efficient workflow systems for new composite applications
TRANSCRIPT
Eff ic ient Workflow Systems for
New Composite Appl icat ions
5 t h I n t e r n a t i o n a l C o m p o s i t e C o n fe re n c e 2 0 1 9
Julien Sellier
Messe Stuttgart Congress West – 12th September 2019
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S T R U C Te a m M a r ke t s
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Composite
Application
Development
Across
Sectors
Renewables
Marine
Civil and Structural Engineering
Automotive
Industrial and
Chemicals
Oil & Gas
S T R U C Te a m S e r v i c e s fo r S t r u c t u ra l
A d va n c e d M a t e r i a l s – S i n c e 2 0 1 0
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CME Services Engineering Services:Material
Design
Manufacture
Supply Chain
Expert Witness
Advisory Services
Training and Experience Development Services
Raw Material
Manufacturer
Intermediate Material
Manufacturer Part Manufacturer O.E.M
Adopting Advanced Materials
Efficient Workflow System
Workflow Case Studies
Conclusion
A ge n d a
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Adopting Advanced Materials
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A d va n c e d M a t e r i a l D e m a n d s
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• Aerospace• Wind• Auto the big question• Others
?
3x
2x}?
Market Size
(Source: STRUCTeam Ltd, Carb Consult, others)
Reinforcements only
A d va n c e d M a t e r i a l D e m a n d s
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(Source: STRUCTeam Ltd, Owens Corning, others)
Reinforcements only
M a t u re S e c t o r
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Backlog Year
(Source: STRUCTeam Ltd, JEC, others)
E m e rg i n g S e c t o rs
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InfrastructureComponents
or system
Infrastructure,Components
Super StructuresInfrastructure,Components,Rolling Stock
Including Thermoplastics
Note: Economics needs to adopt / add up for Business Case & Cost benefits
(Source: STRUCTeam Ltd, JEC, others)
A C o m p l ex S u p p l y C h a i n
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Raw Material
Manufacturer
Intermediate Material
Manufacturer Part Manufacturer O.E.M
OlinDowAksa
CPIC FibreglassToray
ArkemaOwens Corning
ExxonMobil
GoldwindGE
BMWSiemens Gamesa
Airbus
SMEs
A p p l i c a t i o n Re q u i re m e n t s
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Mature Sector Emerging Sector
Marine Wind Energy Aerospace Civil Oil & Gas Shipping Rail
Material
Thermal Durability u u u u u u
Impact Resistance u u u u
High Heat u u
Chem. Corrosion
Resistance u u u
Fire Retardant u u u u
Insulation Properties u u
Design
Design Freedom u u u u u u
High Strength to
weight ratio u u u u u
Specific Stiffness u u u u
Sound Damping u u u
Manufacturing
Light Weight u u u u u u
Design for
Manufacturing
Adaptationu u u u
Supply Chain
Cost u u u u u u u
Price Index u u u u
Evo l u t i o n a r y v s . R a d i c a l
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2 approaches to achieve material adoption
¤ Evolutionary (normal) approach
¤ Radical approach
Evolutionary vs. Radical
Mature Market Emerging Market
Composite Leaf Spring, Corvette Increased Advanced Materials BOM,
Airbus 787 Dreamliner
Pushing the limits on performance with
adoption of materials, America’s Cup sailing vessels
Tra d i t i o n a l M a t e r i a l s Wo r k f l o w
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Is it really easy to adopt?
Materials
Process Design
Material Considerations
A d o p t i n g A d va n c e d M a t e r i a l s
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Process Considerations
A d o p t i n g A d va n c e d M a t e r i a l s
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Wet lamination Press Infusion
PultrusionPrepreg/Resin Film
InfusionAutomation
Design Tool Considerations
A d o p t i n g A d va n c e d M a t e r i a l s
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A d o p t i n g A d va n c e d M a t e r i a l s
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Materials
Process Design
Efficient Workflow
Eff ic ient Workflow System
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Te c h n o l o g y Re a d i n e s s L e ve l s ( T R L )
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Nasa
A d va n c e d M a t e r i a l s Wo r k f l o w S y s t e m
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Commercial Feasibility
Concept Design
Detail Design
Prototype
Preproduction
Serial Production
• Market Gap Analysis• Business Case Analysis
• Preliminary Design• Technology Selection• DFMEA
• Detailed Design Analysis• Tooling Analysis• PFMEA
• Material Qualification• Manufacturing Documentation• Supply Chain Management
• Null Series Evaluation• Part Acceptance Testing
• QM / QA Documentation• Certification Liaison
Cost Benefit Analysis
TRL 1 - 3
TRL 9
TRL 7 - 8
TRL 5 - 6
TRL 4
Critical Review Meeting
Workflow Case Studies
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C i v i l & I n f ra s t r u c t u re
N e t w o r k R a i l Pe d e s t r i a n B r i d ge
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End User Need
¤ Safety
¤ Low maintenance
¤ Low setup costs
¤ Reduced weight
¤ Ease of manufacture
¤ Ease of assembly
¤ Lower OPEX
W i n d E n e rg y & Re n e w a b l e s
P U L LW i n d
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End User Need
¤ Reduced weight
¤ Lower CAPEX
¤ Lower OPEX
¤ Improved cycle times
¤ Improved performance
¤ Ease of manufacture
O i l & G a s
B e l l e v i l l e S p r i n g
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End User Need
¤ Material selection suited
for mass production
¤ Improved fatigue
capabilities
¤ Corrosion resistance
¤ Abrasion resistance
¤ High temp. performance
¤ Weight reduction
¤ Simplified assembly
Conclusion
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The demand for the adoption of advanced materials is on the rise and
requires a suitable workflow system to achieve this
2 Approaches possible;
¤ Evolutionary Mature Market
¤ Radical Emerging Market
Focus on combined workflow methods considering;
¤ Materials
¤ Processes vs. Supply Chain and Commercial Reality
¤ Design
For improved workflow efficiency and other application benefits
C o n c l u s i o n
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Thank you for your attention
Questions?
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Julien Sellier
STRUCTeam
www.structeam-ltd.com
+44 (0)1983 240534