composites formatting: optimizing materials, · pdf filecomposites formatting: optimizing...

© 2016. Web Industries, Inc. All rights reserved. Proprietary & Confidential.www.webindustries.com

© 2016 Web Industries Proprietary & Confidential

Composites Formatting: Optimizing Materials, Machines, and Methods for Better Fabrication Solutions Patrick Markert & Sebastian FehlCFK-Valley Convention 2016, 15-16 June, 2016

© 2016. Web Industries, Inc. All rights reserved. Proprietary & Confidential.

Meeting Goals:

1. Introduce Web Industries

2. AFP Technology Advancements & New Industry Challenges

3. CFRP Slit Tape Trends & Developments

4. Thermoplastic Formatting

5. Conclusions

6. Questions

2


Introductions:Web Industries Executive Briefing

● 46+ years experience processing, manufacturing, and innovation with flexible materials

● Diversified market niches● Aerospace Composites● Medical In-Vitro Diagnostics● Heath & Hygiene● Wire & Cable Components● Industrial Fabrics & Components

● 450 employees, privately- held, and financially strong

● 7 facilities and 60+ processing lines providing contract manufacturing capability

● Industry certifications: ISO 9001, 13485, 14001, AS/EN9100C, FDA Registration

3


An Evolution:Technical Innovations Lead to Future Opportunities

1970’s - 1990:

● Proving the potential of CFRP in Aerospace

● Developing Primary Manufacturing Methods

1990 – 2015:

● Fully validated uses of CFRP in Aerospace

● Multiple manufacturing technologies proven-in

● Automated Fiber Placement (AFP) and Slit Tape adoption in major programs

2015 & Beyond:

● Great potential for optimization , speed, efficiency

● A wide-array of composites formats will be needed to enable next-generation manufacturing methods

4


Custom Attributes

Precision-Oriented

• Spools

• Pad-Rolls

• Ply-Cutting

• Kitting

• Chop/Flake

• Hand Layup

• Automated Tape Layup (ATL)

• Automated Fiber Placement (AFP)

• Compression Molding

• Wing Skins

• Spars

• Stringers

• Engines

• Fuselage

• Secondary

• Thermoset

• Thermo-Plastic

• UD Pre-Preg

• Fabric

• Glass

• Matrix/Hybrid

APPLICATIONS

Market Demand:Meeting the Growing Need for Precision Composites Formatting

MATERIALS

MANUFACTURING

FORMATTING

5


Supply Chain:Enabling Aerospace Manufacturing with CFRP Formatting

6

Fiber Precursor

Resin

Fiber

CompositesMaterials

Fabric / Weaving

Aero-Structure FabricationPrecision

CompositesFormatting & Kitting

Tooling &Equipment


Services:Web Industries in Advanced Composites for Aerospace

Web Industries is the premier provider of the most comprehensive and advanced set of formatting services for composite-based manufacturing in the aerospace industry.

The most trusted composites formatter for the world’s most stringent aerospace programs.

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RESEARCH & DEVELOPMENT CENTER

AEROSPACE QUALITY & FOD CONTROL

MATERIAL MANAGEMENT & LOT TRACEABILITY

FREEZER STORAGE

COMMERCIAL SCALE CAPACITY

COMPOSITE PLY KITTING

CAD-CONTROLLED LASER & KNIFE CUTTING

THERMOPLASTIC CHOPPING

CUSTOM SLIT TAPE SPOOL PACKAGE DESIGN

PRECISION SLITTING & WINDING

CUSTOM REPORTING & MATERIAL LABELING


The Challenges Ahead:Industry Demand for Materials & Automation

● What is the right material and manufacturing method for my part?

● Prepreg-based Processes: ATL vs. AFP used in large part construction

● ATL productivity with AFP performance and yield benefits

● Demand for greater productivity from both technologies

● Are there opportunities for enabling cross-over/combination of AFP and ATL technologies?

● Can pre-combining of materials enabling process efficiencies and shortened manufacturing cycle times?

● How do we harness the rapid growth in Thermoplastics automationleveraging years of thermoset-based AFP and ATL programs

● Ultimately…how do new possibilities in Slit Tape configurations impact the range and reach of AFP technology?

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Materials:Performance, Yield, & Cost

● Aircraft Builders want the Material Supply Chain to improve productivity, reduce yield loss (“buy to fly” ratios), and drive down material costs.

● New Composite airplane programs will increase demand for improved production efficiency and lower material costs.

● Opportunities: Material Supply Chain● Optimized prepreg parent roll widths and lengths

for input and productivity ● Improved Spool Package Density and AFP Spool

handling to raise productivity and reduce waste● Opportunities to combine materials and

save lay-up steps in the process● Minimizing environmental impact and cost

9


Automation:New AFP Technology & Productivity Challenges

AFP Technology is advancing…

● Nimble designs and flexibility in AFP heads on robotic machine base

● New lines combine AFP and ATL capabilities for large-scale parts

● Combinations of multiple discrete AFP robots working simultaneously on large parts

● AFP heads carrying multiple widths of slit tape for more efficient laydownand fill-in applications

● Machine innovations are driving the need for better collaboration and more robust formatting solutions

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EFFORT SUCCESS

End-to-End Collaboration:

+ Prime Aerospace Co

+ Material Provider

+ Web Industries

+ AFP Equipment

+ Fabricator

Better Over-All AFP Economics

Increased Lay-Down Rates / Pounds-Per-Hour

Improved AFP Set-Up / Doffing / Change-Over

Improved AFP Asset Utilization & Precision

Increase Overall Material Yield

Optimize Material Handling and Storage

Kitting, Prep-for-Use, Optimized Packaging

Reusable Packaging

Proximity & Logistics

Remnant Reclamation Strategies

Collaboration is Key:Optimizing Material Formats for AFP Success

11

=

Leaving any one of these parties out of early design and developmentcan lead to processes and specifications that will be less than ideal.


PR

IMA

RY

Quality & Defects

Length

Width

Resins

Tack Levels

Thickness / FAW

Tolerances

Defect Removal (logged & unlogged)

Slitting Speed

Inspection

Splicing

Asset & Labor Utilization

Slit Tape Width

Final Spool Configuration

Overall Tape Length

Spool Width

I/D & O/D

Spool Weight

SEC

ON

DA

RY

● Fiber Types

● Moisture Content

● Wet-Out

● Thaw-Time

● Order Lead-Time

● Set-Ups

● Batch Sizes

● Paper Removal

● Out-Time Windows

● Tolerances

● Blade Management

● Poly Interleaving

● Tension

● Yield / Scrap

● Doffing

● Cleaning

● Environmental Factors

● Poly Width

● Poly Thickness

● Tension

● Wind Pattern

● Spool Core Width

● Spool Packaging

● Final Packaging

● Final Inspection

The Levers of PrecisionSlit™ Slit Tape:Inputs and Outputs Drive Cost and AFP Productivity

MATERIAL INPUTS PROCESSING FACTORS OUTPUT FORMATS

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New Directions in Slit Tape

● Formats not limited to current (1/8", 1/4", 1/2")

● Optimized slit tape widths per part

● Maximize throughput, minimizing yield loss

● Narrow for complex part segments/fill-in zones

● Wider (1" to 2") tapes for large, less complex parts

● Crossover/combination between AFP and ATL

● Multiple ATL rolls feeding multiple tape laydown heads(e.g.: Mtorres 2-tape and 4-tape ATL heads)

● Customized spool lengths optimized to the lay-up process

● Shorter spools on outer edges, longer spools in the middle

● Yield improvement, limiting remnant reprocessing, etc.

● Improve the density and run time of prepreg spools

● Reduced thickness and width of liner to enable more prepreg on the spool

● Reconfigure spools shape (taper to square edge)

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Example: Trial Spool Winding for Wide Slit Tape (pictured example)

● 1.5" Slit Tape Width

● 6" Core Inner Diameter

● ½" wall for stability

● Liner is slit to net width of tape

● 16" spool face length

● OD shown here: ~10 inches,

● Slit tape length: ~6,000 lin. Ft(69 m2) prepreg

14

Square edge

spool

profile=more

length


Length inLinear Feet

Weight(Prepreg) Total Weight

Total ft2 (m2) per spool 32 spool creel

9,665 24.3 lbs 27.6 lbs 404 (37) 778 lbs

Process Impact:Innovative Spool Designs Drive Significant AFP Gains

New Spool:

● ~190 FAW material, 1.5" slit width

● 16" face width by 16" OD

● Maximum spool weight – 103 lbs

15

Length inLinear Feet

Weight(Prepreg) Total Weight

Total ft2 (m2) per spool 20 spool creel

11,109 83 lbs 103 lbs 1,389 (129) 1,660 lbs

Compared to current spool:

● 9,665 linear feet x 0.5" wide x 9.5" OD x 16" face width


Benefits for the Customer

FUNCTION BENEFITS

Spool Package Optimized for AFP with More Material perSpool

• Cost Reduction of Slit Tape

• Better AFP Utilization & Productivity

• Fewer AFP Change-Overs & Cleanings

• Higher Material Yield

• Fewer Scheduled Cleanings

• Better Freezer Utilization

• Lower Freight Costs

Precision w/“Net Width” & Thinner Poly Liner

• Better Slit-Edge Quality & Precision

• Less Exposure to FOD on Incoming Parent Rolls

• Less Exposure of Slitting Blades to Resin

• Less Resin Build-Up, Less Fuzz

• Fewer Stringers

• Reduced Cost of Poly & Paper Liners

• Reduced Poly Liner Waste (Thinner / Narrower)

• Environmental Benefits

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Combination of Materials Prior to Slitting/Spooling

● Currently – Multi-layer laminations are built with individual AFP and/or ATL lay-ups of various component materials, sometimes requiring transporting parts between machines

● Developing – Pre-combined materials (laminated wide-web rolls), are then converted into slit tape to reduce production steps and shorten part manufacturing cycle times ● Goal – AFP manufacturing time

and complexity fall ● Logistics costs eased, product handling

reduced, yield loss improvements likely to be realized

UD Prepreg

SecondMaterial

Big gains in productivity may come from challenging our current

notions of process design and not just “turning up the speed dial”.

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https://www.google.com/imgres?imgurl=http://www.sensorprod.com/glossary/lamination-process/lamination-equipment-schema.jpg&imgrefurl=http://www.sensorprod.com/glossary/lamination-process/lamination-process.php&docid=hf13JJxVwmCt7M&tbnid=rH2LK5AE6lJcAM:&w=450&h=188&ei=3GoAVpyACoeZgwTl0Z_ABw&ved=0CAIQxiBqFQoTCJzet_T9iMgCFYfMgAod5egHeA&iact=c&ictx=1


Pre-Combined Materials, cont’d

● Potential for two or more layers● Prepreg/Adhesive layer● Prepreg/Lightning strike layer● Prepreg/Fiberglass (impact protection)● Prepreg/Prepreg (bias ply layers)

● Challenges – Bonding layers well is critical; dissimilar materials will behave differently in the unwinding and lay-up process if separation occurs

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Trading hours gained of Production time on AFP for added value/cost

in material? The analysis may reveal some good potential opportunities

if all-in costs are measured.


Kitting and Combination of Products to Drive Work Cell Production

Concept – Deliver a set of Prepreg products sufficient to fulfill a multi-process component build-out

● Kitting of various products/materials to feed a work cell center (combined materials, ply cut parts, slit tape, slit rolls, etc)

● Focus – Distributed manufacturing cells for part production

● Example – Precision CFRP components combined in the following scenario:

Enhancements to the material for process-ability without reducing

mechanicals are a key part of improving long-term productivity.

19


One Example:Combining Precision CFRP Components

● A base structure created by Hand-Layup ply-cut parts labeled and packaged for each component

● That structure is combined into an AFP part-mold, onto which the extended structure might be built with AFP lay-up and component UD prepreg slit tape

● Finishing that structure might require either lightning strike or strengthening layers, which were provided in specified amounts of prepreg plus “special property” materials combined and slit for final AFP layering before curing

● Kit structure of component materials could be delivered to the workcell by part order, reducing on-floor storage, yield waste, and easier logistics in-plant

20


ThermoPlastic Materials:Automated Fabrication and Formatted TPC Materials

Hand lay-up is giving way to Automated Processing in parts fabrication

● Thermoplastic materials

● Aerospace

● Automotive

● Industrial

● New technologies

● AFP technologies and scale appropriate for the market

● Compression Molding

● Welding and Joining techniques

● Applications

● Abundant and growing

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Developing Continuous Fiber Thermoplastic Slit Tape

Ongoing Collaboration with Major Material Suppliers

● Increasing material product offerings

● Industry standards developing: PEEK, PEKK, PEI, and PPS

● Very limited, or defect-free incoming material

● Increasing incoming master roll sizes, lengths, and widths

Customized Requirements for Process and Cost Control

● Can be specific to the particular automated process line and/or part

● Outgoing spool size and configuration (larger/longer for more run time)

● Slit widths and tolerances matched to process and part optimization

● Material splicing. Goal = “fly-away” splices that don’t require removal at the AFP line

22


Take-Aways

● Great Potential in prepreg based Automated Fiber Placement (AFP)

● The industry is just beginning to understand the potential for CFRP in large scale production

● Mid-sized and more specialized parts are beginning to justify smaller scale production technologies

● Development of fully engaged and committed resources by Supply Chain partners is needed for market acceptance of improvement opportunities

● Past 10 years –Fully validated use of CFRP and Slit Tape for Automated Fiber Placement (AFP)

● Next 10 years –Great potential for optimization and next generation developments using an array of composites formats.

23


Benefits of Using Web Formatting Services

Outsource It● Focus on Your Core Competencies – Making Airplanes

● Lower Costs and Reduce Capital, Space, and Labor

● Utilize the Most Advanced Slitting & Ply-Cutting Technologies in the World

Leverage Web’s Experience● All Major Commercial, Defense, & Space Programs

● All Major Pre-Pregs and Fabrication Approaches

● Industry Certifications and Reputation

● AS9100C Aerospace-Grade Processes and Systems

Added Value● Materials Sourcing & Management

● Process Controls, Reporting, Labeling, Traceability

● Kitting, Inspection, Packaging, DRP

● State-of-the-Art Composites Development Center(Thermoset, Thermoplast, Dry Fiber, Laminates, etc.)

24


Thank You

Proprietary & Confidential. All content contained within this document is the sole property of Web Industries, Inc. No portion may be copied or redistributed without the expressed written consent of Web Industries.

Contact Information

Patrick MarkertHead of Business Development EuropeWeb Industries Stade GmbHSophie-Scholl-Weg 22A21684 Stade

Mobile: +49 (0)160 589 4485Email: [email protected]

25

Sebastian FehlApplications EngineerWeb Industries Stade GmbH

Sophie-Scholl-Weg 22A

21684 Stade

Mobile: +49 (0)160 487 3560Email: [email protected]

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