modern composites, the composite prototyping center · dreamliner. the global market for carbon...
TRANSCRIPT
Modern Composites,
The Composite Prototyping Center&
“STEAM” Powered High Schools
Jim KaranikDirector of Training
Composite Prototyping Center
Presentation to
Nassau BOCES STEAM Powered High Schools
May 24, 2016
COMPOSITES
Composite materials are made from
two or more constituent materials
with significantly different physical or
chemical properties that when
combined, produce a material with
characteristics different from the
individual components.
The new material is stronger, lighter,
and more cost efficient.
Benefits of Composites
• Carbon fiber construction offers exceptional strength and
stiffness at a lower density than traditional metal materials.
• The high temperature epoxy resins with which the fibers are
cured are highly resistant to water, fuel, anti-freeze, and
solvents which might cause wear or deterioration, and they
can be protected from ultraviolet radiation using the same
paint finishes used on metal airplane components.
• Composite parts are qualified for use in weather and climates
found anywhere in the world and at all certified altitudes.
Industrial markets where advanced composite
materials are used:
• Aerospace (commercial & military
planes/helicopters/UMV Drones, space vehicles)
• Racing Cars
• Sporting goods
• Wind Energy equipment such as wind blades
• Oil drilling
• Infrastructure projects such as bridges, tunnels,
skyscrapers
• Tanks such as CNG tanks, waste tanks, etc.
Composites Serve as Primary Structural
Material
Composites
50%
Aluminum
20%
Titanium
15%
Steel
10%
Other
5%
Carbon laminate
Carbon sandwich
Other composites
Aluminum
Titanium
Titanium/steel/aluminum
Boeing 787
Dreamliner
The global market for carbon fiber composite material and
products reached over $15 billion (US dollars) in 2013, with
an annual growth rate of more than 7 %.
Composite Prototyping Center (CPC)
Our Mission
CPC’s core mission was developed in recognition of the growing demand and
opportunities in advanced manufacturing using composite material such as
carbon fiber, fiberglass and aramid.
It is:
To take the best assets available to form a core manufacturing competency in the rapidly growing composite market, while providing companies access to essential training /workforce development, process technologies , prototype manufacturing and test capabilities. Thus enabling these companies to meet the rapidly growing advanced composite manufacturing supply chain needs of prime contractors and OEMs.
Our Primary Objectives
• Establish premier resource for composite prototype production for application across
diverse markets, from aerospace, automotive, energy, infrastructure, transportation
and leisure goods.
• Equip the CPC with essential production line technologies and staff the center with
expert technologist.
• Assist companies to become qualified suppliers to the OEMs and prime contractors
for composite components / assemblies.
• Continue to secure government grants and private funding to facilitate CPC’s future
growth and development.
• By working closely with universities and community colleges, help develop multilevel
certificate and degree programs consisting of advanced composite technologies for
post secondary and undergraduate students thereby creating a highly-skilled
workforce.
• STEM training with local high schools.
Composite Training and Education
CPC’s training classroom is equip with: • Dell Workstations (seven)
• Software Tools :• CATIA v5 CAD/CAM with composite module
• Siemens CAD /CAM (Nastran (FEA) /ANASYS)
• Fibersim Composite Design
• Pro-E Wildfire
• SolidWorks s/w
• Video Conferencing & Webinars
• Mfg. process equipment networked to enable easy up/down loading of programs and of line programing
Education Curriculum and Certificate Programs:• CPC offers introductory and composite design training courses for industry
• CPC is currently developing a Composite Technician Certification program
• CPC has launched a STEM Composites Initiative with local high schools which includes credit from Vaughn College
Software Design & Analysis Tools: CATIA, Pro-E & Nastran, Fibersim, etc.
CPC Manufacturing Floor
CPC will support the following processes & functions:
Automated Fiber Placement RTM / VaRTM 5 Axis CNC Routing Cell
Autoclaves , Ovens Compression Molding, Heated
Press
Hand Lay-Up with Laser
projection assisted templates
and kitting capabilities
Clean Room (Class 100,000)
3D Printer
Single Ply Cutting System with
nesting s/w
Walk-in Freezer
Test and inspection – NDT and
CMM tools and instruments
Site Specifications
• Building: 121 Express Street, Plainview N.Y.
• Total sq. ft. = 25,500 sq. ft.
• 1st floor: 20,000 sq. ft. ; 2nd floor 5,500 sq. ft.
• Electric power: 2,500 amps /480 volts & 1,200 amps /208 volts
• Other utilities: Natural gas, N2, compressed air, vacuum, water
• Ceiling height: 20 ft. (clear under roof structure)
• Fully air conditioned
• Shipping dock and drive - in entrance for large deliveries
• High efficiency LED high bay lighting
• Secured controlled access
• Mfg. parts up to 90” long by 48”
cross section/diameter
• Thermo-set Heads, 4 -1/4” tows
• Thermo-plastic Heads, 1 - 0.25”
/0.50” tape
• Flat panel capable (48”x 96”)
Automated Fiber Placement (AFP) MachineManufactured by Automated Dynamics
Automated Fiber Placement Laser Head Prototype Pressurized Tank Proof of Concept
THE CURRICULUMThis course is a 15 hour, four-week program
taught by the engineering facility from
Vaughn College and CPC Personnel. The
curriculum consist of both classroom
lectures and hands-on lab experience.
Students that successfully compete the
course will receive one college credit from
Vaughn College.
Introduction to Composites
Design with Composites
Analysis with Composites
Composite Materials and Processes
Manufacturing with Composites
Hot Bond Repair
INTRODUCTION to COMPOSITE
TECHNOLOGY
EDUCATION PROGRAM
STEM HS COMPOSITE TECH PROGRAM
STUDENTS COMPOSITE PANEL
FABRICATION PROJECT
STEM HS COMPOSITE TECH PROGRAM
STUDENTS COMPOSITE PANEL
PROJECT REPAIR
STEM HS COMPOSITE TECH PROGRAM
STUDENTS COMPOSITE PANEL
PROJECT REPAIR
COMPOSITES TECHNOLOGY
VETERANS TRAINING
STUDENTS FROM EASTERN SUFFOLK
BOCES’S STEM HIGH SCHOOL
PROGRAM ATTENDED THE 2015
MANUFACTURING DAY AT THE CPC
SENATOR KIRSTEN GILLIBRAND
ANNOUNCES NEW LEGISLATION
SCALE-UP MANUFACTURING INVESTMENT
COMPANY ACT OF 2015
Composite Prototyping Center Wins National Designation as theDepartment of Energy’s Institute for Advanced Composites Manufacturing Innovation’s
Designated Center for New York and the Northeast Corridor
Plainview, NY… (October 15, 2015) The Institute for Advanced Composites Manufacturing (IACMI) today signed a Memorandum of Understanding with the Composite Prototyping Center (CPC, Plainview, NY CPC) outlining a collaborative arrangement in which both will work to bring advanced composite materials and technologies to the marketplace. It is a major achievement for the CPC which has earned this national recognition as the IACMI’s designated center for commercializing advanced composites manufacturing on Long Island, New York State and the broader Northeast corridor. The agreement provides the framework for collaboration in research, product development, commercialization, workforce training and STEM (Science, Technology, Engineering and Math) education.
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Think Tank Vision
CompositesNanotechnologyGenetic EngineeringBiological WarfareInformation WarfareDirected EnergyCompositesRobotics
COMPOSITE PROTOTYPING CENTER121 Express Street , Plainview, NY 11803
1-516-597-5445
www.compositepro.org
https://www.facebook.com/CompositePrototypingCenter
https://www.linkedin.com/groups/Composite-Prototyping-Center-
Consortium-CPC-3109255
https://plus.google.com/105156980143836753864/posts
Jim KaranikComposite Prototyping Center
Director of Training