SEPTEMBER/OCTOBER 2023 www.composites.media SUBCONTRACTING SOLUTIONS A FOUNDATION FOR SOLID GROWTH p53 DEDICATED TO THE WORLD OF COMPOSITE MATERIALS MANUFACTURING MEMBERSHIP DIRECTORY 2023/2024 Page 13 Trade Association Composites
New thinking on prepreg materials Doing things differently (+44) (0)1202 680022 | enquiries@prfcomposites.com | www.prfcomposites.com Contact our team for more information on our innovative prepreg systems today. Discuss your requirements with our team at the International Composites Summit, 6–7 September 2023, Milton Keynes eXpress cure New carbon prepreg material made with recycled chopped carbon mat Groundbreaking prepreg tooling technology Standard and fire-retardant snap cure systems Providing technical innovation, exceptional quality, lowering cost-per-part and offering improved sustainability. Kit cut to our customers’ requirements, with standard products available from stock.
The third International Composites Summit (ICS) has finally arrived. Taking place on September 6-7, at the Marshall Arena, Milton Keynes, ICS has become the premier platform for costeffective and sustainable composites business in the UK. The event brings together influential industry leaders and researchers, as well as forwardthinking innovators from across the composites sector. The forums will explore the latest themes and hot topics covering key sector challenges and opportunities. These include circularity, exploring strategic global opportunities, navigating the political landscape for manufacturing, and trade-focused panel comprising Q&A sessions with industry experts. It is often said that variety is the spice of life, and this sentiment can be applied to what many tradeshows and conferences spin us every year. Don’t get me wrong, it’s great to meet old faces, catch up, press the flesh and recount fond memories, but these events have a real responsibility to provide fresh opportunities to meet new and potentially lucrative customers – the kind that they wouldn’t normally expect to see at these events. Opportunities that can help initiate healthy synergies between different manufacturing sectors. And the ICS will arguably offer the best opportunity to discover more about someone - or something - you didn’t know existed. It is a chance to look over someone else’s shoulder and satisfy the remit of gathering an eclectic and diverse mix of the UK and international composites sector. Hopefully, ICS will deliver on its promise to exhibitors and visitors alike, allowing them to experience both new customers and new products. ICS co-director, Sue Halliwell reckons this year promises to be a transformative event for the industry that will inspire meaningful collaborations and solutions for a sustainable future. I wish joint organisers Composites UK and Fluency Business Group the very best of luck. An industry awaits! Mike Mike Richardson, Editor Contents... EDITORIAL Editor: Mike Richardson e: editorial@composites-manufacturing.com Deputy Editor: Ed Hill e: ehill@mitpublishing.co.uk Digital content coordinator: Michael Tyrrell e: mtyrrell@mitpublishing.co.uk SALES Business Development Manager: David McCauley T: +44 (0)7557 308369 e: dmc@composites-manufacturing.com Key Account: Andy Morley T: +44 (0)1634 830566 e: sales@composites-manufacturing.com PRODUCTION Production Coordinator: Ewa Hodden e: ehodden@mitpublishing.co.uk T: +44 (0)1634 825703 Art Editor: Sarah Blake e: sblake@mitpublishing.co.uk T: +44 (0)1233 770781 CIRCULATION AND SUBSCRIPTION Circulation: Perception SAS e: cim@mitpublishing.com T: +44 (0)1825 701520 Financial Controller: Valerie Prentice Publisher: Liam McCauley Director: David Rose Published by: MIT Publishing Ltd Featherstone House 375 High Street Rochester, Kent ME1 1DA T: +44 (0)1634 830566 F: +44 (0)1634 408488 www.composites.media Whilst every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they arise. Author’s opinions do not necessarily reflect those of the publisher. All rights reserved. No part of this publication may be reproduced or transmitted without the consent of the publisher. Copyright: MIT Publishing Ltd 2023 Printers: Pureprint Group Published four times a year, Composites in Manufacturing (CiM) is distributed free of charge to applicants in the UK who meet the publishers’ criteria. Annual Subscriptions are available at £60 for UK and £80 for overseas. An event to inspire 5 NEWS EVENTS 8 Uniting the composites community – International Composites Summit MATERIALS SPOTLIGHT 10 Collaboration driving innovation – Supplier roundup COMPOSITES UK MEMBERSHIP DIRECTORY 13 The ‘who’s who’ reference for the industry MATERIALS SPOTLIGHT 45 Kitting and beyond – Kitting PROCESS SPOTLIGHT 47 A cut above the rest – Flatbed cutting 48 Following the fibre – Filament winding SECTOR REPORT 51 Aligned and refined – Aerospace SUBCONTRACTING SOLUTIONS 53 COVER STORY A foundation for solid growth – Tooling & design NEXT ISSUE: Advanced Engineering show preview, Aerospace sector report, Materials: Finishing and Recycling, Processes: Flatbed cutting systems and Cutting tools, Subcontracting solutions THE INSIDE STORY www.composites.media | SEPTEMBER/OCTOBER 2023 | 3
Register today Discover the latest innovations in plastics manufacturing processes, technologies, materials and services • More than 500 exhibitors • CPD certified conference programme • Technical seminars • Enhanced networking opportunities • Dedicated zones and pavilions @InterplasUK #InterplasUK www.interplasuk.com 26-28 SEPTEMBER 2023 SCAN ME
Atlas Composite Technologies is set to create more than 100 jobs at a new facility on the back of a seven-figure investment. The company is expanding with a new 30,000ft2 building at Pride Park in Derby, opposite Derby County FC’s stadium. The site is due to be fully operational by September and will enable Atlas to ramp up production to meet growing demand for its composites. The facility will initially generate 30 jobs, rising to more than 100 over the next three years. Atlas manufactures complex composites for use in a range of sectors. It currently operates from three sites in Ilkeston, Derbyshire. Its growth strategy is being supported by the WeDo Business Services group, which made a seven-figure investment last year. Ben Swain, head of commercial at Atlas, said: “The new facility takes our total footprint in Derbyshire to more than 90,000ft2. It marks a significant milestone for our long-term growth strategy while also reinforcing our commitment to delivering high-quality products and services to our clients, and helping to drive economic growth in the region. “This expansion is testament to the hard work and dedication of our talented staff, whose expertise and commitment to excellence have been instrumental in our success. We are proud to invest in their skills and provide them with an even greater platform to showcase their abilities, while providing new highly-skilled jobs in the advanced manufacturing sector. The unwavering support and belief in the company’s vision shown by WeDo and Derby City Council have been pivotal in facilitating this expansion.” The company is recruiting for a range of roles at the new Derby site, including shopfloor manufacturing operatives and positions in its engineering, quality, stores and training teams. Interplas 2023 will take place at the NEC, Birmingham from 26-28 September 2023. Said to be the UK's definitive and leading plastics event, Interplas brings together the full range of technologies, materials and processes from across the plastics sector. Celebrating 75 years, the 2023 edition will see over 500 exhibitors present solutions, products, machines and ideas from across the entire spectrum of moulding and forming as well as materials, automation, contract manufacturing and supporting technologies including software, testing, inspection, surface treatments and much more. Over 12,000 attendees, predominantly from the UK manufacturing community will attend to discover solutions to their challenges, to make connections and source the latest technologies and innovations. Alongside the show floor a world class Interplas Insights conference programme will take place encompassing a wide range of current themes important to the plastics industry including sustainability, the circular economy, digitisation, skills, diversity, INTERPLAS ALL SET TO OPEN ITS DOORS www.interplasuk.com Atlas maps out job plan at new site NEWS www.composites.media | SEPTEMBER/OCTOBER 2023 | 5 recycling, materials development, technology advances, regulation and much more. Throughout the event, attendees will get the opportunity to meet with influential speakers in an initiate and collaborative setting. To enhance the on-site networking, the official event app will have the ability to offer personal recommendations using an AI powered matchmaking algorithm. In addition to this will be a dedicated networking area next to the conference theatre. These learning opportunities, alongside the matchmaking programme and networking opportunities, will ensure a visit to Interplas offers tangible value to an attendee immediately with intelligence and contacts that will continue to pay dividends long after the show closes. www.atlascomposites.com L-R: Dave Wakefield, head of quality; Jamie Johnson, head of engineering; Ian Tinkler, head of operations; Lloyd Pearson, managing director; Grace Atkinson, head of strategy; Ben Swain, head of commercial
Following a highly successful week at ITMA 2023 in Milan in June, the UK’s Optima 3D is delivering the special weaving technology it demonstrated to the US, for installation at the University of Maine’s Advanced Structures and Composites Center (ASCC). The 3D weaving system consists of an Optima 3D Series 600 shuttle weaving machine with an integrated 2,688-hook Stäubli SX jacquard and harness. It is also complemented by Optima’s compact warp delivery creel and an associated pirn winder for shuttle bobbins and a spool winder for creel spools. For safety reasons at ITMA 2023, the carbon fibre yarns that will be processed by ASCC on the Optima 3D Series 600 system had to be replaced with polyester, but it was notably the quietest technology in operation during the ear-shatteringly regular intervals of demonstrations held in the weaving halls by the key players in this field. Optima’s looms offer many advanced features over conventional weaving machines, particularly in terms of versatility, as a result of the comprehensive use of digital control systems allowing rapid parameter and sequence changes, coupled with an innovative shuttle system. “Our aim from the start was to look at 3D weaving machine technology with a fresh pair of eyes and produce a machine that is simply better by design and delivers real benefits to our customers,” said managing director, Steve Cooper. “The key interest in this technology has been in producing new structures from expensive fibres such as carbon into workable structures, as the essential reinforcements for composites.” UNIVERSITY BOOSTED BY NEW WEAVING TECHNOLOGY WALTON APPOINTED TO BELZONA BOARD Belzona Polymerics has announced the promotion of long-serving employee, Charli Walton to its board of directors. Walton, who in August 2022 was appointed corporate development director (China) onto the Board of Belzona Molecular Technology (Nanjing), is the first female member of the board. She has been with Belzona for twelve years, originally joining the marketing team in 2011. Walton will be responsible for creating and implementing marketing strategies to consolidate and accelerate Belzona’s growth plans in China. In addition, she will be providing the nexus between the Chinese company, Chinese distributors, and Belzona’s various international headquarters. Commenting on Walton’s appointment, Barry Nisill, Belzona’s CEO, said: “During Charli’s career with Belzona, she has developed an extensive knowledge which, teamed with her boundless enthusiasm, has seen her become an important member of the Belzona leadership team. On behalf of everyone at Belzona, I would like to congratulate Charli and wish her every success for the future.” www.Belzona.com 6 | SEPTEMBER/|OCTOBER 2023 | www.composites.media NEWS www.optima3d.co.uk Belzona Polymerics’ board of directors: (from left to right) Philip Robinson, Neil Robinson, Charli Walton, Jevon Pugh and Jeremie Maillard Fibre Extrusion Technology (FET) says it has completed a series of exhibitions around the globe, culminating in a successful ITMA 2023, which took place in Milan in June. “This was a very hectic period for FET, organising participation in three exhibitions in Europe and Asia over a period of less than four months,” commented FET’s managing director, Richard Slack. “However, this provides a great opportunity for smaller specialist companies like FET to raise our profile on the international stage, showing what we can offer, alongside major corporations. Being able to meet so many customers face-to-face, post pandemic also indicates a welcome return to normal business relationships.” Prior to this was INDEX 23 in April, the world’s leading nonwovens exhibition in Geneva. The exhibition season began earlier in the year with the ‘Green Textile and Innovation Technology Forum and Exhibition’ in Hong Kong, taking a small booth to support the event and FET’s official agent in the region, Chemtax. FET completes exhibitions sequence www.fetuk.com
www.composites.media | SEPTEMBER/OCTOBER 2023 | 7 Advanced Engineering UK is set to commence in just over three months’ time. Taking place on November 1-2, 2023, this two-day exhibition will see leading professionals come together to discuss and showcase innovative products from a variety of sectors. Taking place at the NEC, Birmingham, Advanced Engineering has embraced new sustainable initiatives to address the pressing environmental issues, including climate change, resource scarcity and waste generation. With a firm commitment to sustainability, the event aims to lead by example and inspire positive change across the engineering industry. At the event, attendees will have the opportunity to engage with experts in engineering and manufacturing through four dedicated forums and the Main Stage, which is new for 2023. These forums, namely aerospace, composites, automotive and the AMT Stage, will showcase the industry's leading voices who will engage in discussion around vital topics, such as supply chain management, innovation, digitalisation, sustainability and more. Exhibitors can learn about composites circularity, the future of composites, digitalisation being the key to productivity and more at the Composites Forum. Here, several speakers will be taking the stage from the following companies: AMRC, Creative Composites, NCC, Composites Leadership Forum, Composites UK, KTN, Plataine, Ford Motor Company, WMG, Composite Branding and ADS. “Exhibitors will enjoy a diverse range of content in the three open forums, along with the thrilling inclusion of the Main Stage that will cover various topical discussions across manufacturing and engineering,” explained Alison Willis, director of Easyfairs. “With an impressive display of cutting-edge technologies and a wide array of speakers, visitors can anticipate an immersive and dynamic experience that will both excite and stimulate their interests.” Rather than being divided into several zones as in previous years, engineering exhibitors will be categorised by the services, products and solutions to ensure more cross-industry collaboration. As a result, attendees can expect to find relevant contacts and set up meetings easily Using the Advanced Engineering show app. Speakers announced for Advanced Engineering UK www.advancedengineeringuk.com Base Materials has signed an agreement with B. Beyer to become its official distribution partner in Germany. With Germany’s composites market for epoxy materials predicted to record a CAGR of 6.12% between 2021 and 2026, Cologne-based B. Beyer’s remit includes the distribution of Base Materials’ epoxy range of tooling board materials and compatible ancillary products. B. Beyer will also help to facilitate growth in Germany’s polyurethane (PU) materials market, which is forecast to grow at 2.6% CAGR, via the distribution of Base Materials’ range of medium and abrasion-resistant, high-density PU materials with a focus on meeting demand across the automotive, aerospace, foundry, and thermoforming sectors. Commenting on the new distribution partnership, Kerry Lyons, head of international sales at Base Materials, said: “We are delighted to have B. Beyer as our lead distributor in Germany. This agreement will help us realise our ambitious growth plans to increase our footprint not just in Germany, but across wider Europe. Our strategic partnership provides the ideal platform to provide customers with locally available stock to reduce lead-times, countrybased knowledge, and feet-on-the-ground local support.” BASE ANNOUNCES NEW DISTRIBUTION DEAL www.base-materials.com
8 | SEPTEMBER/OCTOBER 2023 | www.composites.media EVENTS: INTERNATIONAL COMPOSITES SUMMIT o-organised by Composites UK and Fluency, the third International Composites Summit (ICS) is almost upon us. With two days packed with free-of-charge content that is not to be missed, the ICS promises to be a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business. The event, through its partner JEC, the leading organisation dedicated to promoting composite materials and fostering their applications globally, will provide a platform to showcase the huge trade potential for companies from across Europe and around the globe within the UK composites sector. This collaboration aims to facilitate international trade, foster innovation, and strengthen economic ties between the UK and global composites industries. The show organisers recently announced its upcoming informal networking dinner which will take place on the evening of day one of the exhibition, Wednesday, September 6th at the Double Tree Hilton Hotel, located adjacent to the Marshall Arena in Milton Keynes. In a nutshell, what is the International Composites Summit (ICS)? The International Composites Summit is the ultimate platform for conducting cost-effective and sustainable composites business in the UK. It brings together industry leaders, researchers, and innovators from the composites sector for networking, knowledge sharing, and showcasing the latest advancements in composite materials. What makes ICS so unique and who should attend? ICS is not just a national exhibition: it has an international flavour, making it the ideal place to connect and do business. It serves as the central hub for the UK composites industry, providing a platform to learn about the latest trends, innovations, and opportunities in the field. ICS showcases the entire UK composites supply chain, highlighting the edgy and new developments taking place. ICS is a must-attend event for international customers looking to connect with the UK composites supply chain. It is equally important for international suppliers seeking to engage with UK customers. Besides buying and selling, the summit encourages networking among professionals in the industry. What are the key themes for this year’s event? The key themes for ICS 2023 include innovation, decarbonisation and net zero initiatives, and circularity within the composites supply chain. The summit will focus on showcasing innovations in the technology showcase area, particularly Above ICS: bringing people together to do business In a Q&A session, The Fluency Business Group’s managing director, Gemma Hardy looks ahead to the upcoming International Composites Summit (ICS), held between 6-7 September at the Marshall Arena, Milton Keynes. C Below Gemma Hardy, managing director of The Fluency Business Group Uniting the composites community
www.internationalcompositessummit.com ICS is not just a national exhibition: it has an international flavour, making it the ideal place to connect and do business. Scan here for more ICS articles To register to receive regular FREE copies of Composites in Manufacturing magazine visit www.composites.media/subscribe To receive details of advertising opportunities in forthcoming features appearing in Composites in Manufacturing during 2023/2024 or to discuss online marketing options available on our website at www.composites.media contact David McCauley on +44 (0)7557 308369 or dmc@composites-manufacturing.com APRIL/MAY 2023 www.composites.media SUBCONTRACTING SOLUTIONS AIMING FOR AEROSPACE p12 DEDICATED TO THE WORLD OF COMPOSITE MATERIALS MANUFACTURING SHOW PREVIEW PAGE 33 j ¡ j ¡ SEPTEMBER / OCTOBER 2022 www.composites.media SECTOR REPORT: A NET-ZERO REALITY WITH COMPOSITES p42 DEDICATED TO THE WORLD OF COMPOSITE MATERIALS MANUFACTURING Composites UK Membership Directory issue NOVEMBER / DECEMBER 2022 www.composites.media ADVANCED ENGINEERING UK SHOW EDITION: AN ARRAY OF ENGINEERING INNOVATIONS p34 DEDICATED TO THE WORLD OF COMPOSITE MATERIALS MANUFACTURING CiM Subscriptions Half 1122.qxp_Layout 1 16/08/2023 17:57 Page 1 those at the Technology Readiness Levels 7-9 - technologies on the verge of commercialisation. It will also highlight efforts toward decarbonisation and the demonstration of circularity through a case study in the supply chain. How is the international presence being expanded at ICS? ICS is actively working on expanding its international presence. The summit will feature renowned international content and speakers, including representatives from ADS, Make UK, McLaren Racing, GKN, and Princess Yachts. Additionally, international trade associations will have the opportunity to showcase their country's composites industry through a group of pods. In collaboration with the UK Department for Business and Trade, efforts are underway to attract trade missions in the future. How are end-user sectors being involved at ICS? End-user sectors play a crucial role in driving footfall and engagement at ICS. To attract customers from various industries, ICS is collaborating with trade bodies such as ADS (aerospace), SMMT (automotive), RenewableUK (energy), IStructE (construction), Institute of Sport (leisure), British Marine (marine), RIA (rail infrastructure and transport). The inclusion of end-user sector events and forums further enhances industry-specific discussions and engagement. How are business meetings facilitated at ICS? ICS partner, JEC, will bring business meetings focused on specific end sectors to the show floor. The objective is to bring customers from priority sectors to the show and to enable cross-sector business and learning. ICS will be working with JEC to build on the business meeting platform to enable growth of future editions of the show. Finally, how will the ICS Networking Dinner support the event? The ICS Networking Dinner serves as a vital component of the event, emphasising the importance of networking in a more informal and social setting. It provides attendees with a valuable opportunity to connect with peers, establish new relationships, and foster collaborations. The enormous success of last year’s event in London demonstrates the continuous need and desires for an exclusive UK-based composites industry convention. Therefore, we have created an even bigger ICS in Milton Keynes this year. We cannot thank everyone enough for the efforts that have been made with making ICS a dream come true for the UK composites sector. We look forward to seeing everyone this September!
10 | SEPTEMBER/OCTOBER 2023 | www.composites.media MATERIALS SPOTLIGHT: MATERIALS SUPPLY RF Composite Materials celebrated its 40th anniversary last year by launching both its Q.tool prepreg tooling technology and RP570 FR eXpress cure, its snap cure, fire-retardant prepreg system which is qualified for aircraft interiors. This year, the company has unveiled its recycled carbon prepreg material, REEPREG. Dave Ellson took over the reins of managing director from managing director and founder, Robert Burnell in 2022, with Burnell moving to the role of company CEO. PRF’s R&D is driven by developing materials that help its customers achieve better quality and significant advantages in cost and time. The company is also looking at how its products can offer improved sustainability. Whilst it recognises the potential that biomaterials have, PRF believes it can do more by finding ways to lower the impact of traditional composite materials and improve their sustainability, whilst retaining their superior composite properties. PRF’s recycled carbon prepreg material, REEPREG has come out of this driving force. What kinds of demands and challenges are placed on you by your customers? As always, processing time, cost and technical requirements are a significant driver of our product development. Constructors need materials that take less time to layup, less time to process and the development of our new materials have been driven by this – decreasing time/labour requirements to allow our customers to lower their cost-per-part. Increasingly, we are seeing the drive for sustainability in the market. Last year, it seemed that this drive was less focused – our customers knew that they needed more sustainable materials, but they weren’t sure what this looked like. Now, specifically with Q.tool, REEPREG and our eXpress cure products, we are seeing the market move towards improved sustainability; maintaining the use of traditional materials for their technical superiority, but focusing on ways that the industry can lower energy consumption, remove waste – particularly plastic and even composite waste for landfill - and improve life cycles and circularity. This has been our focus for some time now, and we are just beginning to be able to quantify the energy savings gained from using our materials. Please provide any typical examples where your products set you apart from similar competitor offerings? Above PRF Composite Materials: doing things differently PRF Composite Materials’ managing director, Dave Ellson explains how the company’s ongoing facility expansion and product development projects all help to ensure the company continues an upward trajectory. P Collaboration driving innovation
www.composites.media | SEPTEMBER/OCTOBER 2023 | 11 We believe that our latest products – REEPREG, Q.tool and our eXpress cure systems RP570 and RP570 FR are market-leading. I would also add that we are highly experienced in visual quality prepreg, and our kitting service is of the highest quality. We can provide materials cut to our customers’ exact requirements and we can keep kits on stock to be called off as ordered, also helping reduce our customers’ waste. How much customer hand-holding is required in your product sales process? Since our beginnings, we have found the best way to develop new products has been taking a problem that a customer is facing, looking at it from all angles, and ‘doing things differently’. This means developing a solution that doesn’t simply copy what is out there, but rethinks the conventional in order to improve the outcome. Is there a lack of empiric data for companies like PRF to dip into, in the same way that traditional metallics testing companies can access data? We are fully-equipped to test our prepregs, and have support for industry testing standards including fireretardancy standards. We are now looking for solutions to measure environmental impact, such as energy consumed in processing for instance. Is there a concern that less welldeveloped countries can push unqualified, or at least ‘unknown origin’ materials into the supply chain? The aerospace industry has major concerns about counterfeit goods ending up in the supply chain, and whilst that is more akin to parts, the same could occur with resin raw materials - as its relatively easy to synthesise resin raw materials to copy but maybe without the same levels of control required. However, with our trusted supplier relationships, this isn’t something that we are overly concerned with in our operations. Which industries are you seeing the most take-up for your products and services? We are active across a diverse range of industries, including motorsport and automotive, aerospace, marine, medical, renewables, etc. It’s a real strength of ours that we don’t focus in one area. It allows us to have a significant breadth of experience to offer different customers new products, opportunities and perspectives. Are you membered into any industry organisations and are they any good? We are members of Composites UK and the Composites UK Sustainability subgroup. We are working more closely with Composites UK this year. Our marketing director, Hannah Khusainova is on the Advisory Council of the International Composites Summit, organised by Fluency and Composites UK, and we were recently involved in the Tooling for Composites Showcase where we were able to present Q.tool. Price and on-time delivery are givens, but what else do you see as important to serving your customers these days? We find that the best results often come when we are working in partnership with our customers to find a solution that suits their skillsets, processing requirements, technical requirements and costs. As mentioned, an increasing need to provide improved sustainability - in not only our materials but also our manufacturing - is becoming a growing factor. We also look at our customer service from every angle to see where we can provide better solutions for our customers. We have recently implemented our new ‘Fast to Freeze’ manufacturing protocol, which we developed to minimise the time our prepreg tiles are at room temperature in our facilities. We heard from the industry that constructors were experiencing compromised out-life when rolls were cut into tiles, with the cutting process losing up to one day of out-life. We can now manufacture prepreg, cut and freeze tiles typically within one hour – significantly preserving the out-life for our customers. We have also made a significant effort to minimise plastic consumables in our processing. We are now saving over 50% of the plastic consumables we would have previously used in manufacturing, and 99% of our consumable plastics are now recyclable. We are looking at ways to minimise cardboard usage and waste, using a new and reusable wooden crating system with our customers calling prepreg materials off stock. Lastly, I think there is much to be said about trust and integrity. We hold integrity highly as a core value of our business and I would like to think that we are known in the industry for this. What do you feel are the most important assets of a company? In a technological industry, technology is obviously important but when we are Below Dave Ellson, managing director of PRF Composite Materials Above Ellson: “We will continue to invest in innovative product development.” Scan here for more PRF articles
12 | SEPTEMBER/OCTOBER 2023 | www.composites.media MATERIALS SPOTLIGHT: MATERIALS SUPPLY developing technology, without delivering and servicing that technology, there is little value for the customer. As a customer-focused company, PRF listens to the needs of our customers, beyond just technology. That requires developing relationships and building trust; trust that the customer can give us the information required, without risk of compromising IP, and trust that PRF will deliver in all aspects required. What differentiates your company from the competition? We developed the phrase ‘Doing things differently’ to encapsulate our approach, particularly to working with our customer and our product development. We look at the problem and what is available on the market, and the outcomes we are aiming to achieve with a new product, and then we set about product development. This is based on creating a new product that achieves the outcomes we set in place – which are set by the market need – rather than imitating and simply bettering what is already available on the market. Is there a particular success story you can shout about involving a satisfied customer? We have worked with many customers over the years, the majority of which we must maintain confidential. However, one customer had a requirement for high volume production using a carbon prepreg that needed to meet the rigorous FST requirements of the aerospace sector. As such, we developed a fire-retardant version of our RP570 to deliver a material that enabled them to achieve the necessary production rate, alongside their quality and technical requirements. We have also recently worked with Piran Advanced Composites – a company that has selected our Q.tool for a large scale tooling project that they are working on for a major aerospace application. Q.tool has been important to this project in speeding up their tool construction, and they have achieved great results with this new tooling technology. Finally, where to next for your company? We will continue to invest in innovative product development, providing materials to the market that bring value to our customers, with a focus on improved sustainability – with real impact – and cost reduction. We will continue to invest and expand the business to ensure that we are ready to meet the next challenges that the industry will face as composites develop into new areas of application. We have and always will work closely with our customers and value good relationships with our suppliers that are built on honesty and integrity. www.prfcomposites.com Above PRF’s recycled carbon prepreg material, REEPREG Below PRF’s Q.tool epoxy prepreg tooling technology
2023/24 Member listings correct up to 2nd August 2023 Photos courtesy (clockwise): Airborne, Compotech Plus, Toray Advanced Composites, ATS, Rockwood Composites, Hypetex Published by Lead Press Partner Trade Association Composites MANUFACTURERS MATERIAL SUPPLIERS EQUIPMENT SUPPLIERS SERVICE PROVIDERS CONSULTANTS ACADEMIA ENGINEERS SOFTWARE PROVIDERS DESIGNERS TRAINERS CLIENTS Membership Directory
Welcome to the latest Composites UK Membership Directory, kindly produced by our lead press partners, Composites in Manufacturing magazine. 2023 has been a very busy and successful year for Composites UK, delivering the key stages in the Association’s strategy. Through 2022 and into 2023, sustainability has become more prominent, cross cutting all our strategic activities. As such, we have updated the website and developed new support services for our members to help them address the twin challenges of net-zero and circularity which are both critical for the industry. We have navigated our way through the green maze to calculate the carbon footprint of our organisation and will be using this experience to help member companies tackle theirs. Once fully analysed, we will be setting ourselves reduction targets and looking at calculating the carbon footprint of our individual events. Composites UK is project managing Project PRoGReSS, a £2 million, three-year scheme, that is partfunded by Innovate UK and leading industry partner Aker Offshore Wind, which seeks to deliver a circular model for wind turbine blades to support the UK’s ambitious climate change targets. The project, which started in 2022, will benefit the wider UK economy, create green jobs and move towards circularity solutions for the GRP sector. Because of the Association’s sustainability focussed work, many of its events focus on this topic. RECOMP, the biggest conference on this topic in Europe, returns for a one-day review of progress on 23 November and 11-12 October we travel to NIACE in Northern Ireland for our Bio-based materials conference. There is a strong sustainability theme running through the forum programme at the International Composites Summit (ICS), 6-7 September, in Milton Keynes. ICS moves this year to the larger purpose-built Marshall Arena enabling the event to strengthen its approach. The JEC Business Meeting Programme will be running across the 2 days, linking UK and International buyers and suppliers. With more space, we’ve been able to secure some amazing showfloor exhibits and demonstrators including the KS Composites simulator, ThrustWSH, rail platform section and many more. UK and International speakers from key end sectors will inform visitors on circularity activities, strategic global opportunities, navigating the political landscape for manufacturing, material and manufacturing innovation, as well as a critical panel session on overcoming trade barriers. There’s also plenty of other events in the pipeline, including our joint event on thermoplastic composites with the British Plastics Federation (4 October) and our prestigious black-tie Awards Dinner (1 November), celebrating the successes of the UK composites industry. The dinner falls on the middle evening of the Advanced Engineering Show where we will once again be hosting a Composites UK Pavilion, offering companies the opportunity to enhance their presence but minimise risk at the show through a turnkey solution allowing companies to book a pod, turn up and ‘go’. Composites UK was proud to have organised the UK Pavilion at JEC World 2023. The 170m2 stand, larger than in 2022, housed 30 SMEs and supporting partners, Welsh Government and the National Composites Centre. The Composites UK pavilion will return in 2024 and we are already taking bookings for this. The Association will release the 2023 report at ICS where updates on the UK composites sector will be presented by our CEO, David Bailey. The Association estimates that in 2021 the UK composites sector was worth £10.72 billion and employed around 47,500 people so it will be interesting to see if there are significant changes for 2022. Produced from the data within the Hub – Composites UK’s composites capabilities database – this annual report is invaluable for business forecasting and is free to members. Trading conditions following the materials crisis and EU-Exit continue to be an obstacle for the industry. Composites UK has published regular updates on the materials situation outlining supply and pricing issues so the industry can plan accordingly, although that has started to ease during 2023. Complementing this is the work the Association is doing around UK REACH regulations, not to mention the support given to members with trade challenges following the EU-Exit, including trade remedy review investigations. We will have some new support material for members on skills and workforce development coming out later in the year to help them tackle the growing skills issue. Working alongside the HSE, as well as member companies, Composites UK continues to raise awareness of resources and support available on health and safety topics but particularly around mental health. The Association continues to provide support to the newly restructured Composites Leadership Forum which drives the strategic direction of the sector and facilitates the development of programmes to find solutions to critical industry challenges. The above is in addition to the day-to-day support provided by a small team of nine, dedicated to providing ongoing commitment to support the UK composites industry. Alan Banks, Chair, Composites UK n COMPOSITES UK CHAIR’S REPORT 2 | Composites UK Membership Directory 2023/2024 For more information, go to www.compositesuk.co.uk The year in focus Alan Banks, Chair, Composites UK
PRF COMPOSITE MATERIALS n PRF Composite Materials is a leading manufacturer and supplier of high-performance materials for the advanced composites industry, including aerospace, motorsport, renewables, defence, sports & leisure, medical and marine industries. We are known for our class-leading, innovative prepreg materials. Our product development is driven by helping our customers achieve superior results, and we are now looking at how our materials can also provide improved sustainability. Whilst we recognise the potential of biomaterials, we believe that we can make significant advances now by improving the circularity and reducing the impact of traditional composite materials; making them more sustainable whilst retaining their superior properties. From this commitment, we have developed REEPREG, our carbon prepreg made with recycled chopped carbon mat. REEPREG is drapeable and easily handled by the constructor, without falling apart when used – which we believe sets it apart from other recycled mat products available. The mat is made using recycled carbon prepreg waste, reducing landfill from kitting and trimming. We are also looking at lowering energy consumption per part, with Q.tool and our eXpress cure prepreg systems. UK Patent Pending, Q.tool is groundbreaking prepreg tooling technology which significantly reduces the time and costs of carbon tool manufacture, with its uniquely designed surface and 1020g/m2 bulk plies. This combination provides the same weight and thickness as the 1:8:1 system, and significantly reduces the number of debulks to as few as one. Q.tool offers the constructor: up to 50% reduction in labour time/cost, improved sustainability by reducing energy consumption and plastic consumables, and provides exceptional drapeability and surface finish. Our class-leading eXpress cure prepreg systems also provide opportunities to improve sustainability. Our RP570 eXpress cure is a snap cure system that has a complete processing time of 4 minutes at 140ºC; our RP570 FR is our fire-retardant version which cures in 5 minutes at 160ºC. With both systems, there is no need to cycle the mould tool, or cool the tool before demoulding. For customers using autoclave, we have also seen significant energy savings with these systems; RP570 FR typically takes 50% less time to process in autoclave than similar materials. Developed to minimise the time our prepreg tiles are at room temperature in our facilities, we have also introduced our new Fast to Freeze process. We can now manufacture, cut and freeze our prepreg typically within 1 hour – significantly preserving the out life for our customers. We are also saving over 50% of the plastic consumables that would have been used operationally and are eliminating single use plastics – up to 99% of consumable plastics used in our manufacturing are now recyclable. In packaging, we have a new crating system for deliveries; using reusable wooden crates to ship our prepreg and avoiding significant amounts of cardboard waste. With our wider range of advanced materials, we provide solutions for manufacturers using hand layup and infusion processing, including reinforcements, epoxy resin systems, mould release and cutting tools. Doing things differently, PRF is passionate about quality and innovation, and is committed to providing a professional and responsive service with technical support. Our focus going forward is to continue to help our customers improve quality, reduce manufacturing time, and achieve benefits in efficiency, cost-effectiveness and sustainability. n For more information, go to www.compositesuk.co.uk Composites UK Membership Directory 2023/2024 | 3 PRF Composite Materials 3 Upton Road, Poole, Dorset BH17 7AA Hannah Khusainova Marketing Director T: +44 (0) 1202 680022 E: enquiries@prfcomposites.com W: www.prfcomposites.com
A n MIRKA 4 | Composites UK Membership Directory 2023/2024 Mirka (UK) Ltd Saxon House, Shirwell Crescent, Furzton Lake, Milton Keynes, MK4 1GA T: +44 (0) 1908 866100 E: marketing.uk@mirka.com W: www.mirka.co.uk Mirka’s innovative Galaxy abrasive combines effectiveness with long life, thanks to a new self-sharpening ceramic grain, a clog resistant coating and the new Multifit™ hole configuration. For further information or to arrange a demonstration, please contact Customer Services on 01908 866100. Self-Sharpening Grain Technology Mirka® Galaxy See it in action at www.mirka.co.uk Mirka is a leading manufacturer of abrasives, tools and polishing solutions that are suitable for use across multiple applications and sectors. As job requirements continue to evolve with advances in technology, Mirka is in constant communication with its customers to gain valuable insights into the challenges and opportunities within their industries. This information is then circulated to the R&D team, who use it to design innovative and versatile products that meet the requirements of the user and assist in increasing productivity and efficiency, providing a dustfree work environment and maximising profitability. As part of Mirka’s continued commitment to help the industries it targets grow and develop, it has invested significantly in training programmes, which are available both on site and at its state-of-the-art national training centre in Milton Keynes. This investment enables Mirka to provide its customers with expert training and development around the high-quality abrasive, tooling and polishing solutions available in its product portfolio, so they can increase their knowledge and skills, improve their work flow and expand the services they can offer their customer base. n
Shimadzu has released the AGX-V2 series of AUTOGRAPH precision universal testing machines (UTM). The new AGX-V2 series expands on the existing AGX-V series – two table-top types and four floor types – with new wide-frame models, reinforced yoke models and separate controller models. AGX-V2 means that AUTOGRAPH can now provide a dedicated solution for almost every application and material. In combination with the latest version of TRAPEZIUMX-V software, the AGX-V2 series is ideally suited for testing both regular materials as well as for those requiring large test forces, such as metals and carbon-fiber-reinforced plastics (CFRP). In addition to including the many valuable features of the AGX-V series, the AGX-V2 series also offers improvement in operability. This is accomplished through an optional operation controller, which delivers fast results and analyses directly to the machine without the need for an additional computer. It also includes a voice operation mode that increases operational speed when multiple simultaneous actions are required.n https://www.shimadzu.co.uk/agx-v SHIMADZU UK LTD n www.shimadzu.co.uk/usf-2000 1010 cycles in 6 days Very high cycle fatigue testing system Detects and monitors fatigue mechanisms, micro-defects and inclusions Suitable for long-life evaluation of materials Possible to generate high stress, e.g. for steels having tensile strength of 1,000 MPa or higher No oil or cooling Shimadzu UK LTD Mill Court, Featherstone Road, Wolverton Mill South, Milton Keynes, Buckinghamshire, MK12 5RE T: 01908 552 209 E: info@shimadzu.co.uk W: www.shimadzu.co.uk
Zünd is a leading manufacturer of multifunctional digital cutting systems. Our success stems from our leadership in innovation, superior technology, modular design, and a dedicated focus on customer needs. We have over 35 years’ experience supplying the aerospace, motorsport, renewable energy, defence, sports & leisure, medical and marine industries. Our cutting systems are highly sought-after solutions for processing a wide variety of materials. Many OEM manufacturers have made Zünd their single ply cutting equipment of choice. Zünd cutting systems are based on a modular design concept that is unique in the market, flexible and easily expandable. Each Zünd cutter is hand-built to the customer’s specific requirements and guaranteed to be futureproof. Our digital cutters include a comprehensive selection of tools and modules for composite applications. Our tools are designed to process carbon fibre, structural foam, honeycomb, prepreg, aramid fibre and glass fibre. We also offer a range of innovative accessories such as material registration, contactless part-marking and projection for part identification and picking. Every Zünd cutting system is equipped with our proprietary software - Zünd Cut Centre (ZCC). ZCC software facilitates every aspect of the production workflow – from file import and production planning, to cutting data optimisation, cutting system management and remote production monitoring. ZCC also offers a nesting functionality that automatically nest a set of parts during data import. Visit our state-of-the-art demonstration centre in St Albans, Hertfordshire to gain first-hand experience of the benefits of the latest in Zünd Technology. You can also bring your own material and cut files for testing. Virtual product demonstrations are also available upon request. n ZUND UK LTD Unit 1 Spring Valley Business Centre Porters Wood, St. Albans Hertfordshire, AL3 6PD T: +44 (0)172 783 3003 E: infouk@zund.com W: www.zund.com n ZUND UK LTD Carbon 昀bre Structural foam Honeycomb Prepreg Aramid 昀bre Glass 昀bre Zünd can offer you a modular, 昀exible, cost-effective and expandable cutting system for processing various materials with impeccable precision. For more information please e-mail infouk@zund.com or call +44 (0) 172 783 3003 Cutting technology for maximum performance
OB2B Industrial Marketing & PR specialises in promoting metals, polymers, composites, engineering plastics and structural adhesives, from base materials, additives, compounds and reinforcements to extruded, moulded and machined fabricated products. Established in 2009, OB2B now has a global customer base of multinationals and SMEs across the manufacturing supply chain, providing cost effective technically based, B2B industrial marketing and press release (PR) support which helps companies secure new business and grow sales faster. The founder, Nigel O’Dea, has over 28 years of blue chip multinational business experience in senior commercial roles, along with a CiM Marketing diploma and a BSc. (Hons) degree in Materials Science. This background enables him to quickly understand the technical and commercial aspects of a client’s products, from raw materials and processing to finished parts, and then produce engaging marketing content, PR and promotional tools. OB2B Industrial Marketing & PR is a long standing Composites UK member. n OB2B Industrial Marketing & PR 4, Hobbs Hill, Rothwell, Northamptonshire, NN14 6YG T: +44 (0) 1536 210133 E: info@ob2bindustrialmarketing.com W: www.ob2bindustrialmarketing.com OB2B INDUSTRIAL MARKETING & PR n www.ob2bindustrialmarke琀ng.com All the benefits of a big marketing team, but only when you need it. Cost Effective Marketing and Publicity that Delivers Results Find out how we can support your sales team and add value to your business Call: +44 (0)1536 210133 Email: info@ob2bindustrialmarketing.com Marketing & PR Specialists for Composites & Engineering Materials Nigel O’Dea, BSc (Hons), Founder & Director, OB2B Industrial Marketing & PR DOPAG is one of the world’s most experienced manufacturers of high-quality metering technology. Wherever adhesives, resins, silicones or lubricants are metered and applied in industrial production, we offer reliable, precise solutions. We provide systems and components for highly automated production processes, including for the automotive, wind, household appliances and electrical industries, as well as for aviation and space travel. The high quality standards of DOPAG products guarantee maximum precision and repeatability of the results. DOPAG systems achieve all requirements for a precise mixing, metering and application of material, always aligned to the individual requirements of our customers. DOPAG is a member of the HILGER & KERN GROUP that has been a reliable supplier as well as an experienced development and service partner for industrial enterprises across various market segments for more than 90 years. The company employs about 350 people and is represented in more than 40 countries via subsidiaries and distributors. n DOPAG (UK) Ltd. Ryelands Business Centre, Ryelands Lane Elmley Lovett, Droitwich WR9 0PT Contact: Darren Holyhead, General Manager T: 07815 887689 E: dholyhead@dopag.co.uk W: www.dopag.com DOPAG (UK) Ltd. n Individually configured systems for bonding, sealing, greasing, potting and gasketing • All applications from one provider • For processing one- and multi-component materials: lubricants, adhesives, sealants, potting compounds • Implementation of specific requirements and automation • A dedicated technical centre for testing and customer training • Close collaboration with material manufacturers Contact and more information: www.dopag.co.uk uksales@dopag.com YOUR PARTNER FOR METERING AND MIXING TECHNOLOGY
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