Show Stopper: Additive-Manufactured Shelby Cobra

WEDNESDAY, OCTOBER 28, 2015
IN ASSOCIATION WITH
Dallas, Texas
Convention
Center
Orlando,
Florida| Dallas
| Orange
County Convention
Center
Manufacturing in Space
3D printing has out-of-this-world
applications for space program. pg 3
Reception Channels
State Fair
Show Stopper:
Additive-Manufactured Shelby Cobra
Tonight’s Specialized Market Segment
Reception offers networking, plus games
and concessions. pg 4
Visitors to CAMX 2015 can’t help
but notice the retro Shelby Cobra
on exhibit by Oak Ridge National
Laboratories (ORNL, Oak Ridge, TN).
It’s the unlikely but stunning product
of additive manufacturing, using the
Big Area Additive Manufacturing
(BAAM) technology developed by
Cincinnati Inc. (Harrison, OH) in
collaboration with ORNL. Design
and manufactured in just six weeks,
the 635-kg car includes 227 kg
of BAAM-printed parts, using a
chopped carbon fiber-reinforced
ABS provided by Sabic. Cincinnati’s
BAAM technology was also a
winner of one of the CAMX Awards,
announced yesterday at the CAMX
general session.
CAMX Award Winners
3D printing, automotive lightweighting
win best of the best. pg 5
Transportation Breakthrough
Co-cured composites in refrigerated
truck structures. pg 6
Snap-Cure Resin Success
Gurit says any resin formulator can make
a resin cure in 1 minute. pg 6
Live at CAMX
Real-world parts produced in on-floor
demos. pg 8
EVENTS NOT TO MISS
• Registration Open
7:00 a.m. – 6:00 p.m.
• Conference Programs
8:00 – 11:00 a.m., 2:00 – 5:00 p.m.
• Exhibit Hall Open
9:00 a.m. – 6:00 p.m.
• Poster Session—
Meet the Authors
9:30 – 11:30 a.m.
Registration Area
• Market Segment
Reception
Texas Fair Style
5:30 – 7:00 p.m.
Registration Area
theCAMX.org
www.theCAMX.org/mobile
ACMA ACE Winners Cover
Simulation, Auto, Industrial,
Consumer Applications
ACMA’s Awards for Composites Excellence
(ACE) are given each year to composite parts and
technologies that represent unusual creativity
in design, processing and application. The 2015
ACE nominees are on display in the ACE Awards
Pavilion on the exhibit hall floor, where yesterday
the winners were announced. They are:
Design Category, Most Creative Application
Award: Advanced Composite Orthotic Systems,
from Kingetics LLC. This orthotic system,
comprised of two hinged composite insoles, is
designed to increase puncture, blast and fire
resistance 300-1,000%. It also increases the energy
efficiency of gait with the spring-lever orthotic
and prosthetic mechanism. Combat boot weight
is decreased 25% compared to current U.S.
Army-mandated issue polyurethane foam boots
reference.
Manufacturing Category, Material and Process
Innovation Award: Nanoscilica-Infused Resin for
Use in Automotive Driveshaft, from QA1 Precision
Products. This automotive driveshaft carries
torque from the engine to the rear axle. All QA1
driveshafts are wet filament wound with carbon
See ACE AWARDS, continued on page 3
Keynote: Automotive
Industry in Midst of
Substantial Change
By Jeff Sloan
CompositesWorld Magazine
compositesworld.com
Gary Smyth, executive director of Global Research
and Development at General Motors, formally
kicked off CAMX 2015 yesterday with a keynote
address to an audience of about 2,000. He emphasized the social, technological and material
evolutions that
are reshaping how
cars and trucks are
being manufactured and used.
The change
taking place, he
said, requires a
Gary Smyth,
executive director of
Global R&D at GM.
See KEYNOTE,
continued on page 4
It’s the
Lean
Mean
Process
Machine...
Redux
It’s the Lean Mean Process Machine….Redux.
A three-day event with over 20 closed mold and advanced process demos in a massive enclosed
staging area. Building real-world parts, from aerospace nose cones and mini nacelles, to marine
dashboards and the coolest long boards you’ll see anywhere! Watch a Light RTM work cell in action,
see time-lapse video showing a 3D-printed mold go from concept to reality in hours, and talk to
closed mold and advanced process experts. Leave with new ideas and insights, and maybe even a
tricked-out skateboard if you win this year’s raffle.
See it LIVE at Booth #S94
Presented LIVE by Composites One, the Closed Mold Alliance and our industry partners
2015
Manufacturing in Space Helps Reduce Launch Costs
By Sara Black
CompositesWorld Magazine
compositesworld.com
“The era of in-space manufacturing has
begun” was the title of Andrew Rush’s
presentation in the Market Applications
(Aerospace and Defense track) chaired
by John Russell of the Air Force Research
Laboratory. The former intellectual property lawyer, now president of startup firm
Made in Space, founded in 2010, described
his firm’s philosophy: “People should
be able to live and work better in space,
since we may be colonizing new planets
someday.” How would these explorers
produce products or tools for themselves?
By 3D printing, of course.
“A 3D printer is a meta-tool,” says Rush.
“It’s capable of making other tools.” His
argument is that if additive manufacturing
(AM) could be a part of a launch mission,
less “stuff” would have to be carried aloft
during launch. And, he showed NASA
statistics that 82% of part failures or breakdowns on the International Space Station
(ISS) could have been repaired, had such
capability been available. The company
developed its own, robust, AM printer,
since off-the-shelf 3D printers could not
Early tests of the Made In Space device during parabolic weightless flights.
ACE AWARDS, continued from page 1
IN ASSOCIATION WITH
Dallas,
Texas
| Dallas
Convention
Center
Orlando,
Florida
| Orange
County Con-
theCAMX.org
www.theCAMX.org/mobile
SHOWDAILY STAFF CONTRIBUTORS
CompositesWorld Magazine
Jeff Sloan, Editor-In-Chief
Mike Musselman, Managing Editor
Sara Black, Technical Editor
Ginger Gardiner, Senior Editor
Heather Caliendo, Managing Editor - Electronic Products
Rick Kline Jr., Group Publisher
Ryan Delahanty, Publisher
Kim Hoodin, Marketing Director
Barb Businger, District Manager
Rick Brandt, District Manager
Eddie Kania, European Sales Manager
SHOWDAILY PRODUCTION
Rhonda Weaver, Production Manager
Kate Hand, Editor
Jeff Norgord, Art Director/Photographer
Becky Helton, Advertising Manager
The CAMX ShowDaily is published by
Gardner Business Media, Inc.
6915 Valley Ave., Cincinnati, OH 45245
©
2015 by Gardner Business Media, Inc.
fiber and a thermoset epoxy, which uses a
spherical nanoscilica (3M’s Matrix Resin
4833 epoxy). This nanoscilica improves the
properties of the resin, including tensile
modulus, fracture toughness and moisture
absorption.
Manufacturing Category, Equipment
and Tooling Innovation Award: Productive
Engineering Software for Virtual Allowable
Generation, from e-Xstream engineering.
Digimat-VA is a software solution
designed to replace or complement lengthy
physical testing of composites. Finite
element modeling is used to represent the
coupon tests required for material characterization. Generation of virtual allowables enables significant time and cost
reductions.
Virtual allowables can be generated
before the actual allowables, speeding up
the early design of composite parts; they
can complement an existing physical test
matrix (for instance to explore new layup
stand up to the rigors of microgravity.
The unit was actually flown on a resupply
rocket to the ISS in November 2014, and
worked flawlessly, printing 21 objects with
ABS plastic, among them a fully functional
torque wrench needed by an astronaut.
The machine and the parts returned to
Earth, and those parts are currently being
extensively tested to see what differences in
properties, if any, might be present.
The company has improved and updated
its AM machine, which can now print with
three heads using three different materials.
Looking further down the road, Rush says
his group is thinking outside of the box, with
concepts like units that could be launched
into space and actually print satellites in
the space environment—making structural
parts such as beams or trusses with cached
materials and components (possibly sent
into space by other missions). There are
issues that must be addressed, such as
the lack of convective heat transfer to pull
heat away from the parts as they’re made,
because no atmosphere is present. And
power draw is tricky, since all power must
come from a solar array.
A key point is that today, everyone,
whether friend or foe, knows about payloads
going into space. With this technology,
payloads would be built as needed, on orbit.
Concludes Rush, “We have two paradigm
shifts happening: AM in microgravity, and
in-space assembly and deployment.” The
print file for the torque wrench is open and
available online. Visit madeinspace.us for
more pictures and videos.
possibilities), and they can reduce physical
testing by replacing material batches to be
tested. Overall, time and cost reductions
range between 20 and 40%.
Market Growth Category, Infinite
Possibility for Market Growth Award:
Composites Help Steer Toward a Wireless
Road Infrastructure, from Strongwell
Corp. Strongwell’s pultruded fiberglass
DURAGRID HD-4000 2.5-inch grating
panels are installed as a trench cover at the
Utah State University Electric Vehicle and
Roadway (EVR) research facility in Logan,
UT.
The EVR serves as the vehicle systems
integration facility for the Center for
Sustainable Electrified Transportation.
Housed beneath the grating are magnetic
transfer plates, which charge electric vehicles in motion.
DURAGRID HD-4000 provides ample
support for vehicle loadings while
protecting the magnetic transfer charging
plates on the electrified, quarter-mile test
track.
theCAMX.org
3
THE COMPOSITES AND ADVANCED MATERIALS EXPO
KEYNOTE, continued from page 1
collaboration with composites materials
and parts suppliers, with the goals of
reduced vehicle weight, increased safety
and customer satisfaction. “You can look
at what’s happening with the transformation of the industry, and the disruption of
the industry,” exhorted Smyth, “and really
look at what can you do and how you can
be proactive and again be a part of that
transformation.”
As part of this transformation, Smyth
discussed where and how advanced
materials have been applied on GM cars in
recent years—including use of aluminum
in the Corvette frame and carbon fiber in
its hood and roof.
Smyth then focused on three broad
drivers of change in the automotive
industry. First, regulatory, in the form of
fuel efficiency and emissions requirements
in the U.S., Europe and China. As has been
reported, U.S. standards call for corporate
average fuel efficiency (CAFE) to be 54.5
mpge by 2025. In Europe, the standard is 58
mpge by 2020; in China, 56 mpge, also by
2020. This is forcing GM and other automakers to push out more hybrid-electric
and all-electric drivetrains.
However, he cautioned against thinking
that those dates represent fuel efficiency
finish lines. “2020 for Europe or China is
not the end,” he said. “It’s basically a gate
we’re going to go through and continue to
reduce CO2.”
Smyth next focused on the demands of
the urban driving environment shaped by
mega and hyper cities, such as Tokyo and
Mexico City, which create preference for
smaller, safer vehicles. This is engendering
sensing technologies that help make vehicles aware of each other, pedestrians and
cyclists.
Finally, Smyth assessed the state of
self-driving vehicle technology and GM’s
response, which led to a discussion of
the vehicle-sharing economy and the
prospect—especially in urban environments—of sharing replacing ownership.
Smyth’s assertion is that younger drivers,
increasingly, don’t see vehicle ownership
as imperative as their parents and grandparents do.
During Q&A, Smyth was asked what
kind performance a company like
GM expects from a high-performance
composite material. Smyth quickly turned
the question around and put the onus on
the composites fabricators to prove to automakers the value of their products. “I think
composites can play a role, even beyond
the Corvette,” he said. “What I’m looking
for from you is put together what you see
as the value proposition [of your products].
We’re looking for a good value proposition
that can improve the emissions of
the vehicle, the recyclability of the
vehicle, the performance of the vehicle,
the mass, etc.”
Ultimately, Smyth said, GM—and all
automakers—need help from the entire
supply chain to help move the auto
industry forward: “In the end, we can’t
stop. Look where we are today in regards to
efficiency and look at what we need to do
over the next five to ten years. We have to
do the right thing whether it’s regulated or
whether it’s just the right thing.”
Catch a Shuttle Bus
CAMX provides transportation to and from
CAMX hotels to all attendees and exhibitors. The shuttle bus stops are located in the
main bus drop off area on Ceremonial Street
(Level 1) near D100 conference program
rooms. If you require an ADA shuttle bus
or would like additional information, call
310-466-4699. (Call at least 30 minutes prior to
desired pick-up time if an ADA bus is required.)
Hotel
Route
Hyatt Regency Dallas
1
Sheraton Dallas
2
Crowne Plaza Dallas Downtown
3
Homewood Suites Dallas Downtown
3
Springhill Suites Dallas Downtown
3
Hours of Service*
Wednesday, Oct. 28
7:00 – 10:00 a.m.; every 10 – 15 minutes
10:00 a.m. – 3:00 p.m.; every 30 minutes
3:00 – 7:30 p.m.; every 10 – 15 minutes
Thursday, Oct. 29
7:00 a.m. – 2:00 p.m.; every 10 – 15 minutes
2:00 – 6:00 p.m.; every 30 minutes
*Last bus leaves from hotel 30 minutes prior to end time with
no return service.
Composites and Texas State Fair Combine at
Tonight’s Market Segment Reception
Even though the State Fair of Texas
recently concluded its run for this
year, CAMX attendees can still get a
taste of that fair experience while also
discussing all things composites at
tonight’s Specialized Market Segment
Networking Reception. The reception takes place 5:30 –7:00 p.m. in the
registration area and is sponsored by
Composites One.
It provides the opportunity to try
your hand at some fair games, and
network with people interested in the
following market segments: corrosion,
aerospace, automotive/transportation,
wind energy, architecture and sporting
goods and recreation.
4
Wednesday, October 28, 2015
Iconic Big Tex presides over the State Fair of
Texas fairgrounds. Tonight’s Market Segment
Reception features specialized topics with
a fun fair theme.
Check out TenCate Advanced
Composites’ BMC Billet Stock in
Booth R100—up to 76 mm thick,
made from flat-molded chopped
carbon fiber and epoxy sheet stock
that is CNC-machined like metal
for prototyping or limited-volume
production of metal-to-composite conversion parts without
tooling cost and time. Also used
as reduced labor inserts for hard
point attachments in 50-100 ply
laminates. Shown here, a V-22 part
made from chopped CF/epoxy
with 177°C Tg replaces aluminum
at 40% weight savings; CNC-cut
disk and die from billet stock.
2015
CAMX Awards Winners Emphasize 3D Printing,
Automotive Lightweighting
CAMX 2015 organizers announced
yesterday morning at the show’s opening
general session the winners of the second
annual CAMX Awards, given under two
categories: Combined Strength, emphasizing creativity and collaboration; and
Unsurpassed Innovation, emphasizing
process or material innovation.
Winner of the Combined Strength
Award was BAAM, Big Area Additive
Manufacturing technology developed
by Cincinnati Inc. (Harrison, OH) in
collaboration with Oak Ridge National
Laboratories (ORNL, Oak Ridge, TN).
BAAM encompasses a number of innovations that enable large-scale 3D printing.
Its first generation offered a build platform
measuring 13 by 6 by 3 ft; the latest version
has a build area of 20 by 8 by 6 ft. The
BAAM enables components of arbitrary
geometry to be 3D printed at a scale that
is times larger than any other commercial
system, using a screw-extrusion technology for deposition, similar to what is
used in the injection molding industry.
Cincinnati Inc. and ORNL designed an
extrusion screw specifically for the BAAM
system and mounted it on a high-speed,
high-resolution gantry system. BAAM is
also the first to deposit with carbon fiber
reinforced-plastic pellets and uses a novel
Z-table that provides the capability to build
large parts. The system also features innovations that improve layer-to-layer adhesion
and the ability to easily separate support
material from build parts.
Receiving the award were Rick Neff,
manager market development at Cincinnati
Inc., and Lonnie Love, group leader at
ORNL. They commented on the Shelby
Cobra (on display at CAMX) that was
designed and then manufactured with
BAAM in less than two months in late 2014
and early 2015. “ORNL first mentioned the
Cobra on Nov. 10 of last year,” Neff recalled.
“By January it was done and you couldn’t
tell that it was additive manufactured.”
Love and Neff credited a variety of partners,
including Techmer, Sabic and Alpha Star.
Winner of the Unsurpassed Innovation
Award went to Continental Structural
Plastics’ (CSP, Auburn Hills, MI) TCA
Ultra Lite, a sheet molding compound
composed of a proprietary thermoset resin
matrix combined with Advantex glass fiber
from Owens Corning (Toledo, OH) and
glass bubbles, instead of CaCO3, to create
a lightweight composite for automotive
Lonnie Love, group leader at ORNL, and
Rick Neff, manager, market development,
Cincinnati Inc.
structures. Suitable for Class A body panels
or structural components for light vehicles
or heavy trucks, CSP says design studies
have shown that at 1.2 specific gravity Ultra
Lite offers weight savings of up to 28%
over the company’s mid-density TCA (1.6
specific gravity), and 43% over its industry-proven standard-density TCA material
(1.9 specific gravity).
CSP says the use of glass bubbles allow
the resin to adhere to the matrix and
increase the interfacial strength between
the bubble and the resin. This is a patented
treatment technology that results in a more
robust resin mix that makes molded parts
more resistant to handling damage, and
prevents the microcracks that cause paint
pops, pits and blistering.
theCAMX.org
5
THE COMPOSITES AND ADVANCED MATERIALS EXPO
CAMX Award Finalist in Transportation Spotlight
By Sara Black
CompositesWorld Magazine
compositesworld.com
The nominees for this year’s CAMX
awards, sponsored by Ashland, aim to
grow composites’ market share. One
of those nominees, “Next Generation
Affordable Composites for Transportation
Applications” by Structural Composites
Inc. (Melbourne, FL), is already impacting
the transportation market, with a breakthrough that brings composites close
to cost parity with traditional designs.
Structural Composites, through a broad
collaborative effort that includes market
insertion intermediary Composite
Application Group (CAG, Oak Ridge, TN)
and several material suppliers, has translated its innovative and cost-effective
design work for the U.S. Navy combatant
craft into refrigerated truck trailers, which
are now in production at Wabash National
Corp. (Lafayette, IN). BASF was part of the
collaboration, as was PPG and Interplastic.
Wabash went public on Monday, Oct.
26, with the announcement of its new
composite refrigerated trailers, one of
which is on display in the CAMX awards
area; the company is also displaying the
concept at the International Foodservice
Distributors Assn. Distribution Solutions
Conference in Phoenix this week. But the
technology behind the new product is
A refrigerated truck trailer on
display in the CAMX Awards
Booth C120 incorporates innovative
and cost-effective design work.
fascinating.
Structural Composites’ Scott Lewit,
Wabash National’s structural engineering
manager Andrzej Wylezinski, and Jeff
Austad, national sales manager at Magnum
Venus Products (MVP, Knoxville, TN) gave
a paper Tuesday morning with some details.
Key to the technology is what Lewit calls
CoCure Strain Tunable Resin. Low-cost,
commodity polyester resin and gel coat
can be mixed with polyurethane, with the
polyurethane ranging from 1 to 6 percent
by volume, to achieve higher elongation, toughness and better long-term
performance.
The resin mix can be varied spatially,
across the part, or through the thickness
of the part, to achieve customized results,
says Lewit: “There’s no need to use the
same resin throughout the entire part. You
can tune the resin to fit the application, by
adding just a bit of the more expensive resin
to a lower-cost commodity material. This
gets resin price under control.” To make
this mixing possible, MVP is developing
application machines with dual metering
capability: polyester and catalyst on one
side, and two-part polyurethane on the
other, that come together at the spray head,
says Austad.
Panels for the roof, walls and floor of the
trailers are composite sandwich designs,
with Structural Composites’ Prisma preform
frames between the skins; the interior space
is foam-filled for maximum insulation.
Wylezinski adds that a big rig trailer environment is “highly stressed” and that the
new design allows for much lighter
weight, up to 25 percent, enabling higher
payloads.
New Snap-Cure Prepreg Produces Class A Parts Out of the Mold
By Mike Musselman
CompositesWorld Magazine
compositesworld.com
“Snap-cure” resins, said William Ricci,
Technical Services, Gurit Composite
Materials (Zurich, Switzerland) as he introduced “A New Snap Cure System for HighRate Composite Component Production,”
are those that cure in 5 minutes or less.
And, he notes, any resin formulator can
make a resin cure in one minute. The challenge is how to accomplish a snap-cure, yet
guarantee the resin will flow well enough
to wet out the fiber, producing a Class A
surface and finished rolled edges out of the
press (no trimming necessary).
His Tuesday morning presentation
focused on Gurit’s recent trials of a
snap-cure resin in a molding process
aimed at the auto-industry’s typical
6
Wednesday, October 28, 2015
100,000-part-per-year production target.
Although the trend has been toward
the use of resin transfer molding or wet
compression molding, Gurit determined
that kitted prepreg would be the easiest
way to ensure a Class A surface.
Gurit began with a thermoplastic-toughened, multifunctional epoxy base resin,
then added a secondary catalyst that
remains dormant, preserving the prepreg’s
standard dynamic flow, until it is activated
at a preset temperature, triggering cure,
which escalates very quickly after that
point. Generally, the cure temperature
controls the cure cycle time.
To reach the production goal, parts must
exit the mold hot, without distortion or
fiber print-though. Ricci says the key here
is the glass transition temperature (Tg). In
very high-temperature molding processes,
the part temperature must be allowed to
fall below the Tg before demolding, which
prolongs the cycle. Gurit’s resin cures at a
temperature lower than its Tg.
In its test run, matched-metal tools
(female convex and a male concave with a
gasketed seal) were prepped with a waterbased spray mold release system. Prereg
resin content was 35 percent, and the
preformed prepreg was 8 plies of uni-tapes.
The part was a complex-curved surface
with a cutout, cured at 150°C. All edges
were finished. Void content of test parts
was 1-2 percent. Ricci says press force need
not be high (120 psi) but fast open/close
are critical to save cycle time.
Based on its test parts, Gurit estimates
the cost to a molder, for a system capable of
20 parts/hr, as follows: Matched aluminum
tool cost: (2 sets) US$230,000, press,
US$900,000, cost per part amortized over
one year, US$11.30.
2015
IKONICS Showcases Precision Abrasive
Machining Technology
assembly processes. In the accompanying
photo, for example, the decoratively vented
opening at left was cut, via PAM, directly
from the molded composite part. That
part replaced one on the right, which was
molded, then had the opening machined
out, then had a metal grillwork riveted into
place in the opening. The grillwork, by the
way, required a ground wire—another step.
IKONICS and PAM, Booth H41
By Mike Musselman
CompositesWorld Magazine
compositesworld.com
Want to precisely decorate or perforate
your composite part with patterns, holes
or geometric shapes? IKONICS Advanced
Material Solutions (Duluth, MN) offers a
method to do so that bypasses expensive,
time-consuming grinding, drilling and
cutting. Precision Abrasive Machining
(PAM) produces a variety of features/
shapes and/or perforations in brittle/challenging materials, including composites, yet
ensures low-stress on the part and minimizes compromises to the substrate.
The process employs an updated form of
traditional sandblasting, but a proprietary
and patented masking system developed
by IKONCS, which protects the composite
from damage. Perforations can be created
in any composite (even Kevlar-reinforced
polymers), with high repeatability (within
50 µm) without the shipping and other
defects associated with conventional
machining. The resulting perforations
have clean edges (no burns or fiber ends to
remove).
The PAM is reportedly “gentle” in that the
The decoratively vented opening at left was
cut, via PAM, directly from the molded
composite part.
stress is applied over a wide area of the part
(rather than locally) in a scanning process.
According to IKONCS, independent testing
laboratory MISTRAS (Princeton, NY)
confirms that stress and internal damage
to the part are significantly minimized
with PAM vs. mechanical drilling. Further,
IKONCS maintains that PAM avoids
substrate burnishing and distortion associated with laser drilling, and layer delamination associated with waterjet processing.
A secondary, but significant, benefit is
the elimination of steps in the customer
Visit us at
Booth G92
CAMX Social Media
Social media is another
key outlet to keep an
eye on during the show
so you don’t miss a thing. The
CW team will be out in full
force covering both the exhibit
hall and conference so stay
tuned to our Twitter account
(@CompositesWrld), which
will have all the latest news,
photos and videos from the
show. Also, on Twitter, check
out the hashtag #CAMX15.
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theCAMX.org
7
THE COMPOSITES AND ADVANCED MATERIALS EXPO
Live at CAMX: On-Floor Demonstrations
By Heather Caliendo
CompositesWorld Magazine
compositesworld.com
One of the best aspects of a trade show is
seeing manufacturing demonstrations take
place live on the show floor. Case in point, as
soon as the exhibit hall opened its doors on
Tuesday, many attendees headed straight to
the massive enclosed staging area in Booth
S94 for the on-floor demos. Composites
One (Arlington Heights, IL), along with the
Closed Mold Alliance and more than 20
industry partners, are presenting closed
molding and advanced process demonstrations during CAMX.
Composites One Director of Marketing
Communications Marcy Offner told CW
that the on-floor demos are focusing on the
following market segments: wind energy,
consumer recreation, corrosion (oil & gas),
transportation, marine and aerospace. For
instance, with transportation, the group is
sponsoring two demos: making a tractor
hood (light RTM) and motorcycle fender
(prepreg). There are also two demos for
aerospace: making an airplane nose cone
(vacuum infusion) and a fairing (3D-printed
mold and prepreg).
“This year, we’ll present the different type
of market segment demos showing realword parts made right on the show floor
using a variety of closed mold and advanced
processes,” Offner says.
Many of the demos will feature systems
from Magnum Venus Products (Knoxville,
TN) and tooling from RTM North Ltd.
(Clinton, Ontario, Canada). Together with
Composites One, they helped to create the
Composites One kicked off CAMX 2015 with an on-floor demonstration for the
transportation market.
Closed Mold Alliance, which is a resource
dedicated to helping manufacturers make
a successful conversion to closed molding
processes. Tools were provided by Janicki
Industries (Sedro-Woolley, WA) and Roush
Performance (Plymouth Twp., MI).
Presented at major industry events for
over a decade, Composites One’s demos
have ranged from building an entire sailboat, to presenting multiple smaller part
demos nonstop.
Whether it is designed to highlight
capability or to educate composite
professionals on manufacturing
processing methods, there is no
shortage of actual manufacturing
taking place at CAMX. Here is the
schedule for the rest of CAMX:
Wednesday, Oct. 28
9:00 a.m.
Demo Area Opens
9:15 a.m.
New Technology – Liquid
Thermoplastic (light RTM)
Consumer Rec (reusable bag
molding & vacuum infusion)
Press Announcement –
Composites One, IACMI, MVP
Transportation (prepreg)
New Technology - 3D Printing
(prepreg)
Wind Energy (reusable bag
molding)
Aerospace (vacuum infusion)
Corrosion (light RTM)
Transportation (RTM with heat)
Marine (light RTM)
10:15 a.m.
11:00 a.m.
11:15 a.m.
12:15 p.m.
1:15 p.m.
2:15 p.m. 3:15 p.m.
4:15 p.m. 5:15 p.m.
Thursday, Oct. 29
9:00 a.m. 9:15 a.m. 10:00 a.m.
10:45 a.m.
The closed molding and advanced process on-floor demos are focusing on several different
market segments during the show.
8
Wednesday, October 28, 2015
11:30 a.m.
Demo Area Opens
Wind Energy (reusable bag
molding)
Marine (light RTM)
New Technology – Liquid
Thermoplastic (light RTM)
Corrosion (light RTM)
2015
Product News at CAMX 2015
General Plastics: Polyurethane Foam Cores
General Plastics Manufacturing Co. (Tacoma,
WA) is highlighting its fire, smoke, and
toxicity- (FST) compliant polyurethane foam
cores—the FR-3800 FST series—and its
molded parts program. As the first halogen-free
polyurethane foam that satisfies FST requirements and Ohio State University (OSU) 55/55
standards, General Plastics’ LAST-A-FOAM
FR-3800 FST Performance Core Series is
available in densities from 3 to 40 lb/ft3. The
product’s mechanical properties are similar to
the FR-3700 and 6700 aerospace-grade core
material series, which also meet FST and OSU
requirements. It withstands process temperatures up to 310°F, providing a larger processing
window to manufacture composite parts.
General Plastics Manufacturing Co., Booth ZA77
PPG Industries:
Direct Draw Glass Roving
PPG Industries’ (Pittsburgh, PA) fiber glass
business is introducing HYBON 2052 direct
draw roving, designed for high- and low-pressure epoxy pipe applications and pressure
vessels and compatible with amine- and
anhydride-cured epoxy resin systems. HYBON
2052 is available in E-glass and E-CR glass
compositions. PPG says the tailored chemistry, which uses an alkyl phenol ethoxylate
(APE)-free sizing system, offers excellent fiber/
matrix interfacial hydrolysis resistance and
strength retention. These products are currently
produced in the U.S. and are globally available in
various TEX/YIELD options in filament diameters ranging from 16 microns to 23 microns.
PPG Industries, Booth K112
MarkForged: 3D Printing System
MarkForged (Cambridge, MA) is returning to
CAMX with the Mark One Composite 3D Printer
and an assortment of ultra-strong fiberreinforced 3D-printed parts and applications.
MarkForged notes that this new approach using
additive manufacturing technology to automate
the composite layup process with thermoplastics
relieves the laborious tasks normally associated
with traditional composite layup. Manufacturers
are no longer limited to sheets of composite, longlead time tooling, clamshell designs, and manual
labor. The Mark One can turn complex assemblies
into one printed part. As the world’s first 3D printer
capable of printing continuous strand carbon fiber,
Kevlar, and fiberglass, the Mark One Composite
3D Printer uses a patented Continuous Filament
Fabrication (CFF) print head alongside a FFF
(Fused Filament Fabrication) printhead to create
tough and functional parts. MarkForged says the
system allows designers and engineers to 3D
print reinforced plastic parts that are up to 30
times stronger and 30 times stiffer than conventional 3D-printed parts made from ABS plastic.
MarkForged, Booth E51
Train for Tomorrow – Certify for Success
CCT Benefits for Companies
CCT Benefits for Individuals
• Increased productivity
• Documentation of professional
expertise
• Lower production costs
• More skilled, forward-looking
workforce
• Industry-wide recognition of skills
• Enhanced career opportunities
Designations
Cast Polymer
Light Resin Transfer Molding
Compression Molding
Open Molding
Corrosion
Vacuum Infusion Process
Instructor
Wind Blade Repair
The Industry’s
Gold Standard for
Composites Training
www.compositescertification.org
theCAMX.org
9
THE COMPOSITES AND ADVANCED MATERIALS EXPO
Product News at CAMX 2015
Reichhold: Vinyl Hybrid Resins
Reichhold (Durham, NC) is launching its new ADVALITE vinyl hybrid resins,
available in styrene-free liquid and monomer-free hot melt prepreg
versions. Both versions reportedly exhibit excellent mechanical
properties with a rapid cure rate to reduce production cycle times.
ADVALITE vinyl hybrid resins can be used in resin transfer molding
(RTM), infusion, filament winding, liquid molding and pultrusion
processes, directly coated or adhesive filmed for fiber impregnation.
At Thursday’s conference, Reichhold’s James A. Bono will present
“Vinyl Hybrid Snap Cure Resin Applications in Filament Winding, RTM and
Prepreg Processes,” (11:00 a.m.); Samuel Freeman will present, “Studies
on the Effect of Degree of Crosslinking of Vinyl/Acrylate Networks,”
(10:30 a.m.); Anthony Skrobacki will present “Mechanical and Thermal
Analysis of Toughened Rubber-Modified Vinyl Ester,” (10:00 a.m.) and
Hildeberto Nava will present “Studies on the Reactivity of 1, 2-Vinyl
Containing Liquid Rubbers in a Rubber Modified Vinyl Ester” (11:00 a.m.).
Reichhold, Booth T66
TR Industries: Mold Releases
TR Industries (South Gate, CA) is featuring its line
of mold releases and related products, including
a variety of paste waxes, liquid waxes, polishing
compounds and semi- permanent release
coatings for traditional fiberglass production and
high-performance composites applications.
Two recent additions to the TR product line
include a liquid polymer wax release and the
MULTI-PULL high-slip, semi-permanent release.
Also featured is TR-214PC, a liquid sealer and
mold release formulated with high-temperature
waxes and proprietary polymer technology.
This release provides liquid wax ease of
application with the added benefits of multiple
releases provided by a polymeric resin.
Finally, TR-930HS is a versatile low-odor,
fast-evaporating, semi-permanent release
that provides added slip on more complex
SAVE THE DATE
Stop by the
2016
SAMPE BOOTH TODAY
September 26–29: Conference
September 27–29: Exhibits
Anaheim Convention Center
Anaheim, California
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UNSURPASSED INNOVATION.
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molds, especially for those molding with
polyester/vinyl ester resins without use of a
gelcoat. This release film cures rapidly at room
temperature (5-10 minutes) with an application range up to 750°F. Multiple releases
for various resins including epoxies, polyesters, thermoplastics, rubber and many other
plastics using metal or composite tooling.
TR Industries, Booth G92
Wednesday, October 28, 2015
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PRODUCED BY
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Meet with staff and learn
about SAMPE membership
benefits and events.
Be sure to visit to test
your knowledge about
the advanced materials
and processes industry
for a chance to win
$1,000 in prizes.
SAMPE BOOTH
Q114
2015
Product News at CAMX 2015
L&L Products: Two-Component Adhesive
L&L Products (Romeo, MI) is featuring a range
of room-temperature-curing two-component
fire, smoke, toxicity (FST) compliant adhesives
for simple assembly of composite parts. They’re
supplied in a two-component cartridge, as well
as in pails or drums. One of the components
contains an epoxy-based adhesive, while the
other contains an amine-based curing agent.
Once the two are mixed, the adhesive adheres
to the surrounding substrates and hardens.
L&L says its adhesives hold a high-strength
bond and are designed to meet the stringent
requirements of the aerospace industry.
The company notes that a 12-second
vertical burn is the minimum specification
to meet FAR 25; L&L’s adhesives exceed the
requirement by passing the most stringent of
the tests at 60 seconds. All of L&L’s two-component adhesives have a 1:1 or 2:1 mix ratio,
enabling easy working conditions using standard
applicator gun sizes. Typical gel times are 5-90
minutes, depending on the material used. All
of L&L’s two-component FST adhesives
are developed with
REACH compliance.
Typical applications include bonding
inserts to honeycomb
panels, panel-to-panel
bonding (ability to
bond multi-material
substrates), composite
potting and fillet seals.
L&L Products,
Booth T122
Virtek: Laser Projection
Systems
Virtek (Waterloo, ON, Canada), a subsidiary of
Gerber Technology, is featuring Virtek Projection
Data Creator (PDC) software to quickly and
accurately visualize, generate and edit projection data from CAD models in a virtual 3D
environment. Virtek says PDC supports a
number of formats and quickly generates
projection files in a virtual 3D environment.
Virtek PDC supports CAD files in IGES, STEP,
CATIA V4/5/6, Siemens NX, Solidworks, DXF, CREO,
Parasolid and Autodesk Inventor file formats. It
also supports Virtek LaserEdge and the Iris Spatial
Positioning System, particularly in the creation of
datum and verification points. Virtek PDC, which
replaces the Virtek Planner software, supports
documentation such as queries, labels or graphics.
Virtek, Booth G113
Know Everything.
Create Anything.
Introducing
Cloud-Based Version
VectorLam Cirrus 2.0 is the newest edition to Vectorply’s proprietary
laminate analysis software. VectorLam Cirrus 2.0 provides a cloudbased, multi-platform compatible approach to classical laminate
theory and provides a suite of services across diversified market
segments. This upgrade from the Excel-based version of VectorLam
allows users to build and access laminates on nearly any internet
connected device.
VectorLam Cirrus 2.0 is your Cloud based laminate analysis
software solution. There is nothing to download, just sign in
and start creating!
Sign-in to VectorLam Cirrus 2.0 at vectorply.com
800-577-4521 | 334-291-7704 | www.vectorply.com
Stop by our booth at CAMX (Booth T112) to see VectorLam Cirrus 2.0!
theCAMX.org
11
THE COMPOSITES AND ADVANCED MATERIALS EXPO
Product News at CAMX 2015
Vectorply: Laminate Analysis Software
Vectorply Corp. (Phenix City, AL) is introducing
at CAMX VectorLam Cirrus 2.0, the latest edition
of Vectorply’s proprietary laminate analysis
software. VectorLam Cirrus 2.0 provides a cloudbased, multi-platform-compatible approach to
classical laminate theory and provides a suite
of services across diversified market segments.
This upgrade from the Excel-based version of
VectorLam allows users to build and access laminates on nearly any Internet connected device.
VectorLam Cirrus 2.0 is designed to help
users achieve goals of stiffness, strength, weight
and cost by allowing them to design a specific
laminate for their application. The VectorLam
Cirrus 2.0 program is free to all users and will
be accessible through Vectorply’s website.
Vectorply’s director of composites engineering,
Trevor Gundberg, presented his technical
paper Tuesday titled, “E-Glass/Polypropylene
Woven & Stitch-Bonded Biaxial Fabrics - Static &
Dynamic Composite Property Characterization.”
The paper covers the mechanical property
testing “static and dynamic” done on Vectorply’s
Thermwood: Additive Manufacturing System
Thermwood Corp. (Dale, IN) a manufacturer
of 3- and 5-axis CNC routers, is emphasizing its new program to develop a 3D
12
Wednesday, October 28, 2015
additive manufacturing system capable of
making large carbon graphite-reinforced
composite thermoplastic components.
Thermwood’s systems uses a “near net
shape” approach where a relatively large
extruder, mounted to the machine, is used
to heat, melt and deposit, or “print,” carbon
graphite-filled thermoplastic material to
quickly create a structure that is almost,
but not quite, the final shape. That structure, when it cools and hardens, is then
5-axis machined to the final net shape.
These new systems will be based on
Thermwood’s Model 77, semi-enclosed,
high-wall gantry machine structures, which
are currently offered in sizes up to 60 ft
long. For the plastic extruder, Thermwood
turned to American Kuhne (Ashaway, RI)
a provider of engineered solutions for
plastic, rubber and silicone extrusion,
which developed a custom system that
integrates closely with Thermwood’s
CNC machine. With the addition of a
second gantry, the additive and subtractive processes can be performed on the
same machine. The second subtractive
gantry will be offered as an option.
Thermwood’s systems will feature
a full 6-axis articulated additive deposition head, allowing it to build layered
structures on a horizontal plane as well
as planes canted in any direction up to
90° from horizontal. Thermwood’s initial
development machine, which is nearing
completion, can make parts up to 10 ft
long by 10 ft wide by 5 ft high, is equipped
with a 20-hp, 1.75-inch diameter, 24:1 L/D
extruder and support equipment capable of
processing more than 100 lb/hr of material.
Thermwood Corp., Booth J72
ThermoPly E-glass/polypropylene comingled
fabrics. Gundberg compared this data with
other types of thermoplastic composites,
including LFRT and similar thermoset composites.
Vectorply Corp., Booth T112
Elliott Co. of Indianapolis:
Foam Core
Elliott Co. of Indianapolis (Indianapolis, IN) is
featuring its line of rigid polyiso/urethane foam
core materials. Supplied as blocks, sheets and
custom shapes, ELFOAM products are said to offer
excellent insulating, fire resistance and structural
physical properties. Depending on performance
requirements, ELFOAM’s ability to save weight,
resist chemicals and handle temperatures of
±149°C may also be of value in a variety of panel,
tank, slope, insert and equipment applications.
Elliott Co. also now offers fabrication
options to complement its sheeting, scoring,
perforating and profiling capabilities.
Elliott Co. of Indianapolis, Booth S106
Renegade Materials:
Non-MDA Polyimide Prepregs
and Adhesives
Renegade Materials Corp. (Springboro, OH) is
exhibiting with sister company, Maverick Corp.,
featuring a range of non-MDA polyimide
prepreg and adhesive products. Renegade
Materials’ 700°F polyimide prepreg system,
RM-1100, has recently been selected for
qualification at multiple international aerospace OEMs.
Renegade’s 600°F MVK-14 Freeform is
now flying on commercial engine and aircraft
platforms and is in evaluation on primary
structure for new, advanced military engines.
BMI prepreg systems, BMI infusion resins and
BMI adhesives are also featured. RM-3004 is
Renegade’s out-of-autoclave-curing BMI with
application in aerospace structures and tooling.
These products are currently in production and
qualification at multiple aerospace primes.
Renegade Materials Corp., Booth X10
2015
Product News at CAMX 2015
BGF Industries: Woven Fiber Reinforcements
BGF Industries (Greensboro, NC) is
featuring its line of woven fiber reinforcements, including those made with carbon
fiber, glass fiber, aramid fiber, aluminized
glass fiber and thermoplastic glass fiber.
• Carbon fiber: BGF offers a
variety of polyacrylonitrile (PAN)- and
pitch-based carbon fabrics using 3K,
4K, 6K, and 12K tow carbon fibers.
BGF says its carbon fabrics offer high
strength, high modulus, light weight,
have high thermal conductivity and
electrical resistivity. Applications include
primary and secondary structures,
including engine components, rotor blades,
radomes, ducting, brake linings and tooling.
• Aramid: BGF’s woven materials for
aerospace composites are made from highstrength DuPont Kevlar (aramid) fiber. BGF notes
that aramid fabrics have excellent thermal and
dimensional stability, perform with no strength
loss up to temperatures of 320°F for extended
periods, are lighter weight than E-glass with
higher specific strengths, demonstrate little or no
change in a composite when indirectly exposed to
UV light, and will not melt or support combustion.
• Glass fabrics: BGF’s E-glass and
high-strength S-glass fabrics for composites
applications use a heavier construction with
complex weave patterns to produce a highstrength, high-performance, lower cost fabric
than carbon or Kevlar. Aerialite fabrics, for
snowboards, are specifically designed to provide
superior handling and cleanliness to ensure a
smooth manufacturing process. Aerialite X is
designed with a range of fiber combinations from
100% Innegra fiber to Innegra hybrid designs.
The latest advancement comprises Innegra fiber
comingled as part of the fiber matrix in both glass
and carbon. Used for high impact applications in
surfboards, SUP boards, auto racing and
protective sports equipment, Aerialite
X delivers impact resistance, damage
tolerance and vibration reduction.
• Aluminized glass: Barracuda
aluminized glass fabric reportedly
looks like moldable steel. It boasts the
look of metal with the functionality of
traditional high-performance fabrics.
Applications include sporting goods,
luggage, motorcycle helmets, kitchen
appliances, dashboards and more.
When combined with the proper resin,
products made with Barracuda emulate
the silver sheen of 3D steel, and beneath the
surface offers the same high-performance
characteristics of traditional fiberglass fabrics.
• Thermoplastic glass: PolyPreg is a woven
comingled glass/polypropylene fabric, available
in weights of 750 gsm and 1,500 gsm and
natural or black colors. It can be directly consolidated, with the addition of heat and minimal
pressure, into a high-strength composite part.
PolyPreg has high glass content, high impact
properties, unlimited shelf life, no emissions,
recyclability and is said to be easy to process.
BGF Industries, Booth ZB82
theCAMX.org
13
THE COMPOSITES AND ADVANCED MATERIALS EXPO
Product News at CAMX 2015
North Thin Ply Technology: Lightweight Prepreg Tapes
North Thin Ply Technology (NTPT, PenthalazCossonay, Switzerland) is featuring in its booth
its new 15-gsm UD Prepreg Tapes. NTPT notes
that while the standard for light prepreg is
around 100 gsm, NTPT made the world’s lightest
prepreg even thinner. The 15-gsm UD tape can
be used to create lightweight sandwich panels
for ultralight aircraft, unmanned aerial vehicles
(UAVs), aerospace applications and
rigid wings for racing yachts. When
weight saving and composite
quality are key, it allows for the
creation of symmetric laminates
with multiple fiber orientations.
NTPT representatives are also
available to discuss automation solutions for high-performance composite fabrication.
North Thin Ply Technology,
Booth ZB105
Thank You To Our Sponsors
Elite Sponsors
Premier Sponsors
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Supporter Sponsors
Contributor Sponsors
Luna Innovations:
Fiber-Optic Sensing
Luna Innovations (Roanoke, VA) is presenting
a paper at CAMX on Thursday, Oct. 29 at
8:00 a.m. titled, “In-Situ SHM of CompositeOverwrapped Pressure Vessels.”
The paper demonstrates how Luna’s
High-Definition Fiber Optic Sensing (HD-FOS)
system is used to monitor distributed strain
in composite-overwrapped pressure vessels
(COPVs) throughout the manufacturing process,
subsequent qualification testing and periodically throughout the service life of the
pressure vessel. Luna’s ODiSI product platform
uses HD-FOS technology to turn ordinary
unaltered single-mode fiber optic cable into
advanced strain or temperature sensors.
Fiber optic cables, when illuminated, have
the equivalent of an optical fingerprint, and
this fingerprint will change, in a predictable
and repeatable way, in response to changes
in strain and temperature. The fiber sensor,
when coupled with Luna’s advanced HD-FOS
technology, will replicate a virtually continuous line of strain gages or temperature
sensors with millimeter spacing between
sensing points. At 150 microns in diameter,
the fiber sensor also has the capability to be
embedded within structures under test.
For strain, this high-density sensing is
suitable for measuring the non-linearity and
high gradients associated with composite
structures, as well as for finite element analysis
model validation of designs with complex
geometries or using new advanced materials.
Luna Innovations, Booth F84
Jushi USA: Glass Roving
Jushi USA is introducing 362J, a direct glass
roving specially designed for the long fiber-reinforced thermoplastic and the continuous
fiber-reinforced thermoplastic processes
and compatible with modified polypropylene.
Jushi says 362J generates less fuzz and
exhibits better abrasion resistance than its
peers. The company also says it performs
well in the industry-standard high-speed and
high-tension process. Jushi notes that 362J
is compatible with polypropylene and polyethylene for good wet-out and dispersion.
Jushi USA, Booth X70
14
Wednesday, October 28, 2015
CAMX Booth S66
Make it Precision Board Plus
High Density
Polyurethane Tooling Board
and Core Material
• Custom tooling blocks
• Closed cell structure
• Custom carving blocks
• No out-gassing
• Custom mandrels
• 15 standard densities
• Exceeds aviation
flammability standards
• 8 sheet sizes up to 24” thick
(800) 845-0745
www.precisionboard.com
Visit us at
CAMX
Dallas Oct. 26-29
Booth #G57