FEBRUARY/MARCH 2024 www.composites.media THE COMPOSITES VALUE CHAIN UNITES SHOW PREVIEW P30 DEDICATED TO THE WORLD OF COMPOSITE MATERIALS MANUFACTURING
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 JEC World 2024, 5–7 March, Paris-Nord Villepinte, Stand 5E57 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.
Welcome to the JEC World show edition of Composites in Manufacturing magazine. Held at Paris-Nord Villepinte Exhibition Centre on 5-7 March, read all about it in our exclusive show preview starting on page 30. JEC World continues to build on its standing as the major international meeting place for composite manufacturing-related companies. Increasingly more manufacturing industry supply chains want a piece of the global composites manufacturing action, and why not? Hardly a JEC event passes by without a new, productionised lightweight composite innovation replacing its heavier traditional metallic component counterpart. This month’s issue features a heavy manufacturing bias as we hear from CNC machine tool specialists, Biesse, Breton, CMS and Thermwood. Whether it’s milling, drilling, near-net shaping, additive manufacturing or patternmaking, these guys have got it covered. Our show issue also features two companies celebrating anniversaries in the composites sector. DK Holdings will be at JEC World raising a toast in celebration of its 65 years of precision diamond tooling manufacturing, whilst CODEM Composites discusses its 15th anniversary celebrations and the rebranding it will be using to support this exciting milestone. Elsewhere in this issue, I catch up with the Leicestershire-based Patterns & Moulds to hear more about the progress the company is making in getting its new Breton Raptor 5-axis CNC machining centre up and running. Finally, there’s exciting news from The University of Sheffield AMRC Training Centre who recently announced it will become the first training provider in South Yorkshire to deliver a new composites apprenticeship. Personally, I would love to get some practical, hands-on composites training as it would help grow my knowledge of the processes used in this ever-evolving industry. Enjoy reading our action-packed JEC World show edition, and I look forward to meeting you in Paris. 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 2024 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. JEC: it’s the place to be! 4 NEWS SECTOR REPORT 10 Mann and the machine – Transport MATERIALS SPOTLIGHT 11 Stop and reflect – Opinion 12 Axes of power – Pattern & mould SUBCONTRACTING SOLUTIONS 14 On a journey to realisation – CODEM Composites PROCESS SPOTLIGHT 17 Going large with print innovation – Additive manufacturing 20 Progressions of power – CNC machining centres 22 Making the impossible possible – CNC machining centres 23 Excelling in pultrusion – Pultrusion 24 All in it together – Cutting tools 26 Testing times ahead for CMCs – Test & measurement 28 Mastering production planning optimisation – Digital manufacturing EVENTS 30 COVER STORY The composites value chain unites – JEC World preview COMPOSITES UK REPORT 38 Review of 2023 strategic activities – Composites UK NEXT ISSUE: Events: Farnborough Airshow, Aerospace sector report, Materials: Kitting and Test & measurement, Processes: Flatbed cutting systems and Cutting tools, Subcontracting solutions THE INSIDE STORY www.composites.media | FEBRUARY/MARCH 2024 | 3
Annually, the JEC Composites Innovation Awards recognise successful initiatives and collaborative efforts within the composites industry. Criteria for the awards include partner involvement in the value chain, project complexity, and commercial potential. After pre-selection of the 33 finalists, one winner has been named in each of the 11 categories by an international jury representing the entire composites value chain: Hüseyin Ates, CTO & Compounding BU Leader, Kordsa; Alan Banks, Innovation & Industrial Engagement Supervisor, Ford Motor Company, Christophe Binetruy, Professor, Centrale Nantes/Nantes Université; Tamara Blanco, Composite Materials & Processes Engineer & Expert, Airbus; Dale Brosius, Executive VP/Chief Commercialisation Officer, IACMI – The Composite Institute; Michel Cognet, Chairman of the Board, JEC; Karl-Heinz Füller, Manager Future Exterior and Materials, Mercedes-Benz; Sung Ha, Professor, Hanyang University; Guy Larnac, Technical Domain Coordinator for Materials, Structures and Industrialisation JTFR, Ariane Group; Véronique Michaud, Head of Laboratory for Processing of Advanced Composites (LPAC), EPFL; Kiyoshi Uzawa, Professor/Director, Innovative Composite Centre, Kanazawa Institute of Technology. The awards ceremony took place in Paris on February 8th, 2024. www.jeccomposites.com JEC reveals Innovation Award winners ICS RELEASE POST2023 SHOW REPORT According to show organisers Composites UK and The Fluency Business Group, The International Composites Summit (ICS), held last September was the best-attended show in its three-year history. Visitor numbers doubled from the previous year as the show settled in to its new home of the Marshall Arena in Milton Keynes. The additional floorspace capacity allows ICS to expand further in the coming years as the only UK show solely dedicated to composite materials. ICS is the single place to do the most cost-effective and sustainable composites business in the UK, bringing together industry leaders, researchers and innovators from across the composites sector. It is a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business. A larger venue meant more exciting features could be included, such as show floor displays like the Venom F5 Roadster from KS Composites, the Thrust Speedboat from PRF Composites and car sub-frames from Ford Motor Company. Exhibitors could bring large machinery and hold demonstrations on their stands, showcasing innovations in manufacturing. JEC Group brought its Business Meeting expertise where attendees could make new connections, and 225 people attended the very first ICS networking dinner. ICS returns on the 4-5 September 2024, again at Marshall Arena, Milton Keynes. Key themes will include innovation, sustainability and digitalisation, an improved layout, a larger networking area, an increased international presence and the co-location of the Fibre-Polymer Composites in Construction conference. www.internationalcompositessummit.com Toray Advanced Composites has launched a Life Cycle Assessment (LCA) programme for its Toray Cetex range of thermoplastic composite materials. The LCA will initially focus on Toray Cetex thermoplastic composite materials manufactured at its site in Nijverdal, The Netherlands, with plans to broaden the programme to include US facilities and their thermoset composite materials. The assessments are being conducted by an independent third party in accordance with ISO14040 and ISO14044. They will provide customers with reliable emission data on Toray’s composite material to help them evaluate their footprints during the product lifecycle. “Toray Cetex has been used within aerospace for lightweighting to lower fuel consumption and CO2 emissions for over 30 years,” stated Marc Huisman, director Research and Development. “We are committed to the ongoing reduction of CO2 emissions across the whole of the product lifecycle, and along with optimising our own processes, are excited to support the industry with relevant, accurate data to help determine the whole emission process in composite part adoption.” TORAY LAUNCHES CETEX RANGE LCA PROGRAMME www.toraytac.com 4 | FEBRUARY/MARCH 2024 | www.composites.media NEWS
Incredible offers Ready to go materials! Cristex are constantly looking for new ways to supply the market with premium materials, and thus have launched Ready To Go Materials. - Easy to purchase - Easy delivery - Dual payment options* - Quality materials - Easy to view - Huge price reductions - Reliable Benefi ts * Further reductions for credit card payments To find out more Email - readytogo@cristex.co.uk Phone - 01282770666 Products If you are interested in seeing the excellent surface finish, parallelism, and perpendicularity delivered by our saws and routers, simply complete the 'JEC Live Demo Booking Form' on our website, scan the QR Code, or contact us directly using the info below. Don’t miss the chance to witness a selection of composite materials and test coupons being cut or machined on the COMPCUT stand (6R89). Book a personal demonstration slot at the show: Join the composite cutting revolution If you're attending JEC World in Paris this year… HALL 6 STAND R89
Zünd has acquired its long-standing sales partner BG Soluções Tecnológicas, which is based in Porto Alegre, Brazil. BG Soluções Tecnológicas is now a wholly-owned subsidiary of Zünd Systemtechnik and will operate under the name Zund Brasil. Zund Brasil is relocating its headquarters from Porto Alegre to São Paulo. A dedicated showroom will allow customers and interested parties to experience first-hand the many possibilities of Zünd’s digital cutting technology. The 10 employees are proven experts in consulting, training, installation, and service. “We are very pleased to welcome Zund Brasil to our global group of companies,” stated Oliver Zünd, CEO of Zünd Systemtechnik. “Working closely with our new subsidiary will allow us to further strengthen our business in Brazil and expand our customer base. The resources at our disposal and our new subsidiary’s extensive experience will allow us to grow further and continue optimizing our customer support.” ZÜND ESTABLISHES NEW BRAZIL SUBSIDIARY KORDSA MAKES BPREG INVESTMENT Kordsa has successfully concluded a significant investment aimed at further enhancing its expertise in composite technologies. The company has invested in BPREG, a Turkey-based sustainable advanced materials company, specialising in natural fibre-reinforced industrial bio-composites and providing eco-friendly alternatives to synthetic composites. Kordsa’s investment in BPREG will not only contribute to the company's growth but also open up opportunities to share knowledge and technology expertise both domestically and internationally. Kordsa production facilities, capable of hosting BPREG's mass production processes, will enable the global offering of BPREG's product portfolio to Kordsa's customers in various parts of the world. Remarking that with the BPREG investment, the company will be adding yet another dimension to its expertise in composite technologies, Kordsa CEO, İbrahim Özgür Yıldırım stated: “BPREG’s aim to be part of the green transformation of major production industries with natural fibre-reinforced advanced composites, aligns perfectly with Kordsa's approach. We are delighted to be a part of BPREG's global growth story and we share their commitment towards a sustainable future.” NEWS Tool-Temp ensures that your processing facilities are kept at the ideal temperature – o ering over 60 standard models and enough individual solutions to satisfy any special requirements you may have. Main features of our new MATIC temperature control units Simple operation Modular Control that is easily expandable Preset actions and easily configurable recipes Anticipatory behavior & predictive maintenance Connectivity Energy e icient control Please contact us on 01933 442 623 or info@tool-temp.net to speak with a member of the Team. 01933 442 623 www.tool-temp.net Swiss Made Experienced in delivering the pe ect temperature www.zund.com www.kordsa.com
Mirka’s innovative Galaxy abrasive combines e ectiveness with long life, thanks to a new self-sharpening ceramic grain, a clog resistant coating and the new Multi t™ hole con guration. 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 www.composites.media | FEBRUARY/MARCH 2024 | 7 Sonichem set to transform automotive industry A consortium led by sustainable technology innovator, Sonichem has been granted nearly £600,000 in funding from Innovate UK’s 'Resource efficiency for materials and manufacturing' (REforMM) programme. The funding will accelerate the development of the proprietary Sonichem ultrasound technology and the production of renewable, cost-effective alternatives to petrochemicals commonly used in the production of composites, plastics and resins within the automotive industry. The cutting-edge CARMA (carbon-neutral agroforestry-derived resins to materials for automotive applications) project will apply Sonichem’s ultrasonic processing technique to automotive applications for the first time. The patented breakthrough approach converts sawdust, the biomass by-product from forestry operations, into high-quality lignin. This renewable material will then serve as the basis for bio-based platform chemicals, creating green alternatives to conventional petrochemical-derived materials currently used to produce various vehicle components. This transformative initiative is being undertaken in collaboration with technology innovation catalyst CPI, the NCC, Scott Bader, SHD Composites and Polestar, with each industry leader contributing its own specialised knowledge and expertise. Adrian Black, CEO of Sonichem, said: “We're extremely pleased to have the backing of Innovate UK's REforMM programme for this strong industrial consortium. This funding is a catalyst in our quest to offer the automotive industry a sustainable alternative to petrochemical-derived plastics. With Sonichem's ultrasound technology and the collaborative expertise of our partners, we are set to make strides toward a net-zero future and strengthen the UK's bioeconomy.” https://sonichem.com
8 | FEBRUARY/MARCH 2024 | www.composites.media NEWS The University of Sheffield AMRC Training Centre will become the first training provider in South Yorkshire to deliver a new composites apprenticeship in a move to sustain the longevity of the capability within manufacturing by creating its workforce of the future. Together with McLaren Racing and McLaren Automotive, the AMRC Training Centre will deliver a new advanced level composites technician apprenticeship, in addition to the metallic machining apprenticeship the centre is already delivering with McLaren. Alongside McLaren, Wirral-based Teledyne CML Composites is also supporting the new apprenticeship – with the aim that more companies will come on board in the future. Nikki Jones, director of the AMRC Training Centre, said it was a real pride point to launch the new apprenticeship: “Working alongside McLaren and Composites UK, a need for such an apprenticeship was identified to help fill the national skills gap of people in composites due to an ageing workforce. “Composites has always been a capability the AMRC has had a big focus on and as its new building is underway to deliver a new programme called Composites at Speed and Scale (COMPASS), which is likely to provide a number of jobs in the region – we are acting now to build our expertise and capacity in composites to help supply the future workforce. “Along with employers, we’ve put a new delivery model together to meet the needs of industry and we are the only people to deliver this composite apprenticeship in the region. This is something we are very proud of and we are excited to see this course grow.” Steve Foxley, CEO for the AMRC, added: “The AMRC Training Centre is helping the manufacturing industry by training new composite apprentices who are vitally needed for the future, while making sure the courses tie into technology areas of growing importance, such as the ones seen in catapult centres including the AMRC. This capability is key for a growing number of businesses in South Yorkshire and beyond for their productivity growth. “It’s fantastic to see how the AMRC Training Centre continues to build on its industry-forward approach by adding another important learning capability to its ever-widening selection of subjects.” Students who are undertaking the 36-month apprenticeship will engage in the production of composite components or products that are used in a range of applications, some of which include automotive, motorsport, aerospace, rail and renewable industries. The first cohort for the apprenticeship started last September, which includes an all-female group based at McLaren’s headquarters in Woking, alongside two other learners at the McLaren Composites Technology Centre (MCTC) in Sheffield. Three more learners are placed with Teledyne CML at its base in Bromborough on the Wirral. AMRC unveils South Yorkshire apprenticeship scheme www.amrctraining.co.uk Norco has announced its formal commitment to the Armed Forces Covenant, a nationwide promise ensuring fair treatment and respect for those who serve or have served in the British Armed Forces and their families. This significant pledge is a testament to Norco’s dedication to acknowledging and understanding the sacrifices made by the Armed Forces community. By signing the Covenant, Norco joins a diverse group of organisations, including the UK Government, the single Services (Royal Navy, British Army, and Royal Air Force), local government, the NHS, schools, charities, and businesses of all sizes. This collective effort underlines a shared responsibility towards those who have served our country. Company managing director, Mark Northey, officially signed the pledge, accompanied by an Armed Forces representative – Andy Kavanagh. “At Norco, we recognise the immense value and sacrifices of our Armed Forces,” stated Northey. “This commitment to the Armed Forces Covenant is not just a duty but a privilege. We are dedicated to ensuring that our practices reflect the respect and gratitude we hold for our service members and their families. This pledge marks a significant step in our ongoing efforts to support and honour the Armed Forces community.” NORCO MAKES ARMED FORCES PLEDGE www.norco.co.uk
Contact us: dk-holdings.co.uk info@dk-holdings.co.uk +44 (0)1580 891662 Setting the standard worldwide. Diamond Tooling solutions For the Composite Industry.
10 | FEBRUARY/MARCH 2024 | www.composites.media SECTOR REPORT: TRANSPORT estled in the soul of Modena, a city echoing with the thunderous symphony of engines and steeped in the storied tradition of automotive prowess, the eclectic and innovative filmmaker Michael Mann assumed the directorial helm to breathe life into the enthralling saga of Enzo Ferrari, the mastermind behind Ferrari cars. Drawing inspiration from Brock Yates’ seminal 1991 biography, “Enzo Ferrari: The Man and the Machine”, Mann's new cinematic masterpiece, ‘Ferrari’ meticulously explores the profound impact of this visionary Italian luminary on the realms of both automotive engineering and motorsport history. CRP Technology, Italy-based 3D printing company known for its advancements in the additive manufacturing (AM) sector, proudly collaborated with Michael Mann’s film production team, swiftly manufacturing and delivering functional 3D printed props, and showcasing remarkable efficiency in record time. Situated in the Motor Valley, CRP Technology shares its birthplace and headquarters with Ferrari, adding a unique layer of significance to this cinematic collaboration. Indeed, applying cutting-edge AM techniques and employing its advanced Windform materials for laser sintering well known among the motorsports leaders, CRP Technology contributed significantly to the creation of functional components, some impacting on the film’s visual narrative. The components were commissioned to CRP Technology while the film crew was shooting in Modena, to be used immediately, during the filming in Modena and northern Italy. CRP Technology managed to provide the required 3D printed parts in a short amount of time thus ensuring the strict shooting schedule. The collaboration involved crafting 3D printed props. These components, created with precision using CRP Technology's expertise and professional 3D printing selective laser sintering (SLS) process, included: driver helmet parts (visor), pit components and cat’s eyes, which contributed significantly to the film’s narrative. The mathematics of the parts was appropriately aged to adapt the 3D components to the scene needs. The 3D printed props also highlight the versatility of CRP Technology's Windform composites: in fact, for many years Windform materials have been used in the most advanced industrial sectors, such as motorsport, aerospace, UAVs and now are proving to be also suitable for high-performance props. Specifically, the carbon fibre filled Windform XT 2.0 (manufacturing material for the pit parts), the glass fibre filled Windform GT (visor), and the rubber-like thermoplastic elastomer Windform RL (cat’s eye) have been chosen for their exceptional mechanical properties and suitability in diverse applications. The materials are part of the Windform TOP-LINE range for selective laser sintering process: Windform XT 2.0 is a Carbon fibre filled composite, Windform GT is a glass fibre filled, and Windform RL is a thermoplastic elastomer. The film production team expressed satisfaction with CRP Technology's contribution, acknowledging the company for availability, efficient production, and timely deliveries. Additionally, they appreciated the quality of the 3D printed components, emphasising CRP Technology's dedication to providing effective solutions. This collaboration illustrates CRP Technology's commitment to advancing industrial 3D printing and reinforces its position as a reliable partner for innovative projects, even in the dynamic film production landscape. Above 3D printed visor in GRP composite Windform GT, assembly test (on left) and helmet built on the scene on actor and dummy CRP Technology discusses its vital role in industrial 3D printing for Michael Mann's latest film, ‘Ferrari’. Mann and the machine N www.crp-group.com Scan here for more CRP articles Image courtesy of Prop On-Set Team
WELCOME www.composites.media | FEBRUARY/MARCH 2024 | 11 MATERIALS SPOTLIGHT: OPINION read an article recently that said your work anniversary should be an opportunity to stop and reflect. As mine coincides with the backwards and forwards-looking nature of January, I thought I would give it a go. I started this job after reaching a ceiling in promotion opportunities, and PRF Composite Materials - the family business which I had never been interested in joining - needed a few marketing activities managed. I interviewed with a panel of three senior managers including my dad, the managing director! I took the job as a stop gap and to broaden my marketing experience into industry. Joining the team to manage an exhibition and create a catalogue ticked both mine and PRF’s boxes. 12 years later, the one exhibition has turned into a decade worth of industry shows. The single catalogue branched into several and then websites, social media, and videos, etc. I’ve learned so much from joining a company with no marketing, having to build this from the ground up, giving voice and visual to a brand that already had a rich and diverse 30-year history. We've taken our exhibitions from shell-scheme to headline sponsors, and built a social media presence from scratch. As a non-technical person, it has surprised me how much I enjoy being part of the advanced engineering community. In 2012, I created a campaign that highlighted what our materials do: generate power, win gold medals, help medics screen for disease, create music, etc. This is still my favourite campaign, because the capabilities and impact of composite materials still amaze me. Not enough people know about composites. As such, it is wonderful to work with projects like ThrustWSH, where the wider public can get interested in what we do. I’m incredibly passionate about PRF. Founded in 1982 (before I was born), PRF has always been a part of my life. It is part of our family, and working in the business has both increased my passion for the brand, and also my awe and respect to my parents for 40 years of building a brand that still honours the Below Hannah Khusainova, marketing director of PRF Composite Materials For some, anniversaries are epiphany moments - natural occasions for reflection and often catalysts for life changes. Here, PRF Composite Materials’ marketing director, Hannah Khusainova looks back on her career in the UK composites industry. Stop and reflect I www.prfcomposites.com What I’ve learned about working in a family business is that the successes and challenges feel bigger, and my duty of care to this brand, that my parents have worked so hard for and that I have been entrusted with, is paramount Scan here for more PRF articles principles it was founded on: highest quality materials, advanced and innovative products, exceptional customer service and doing business based on integrity. It is a challenge to grow a company over so many decades and retain a focus on customer service, so it is a privilege when we receive customer feedback that highlights the quality of our materials and service. It’s also been fantastic to watch the PRF team grow, and as a company to support new careers in composites engineering. What I’ve learned about working in a family business is that the successes and challenges feel bigger, and my duty of care to this brand, that my parents have worked so hard for and that I have been entrusted with, is paramount. I know what has gone into PRF, so there is a huge amount of love and pride that goes into every marketing output created. 12 years later, I’m just the lucky one who gets to tell others about this amazing company and what we do.
12 | FEBRUARY/MARCH 2024 | www.composites.media MATERIALS SPOTLIGHT: PATTERNS & MOULDS t’s been a busy few weeks at P&M with the installation of its new Breton Raptor CNC machining centre. The Breton team has made considerable progress in installing and commissioning the machine setup and it is now really starting to look like the finished product. “As part of our plan to invest in the future, we took on more space midlast year to enable the improvement of existing facilities, as well as make space for the new machine,” begins P&M managing director, Gary Lucas – who along with wife Kate, runs a family business that is never afraid to take on many of the weird and wonderful projects the various industries often throw at them. P&M’s new 300m2 unit comprises a dedicated spray and finishing department housing the company’s new Titan 10 x 6 x 4m spray/bake and curing booth. Alongside this is a new 250m2 inspection and vacuum bag facility, complete with a training room for in-house training and development. Meanwhile, an extension is currently under build to one of the existing units of approximately 200m2 as a dedicated stock build area to serve the CNC machines. “We have increased our staffing numbers and we are delighted to have college leavers joining us, learning and developing in-house alongside our experienced team. We are also currently working towards Cyber Essentials plus (CE+) which will be fully rolled out in the first quarter of 2024, showing the commitment we make on cyber security.” P&M supplies into all areas, including marine, automotive, construction, rail, aerospace, renewables, defence, and leisure - anywhere there is a need for a pattern or a mould, the company is prepared to take on most things. Its CNC capabilities enable large scale machining of single items up to 13 x 5 x 2.5m, and 6 x 4 x 2m on the Breton Raptor. In terms of the types of performance demands placed on his company by today’s customers, price, quality and delivery are vitally important, but the personal touch, customer relationships, after sales support, and the willingness to help with a flexible approach, all help build long-term relationships. As a family business for 56 years, P&M is as invested in its employees as it is its clients. “Our biggest assets are our team of employees,” states Lucas. “Mix their experience with the technology we have and, I feel we are unique in offering such varied skills through our motivated workforce with abilities to turn our hand to anything. Below P&M has installed a new Breton Raptor CNC machining centre Patterns & Moulds continues to invest for the future with the arrival of a brand new Breton Raptor 5-axis CNC machining centre. Mike Richardson catches up with the Leicestershire-based tooling experts to hear more about the progress the company is making in getting the Raptor up and running. Axes of power I During installation, Breton worked professionally to get us up and running. From start to finish, it’s been an excellent experience
www.composites.media | FEBRUARY/MARCH 2024 | 13 www.patternsandmoulds.co.uk “Our long-standing partnerships – both with the client and supplier – are vital, and have brought huge benefits. Without a strong and robust supply chain, we cannot supply our customers with their tooling. Purchasing on availability and quality is just as important as price these days.” A seamless process I’m interested to know more about the purchase and installation of the Breton Raptor 5-axis CNC machining centre, which according to Lucas has been seamless and easy. “Breton has been a delight to deal with from our initial enquiry, their knowledgeable approach has ensured the machine is precisely what we required. The Breton products are superb quality machines - its accuracy and surface finish quality will certainly improve the end product we offer our customers. We’ve found Breton to be honest and open and they have ensured the process has worked effortlessly. “During installation, Breton worked professionally to get us up and running. From start to finish, it’s been an excellent experience. The installation of the Raptor meant that we first needed to relocate one of our other CNC machines. Then the excavation for the new foundations and the casting of a 120 tonne new slab could finally begin.” The industry’s increasing use of latest large scale additive manufacturing (LSAM) technologies has not gone unnoticed by many of the UK’s leading composites manufacturers. So, what kinds of pattern and mould developments will we be seeing in the future? “Large scale additive manufacturing is a very interesting technology, and one we are keeping a very close eye on,” notes Lucas. “Having installed a robotic 3D printing cell for polyurethane material a couple of years ago, we know the process and we are looking to further invest over the next 12 months. LSAM is fantastic technology that has proven to be the right way forward over and over again.” P&M is now looking to push into higher requirement marketplaces over the coming 12 months, particularly in the Above Breton has made considerable progress in installing the Raptor aerospace and defence sectors where tighter tolerances and engineering go into every package of work. “After a year or two of growth and investment, we will use this year to stabilise and formalise our plans to be ready for the next chapter,” concludes Lucas. “Following the last two years of investment into our world class facilities, we have the facilities to be at the forefront of what we do - for decades to come. Meanwhile, we continue our relationships with customers that have been loyal to us for decades and also build on it by starting new partnerships.” Below left The Breton Raptor enable large scale machining of single items Below right Excavation for the new foundations and the casting of a 120 tonne slab
14 | FEBRUARY/MARCH 2024 | www.composites.media SUBCONTRACTING SOLUTIONS ODEM Composites is a leading provider of advanced composite end-to-end solutions from initial concept creation all the way through to product delivery. The company’s services include design, manufacturing, project management, and engineering support. CODEM caters to a diverse range of sectors, such as Formula 1, automotive, space sector, electric vehicles and defence. Firstly, please bring me up to speed with your latest news regarding appointments, new equipment purchases and/or facility upgrades? Kevin: Over the last four years we have focused on strengthening and developing our senior management team. The senior leadership team has over 100 years of combined experience and is comprised of Sharon Hewison, operations director; Rochelle Helliwell, business development manager; Lee Churchill, supply chain manager; Bob West, production manager. The newly appointed team provides us with an excellent platform to support the next phase of our growth strategy. In 2019, we relocated to our purposebuilt 30,000ft2 facility. Where we established infrastructure to enable future growth. This included installing state-of-the-art machinery. At CODEM, we constantly strive to improve our capabilities. One way we do this is by investing in new equipment. Currently, we are looking to acquire a new 5-axis machine. Most of our upcoming facility upgrades will support our pursuit of ISO 14001 environmental accreditation. We aim to introduce this in the third quarter of this year. Congratulations on reaching your 15th anniversary. What plans do you have to celebrate this milestone and what kinds of rebranding plans do you intend to undergo to support this? Rochelle: 15 years of service is a noteworthy achievement that we are all very proud of. To mark this important milestone, we have planned a series of celebratory events and community initiatives as a thank you to our industry partners and employees who fuelled our growth. The anniversary celebrations will also be a chance to reflect on our journey and, most importantly, share our vision for the future. To represent the evolution of our business, we have refreshed our brand with a new colour palette, font style, and website. The rebrand honours our past while looking ahead, which inspired our new logo's teal hues reflecting our mission to be the top choice for sustainable, bio-based composite solutions. What are the types of trends and demands placed on your company by today’s customers? Left CODEM Composites’ senior leadership team celebrate its 15th anniversary In a Q&A session, CODEM Composites’ managing director, Kevin Doherty and business development manager, Rochelle Helliwell discuss the company’s 15th anniversary celebrations and the rebranding to support this exciting milestone. On a journey to realisation Since the composites industry is a niche industry, word of mouth and reputation are paramount to the success of a company. C
www.composites.media | FEBRUARY/MARCH 2024 | 15 Scan here for more CODEM articles Kevin: Over its 15 years of operation, CODEM has observed a growing demand for turnkey, end-to-end project management. Our in-house capabilities allow us to seamlessly oversee each project from start to finish. By housing all operations under one roof, we maintain constant oversight and deliver superior outcomes tailored to each project’s unique needs. Centralising services enable faster lead times, lower costs, and simplified communication through a single point of contact. This consolidation strengthens relationships between CODEM and customers by streamlining collaboration. For our customers, it's about quality, timelines, and price point - and we deliver on all three. Over the years, customer relationships have become the backbone of our business, as many of our customers have become friends. Since the composites industry is a niche industry, word of mouth and reputation are paramount to the success of a company. Rochelle: With the pursuit of Net Zero at the forefront of industrial agendas, the future of composite materials is exciting. The need for more environmentally friendly materials and production processes is a trend that is becoming more and more evident driven by new and innovative markets such as electric vehicles, electric cargo bikes and Formula E. Sustainability is a core value that is deeply ingrained in our company culture. To ensure we stay competitive and ahead of the curve we focus on developing environmentally sound technologies and products, adopting responsible operations, and ensuring accountability throughout the supply chain. To make sure we are maximising sustainable characteristics in our material selection, we have collaborated closely with our material suppliers, SHD and Ru-Bix. Our project team has been tasked with quantifying data that contrasts sustainable material options with conventional materials that are already on the market. One particular project revealed that choosing sustainable materials and using responsible production practices resulted in savings of >12,000 C02e/kg on this particular project. What kinds of technological barriers do you need to overcome to get products to market? Kevin: The innovation in sustainable materials has advanced drastically to follow market trends; however, we do see barriers in the lack of diversity in sustainable material options compared to traditional composite materials, as well as the shortfall of recycling technologies to reuse composites at the end-of-life stage. To overcome this barrier, we are continuously working with our project partners, suppliers, and universities to develop processes and products to rival the traditional options currently available to the market. We have recently faced the challenge of quantitatively demonstrating the energy savings from using environmentally friendly practices and materials. Generating these findings typically requires cradle-to-gate analysis; however, we have found it extremely difficult to access the necessary data from third parties. This lack of data access makes conducting our cradle-to-gate analysis challenging and time-consuming. In the future, developing an accessible industry standard that allows us to quickly generate such data will be paramount. If able, please provide information on the latest subcontract manufacturing project work you are undertaking? Rochelle: We are currently collaborating with Callum, Niche Vehicle Network (NVN) and Nyobolt on the Callum Skye, a highperformance electric vehicle for on and off-road adventures. As Callum's first own-brand vehicle, the twin-motor, all-wheel drive, two-door Skye marks a milestone. We are honoured to be part of this journey. CODEM has been an instrumental partner in developing the Callum Skye build, not just by manufacturing and assisting with the composite design, but also by spearheading its sustainability credentials to align with the project's environmental goals. In close collaboration with partners and suppliers, we selected the most sustainable, fit-for-purpose materials available. Our team conducted a cradle-to-gate analysis to assess the project's footprint. The analysis showed that by choosing sustainable materials and responsible production, we achieved savings of >12,000kg CO2e on the Callum Skye project. What are your views on organisations like Composites UK - are they doing enough to promote UK PLC for the greater good? Rochelle: We recently rejoined Composites UK primarily to access its extensive calendar of events at a discounted member rate. Composites UK's events, such as the new pavilion at the Farnborough Airshow, provide small and medium-sized enterprises like CODEM with excellent opportunities to increase their presence at major tradeshows. We also work closely with the Niche Vehicle Network which is a free-to-join, independent network of UK niche vehicle manufacturers, technology, design, and engineering organisations. We have been a member of NVN for over a year and find the networking and consortium-building activities extremely valuable and a vital part of our networking strategy. In addition to NVN's event offerings, NVN also provides funding for R&D initiatives, which presents valuable partnership opportunities with UK companies focusing on vehicle electrification, zero emissions, and lightweighting which fits perfectly with our sustainability initiatives. Organisations like Composites UK could provide further support by addressing the shortage of skilled workers for key roles. While the composites industry employs over 45,000 people, recruiting for certain Above CODEM is part of a collaboration on the Callum Skye electric vehicle
SUBCONTRACTING SOLUTIONS www.lentuscomposites.co.uk Enabling Products at the Leading Edge of Composite and Metallic Technology. Innovators in Design and Manufacture of Advanced Products and Systems. • COMPOSITE TRANSMISSION SHAFTS AND GEARS • COMPOSITE PRESSURE VESSELS AND ACCUMULATORS • BATTERY CONTAINMENT • COMPLEX COMPOSITE COMPONENTS AND ASSEMBLIES • H2 STORAGE SOLUTIONS • COMPOSITE BLADES AND AEROFOILS • HIGH SPEED ELECTRIC MOTOR MAGNET RETENTION SLEEVES Lentus Advert half page Feb24.qxp_Layout 1 08/02/2024 13:53 Page 1 positions remains a challenge for CODEM and its partners despite the overall size of the workforce. We at CODEM strive to nurture and develop the next generation of engineers through work experience, apprenticeships, and vocational training. We believe these opportunities are valuable for our employees and the composites community and vital for industry success. More companies joining us in supporting the future composites workforce would be greatly beneficial. What differentiates your company from the competition - why should a customer use you over your nearest rival? Kevin: With a strong reputation in the industry, customers often approach us with projects that are new to the composites field, an area where CODEM excels. We support them on the journey to realisation, talking them through the process and creating an environment of cross-pollination where we are using new and innovative methods and materials and applying them to an industry/ project which hasn't previously utilised these technologies. We collaborate closely with our customers to help them achieve optimal results using our engineering expertise. Our senior leadership team boasts years of experience designing and manufacturing high-quality components through various processes and with diverse materials. Regardless of whether the customer requires minimal guidance or a more hands-on approach, our team is always available to provide support. What do you feel are the most important assets of a company? Kevin: People. Our hardworking team members are the backbone of our organisation. Their dedication and expertise drive our company forward each day. It is thanks to their tireless efforts that we continue to thrive and grow. We deeply value the contributions of every one of our employees. Their diverse skills and experiences enrich our culture and enable us to better serve our customers. We are proud to have such a talented group leading us into the future, as our values state we are more than a company - we’re a community. www.codemcomposites.com Have your long-standing partnerships brought you benefits; particularly as trusted relationships can lead to a better way forward for all? Kevin: At its core, CODEM is built on relationships - with suppliers, customers, and staff alike. Effective communication and a nurturing mutual understanding are key to developing these vital partnerships. We have been working with three of our primary customers for more than ten years; if that doesn't demonstrate the value of a strong connection, I don't know what does. Finally, any other business? Kevin: We would like to express our gratitude to Composites in Manufacturing for allowing us to celebrate our 15th anniversary with you all and the wider composite community. In retrospect, we are eagerly anticipating the next fifteen years and attempting to envision the composite industry. It feels both exciting and concerning when you think that we hope to reach carbon neutral emissions in less than 10 years.
WELCOME www.composites.media | FEBRUARY/MARCH 2024 | 17 WEPLRCOOCMESES SPOTLIGHT: ADDITIVE MANUFACTURING hermwood was established over fifty years ago in the US around an innovative approach to moulding wood-grained plastic parts for the furniture industry. The company developed a thermoforming moulding process that reduced part cycle time from around two minutes to less than five seconds using tools that cost 90% less. New markets required complex trimming in addition to moulding so Thermwood began searching for an automated way to trim parts. The company realised that microprocessors, being introduced at the time, could be used to move a machine and trim. This resulted in the major development of a CNC control which was installed on its very first CNC router. The machine was successful in trimming moulded plastic parts, and Thermwood soon realised that there could be a market not only for its plastic parts, but also for the CNC router it had developed. Since then, it has continued to develop and refine these technologies, and today the company builds some of the most capable machines and controls available. Since 2015, it has also gained recognition for its involvement in largescale additive manufacturing (LSAM). It developed this unique 3D printing technology capable of producing large, high-quality thermoplastic components that is now utilised in industries, such as aerospace, automotive, foundry, marine, and others. Thermwood fabricates most of the components for its machines and all electrical, mechanical and software engineering is done in-house as well as sales, service and support. The company is committed to innovation in the field of manufacturing, with a philosophy that revolves around providing cutting-edge solutions for customers, helping them improve efficiency and productivity, and working closely with them to understand their unique requirements to provide tailored solutions. Firstly, tell me about your development of LSAM, the markets and applications for which it is primarily used? LSAM has found applications in the aerospace, automotive, marine, foundry and general manufacturing industries, where the production of large components is critical. LSAM is used to produce large-scale tooling, moulds, fixtures, plugs and even end-use products for various industries. This technology allows for the Above Thermwood’s development of vertical layer printing (VLP) allows for larger parts to be printed in one continual process In this Q&A article, executive vice-president, Jason Susnjara, from large scale additive manufacturing (LSAM) machine builder, Thermwood discusses with Ed Hill the latest developments in its technology. T Going large with print innovation Below Jason Susnjara, executive vicepresident at Thermwood
18 | FEBRUARY/MARCH 2024 | www.composites.media PROCESS SPOTLIGHT: ADDITIVE MANUFACTURING When you purchase from Thermwood, you get a dependable machine, a superior control, reliable performance and the best service and support in the business. rapid and cost-effective production of tooling used in manufacturing processes. Rapid prototyping of large components is also valuable for industries that require quick iterations and testing of designs before mass production. What would you say are the biggest trends and demands from your customers? Our customers generally want to create a tool or mould quicker and cheaper than traditional methods. These methods traditionally require machining a block of aluminium, steel, foam, or wood down to the final shape and size. This usually requires removing most of the material to get the final result. LSAM can 3D print near-net shape, so there is far less removal or subtracting of material. With the standard LSAM configuration, we print from the bottom up. When we 3D printed a boat hull tool several years ago, we needed to print six separate pieces and then assembled them into one single piece. With our vertical layer printing (VLP) option, we are now able to rotate the same boat hull tool and print in one continuous piece, eliminating the need for assembly. In one example, we printed a specific tool the customer already had data for using traditional methods with the VLP method, saving them more than 40% in both time and money compared to the traditional process. We also work with several material suppliers to help create and change material characteristics based on what the customer needs. Furthermore, Thermwood has implemented open platform communication (OPC) and MTConnect data for customers to use which offers a wide variety of information from the machine. Using MTConnect and OPC data provides more efficient operations, improved production optimisation, and increased productivity. What elements of your technology would you say differentiate you from your competitors and bring added benefits to users? We have dozens of patents on both the hardware and software side of LSAM. Some of these technologies include our patented compression roller, melt pump and layer time control. All these technologies are some of the biggest benefits that LSAM utilises, and there are plenty of others. The compression roller is chilled allowing its use for hightemperature material. The compression roller has also been proven to provide a superior layer to layer bond and a void free print. It rotates automatically with the direction of the print simplifying the program. The melt pump helps control the amount of material that comes out of the nozzle, so there is no surging. With Layer Time Control, the control can automatically adjust the print speed to maintain a consistent layer print time as the print geometry changes, dramatically reducing the skill level needed to operate the machine. This is all handled automatically with our proprietary LSAM Print 3D software and CNC control. How do you work with customers new to LSAM and help them to optimise production and overcome any early hurdles? We first learn what the customer’s objectives are and what they are going to use the LSAM for. Most require a demonstration tool to be 3D printed and machined during the sales process. All of that data is then given to the customer before the purchase so they can better understand the process, time, and material costs for a particular project. With the machine purchase, the customer receives anywhere from 2–4 weeks of training depending on what options and software are purchased. On a print-only LSAM, the training will consist of two weeks. For the print/trim combination, four weeks. The customer will be shown how to slice and 3D print a particular object from start to finish. We also offer our Production Assistance service where we will send an expert technician to the customer’s facility to work with them side by side to help give the operator a better understanding and confidence with the system. What R&D projects are you involved in? Would you say there is more development in software improvements or hardware currently? We have multiple R&D projects going on with LSAM, but a big one recently was a project involving the US Department of Energy, Purdue University, and others to design, print and machine tools for the wind energy industry. This project consisted of both hardware and software. Thermwood is always pushing the envelope on what LSAM can achieve and accomplish, especially when it comes to ease of use for the operator. Because we manufacture both the machine and CNC control, we can develop new methods and updates that our customers can benefit from very quickly compared to our competition. These ideas come from within the company as well as listening to what our current customers say about any given product. We currently have at least 35 different material configurations available to all LSAM owners and are constantly researching and adding to this list. What are the latest LSAM improvements that you have introduced? Some minor hardware improvements have occurred recently, but the majority are within the software and control side of the LSAM. Adding more functionality to the slicing software as well as making the control system easier to use so that the operator has to make less decisions based on a variety of factors. Above Thermwood has pioneered the LSAM process with dozens of patents both in hardware and software systems Right Thermwood machines such as the closed configuration 1040 allow users to both print and then trim parts
RkJQdWJsaXNoZXIy MjQ0NzM=