstrator Projects
Rapid response production of
prototype watercraft
Use of portable 5‐axis machining
to produce parts for 9.5m leisure
yacht
Design and manufcature of
prototype mountain rescus
stretcher
Page 42
Simulation
PRESSURE
Induction Welding
Automated Fibre
Placement
COMPOSITE
PREFORM
Resin Transfer Moulding Thermal Forming
/Compression Moulding
Page 43
Materials & Structures
Creation of 3D computer
tomography images from 2D x‐ray
data with a minimum resolution of
10 microns CTE and thermal conductivity
measurements
Application of
new materials
and
manufacturing
Developing train doors for methods for
London Underground the Next
Generation
Space Platform
Page 44
Contents
• Future Advances
• Summary
Page 45
Future Advances
Page 46
NCC Presentation February 2013
Site Layout Page 47 Potential area for parking adjacent

Newlands Farm © National Composites Centre. All rights reserved. Confidential and proprietary document. NCC‐TMP‐038 v2
Contents
• Future Advances
• Summary
Page 48
Summary
• UK Government is recognising the need for coordinated and
sustained funding
• Strong market pull
• Significant opportunity for new parts and applications
• Significant new technology trends in materials, parts, products and
processes
• UK has a significant support infrastructure developing to support UK
industry be globally competitive
We have a large opportunity !!!
Page 49
Any Questions?
© National Composites Centre (NCC). All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of
NCC. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party
without the express written consent of NCC. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not
constitute an offer. They are based on the mentioned assumptions and are expressed in good faith.
Page 50

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Advanced Composites ‐ The Engine for Growth February 2013

0.0% 5.0% 10.0% 15.0%

Creating the Equation for Growth

CAGR 2010 - 2016

Creating the Equation for Growth

The UK Composites Landscape: Large scale building composites

Manufacture of large scale

Light-weighting rail carriage sub-

Offshore renewables investment Wing of the Future Large Scale

2012 2013 2014 2015 2016 2017 >

Page 6 Advanced Composites ‐ The Engine for Growth

Wing of the Future Large Scale

2012 2013 2014 2015 2016 2017 >

Page 15 Advanced Composites ‐ The Engine for Growth

Align Research with Industry “Valley of Death” Technology

Basic & Applied Technology Feasibility, Technology Launch &

Align Research with Industry “Valley of Death” Technology

Basic & Applied Technology Feasibility, Technology Launch &

CIMComp NCC Industry

Align Research with Industry NCC Technology

Basic & Applied Technology Feasibility, Technology Launch &

Automated Fibre AFP In Process Inspection

Thermoplastic AFP – Curved

Flexible End Effector

Surface Treatment for Adhesive

Site Layout Page 47 Potential area for parking adjacent

We have a large opportunity !!!

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