Thank you to all of our Speakers, Exhibitors, Sponsors, and Attendees that made the 2018 Carbon Fiber event a success.
We will be finalizing conference presentations within the next two weeks (December 21st, 2018). At this point, ALL attendees will receive a password protected link via email that will allow them to download the presentations that we have received permission to distribute. There will also be a survey and a final attendee list on this page as well. If you have any questions about our event, please do not hesitate to contact any of the Carbon Fiber Team members.
Thank you again to everyone that made our event possible!
Tuesday December 4th
Wednesday December 5th
Thursday December 6th
12:00 – 1:00 Registration for Preconference Seminar & Exhibitors
Registration for Preconference Seminar & Exhibitors
The Market for Thermoplastic CFRP’s In Aerospace and Automotive Applications The adoption of carbon fiber composites in aerospace and automotive applications has enabled engineers to continually push the boundaries of performance, design, safety/reliability, and revenue generation over the past 50 years. The majority of this history has been focused on the fabrication of thermoset polymer composites. During this time thermoset materials and processes have matured considerably. The adoption of thermoplastic materials and technologies, however, has progressed more slowly. However, recent advancements in thermoplastic chemistry, processing and design techniques are creating new opportunities for carbon composites. Growth in thermoplastic CFRP now exceeds that of traditional thermosets. This seminar will discuss many of the materials, technologies, and advancements leading this change and how they are expected to move the market over the next ten years.
Speakers: Mike Favaloro, President, Composite Techs LLC Chris Red, Founder, Composites Forecasts & Consulting
Enjoy A Continental Breakfast and Informal Discussion with Your Colleagues!
8:15-8:30 Welcome and Co-Chair Introductions
Scott Stephenson – Director, Strategic Initiatives and Events – CompositesWorld Eric Haiss – Executive Vice President – Continental Structural Plastics-A Teijin Company Merlin Theodore – Director, Carbon Fiber Technology Facility – Oak Ridge National Lab
8:30 Keynote Presentation Brett Schneider, President – Global Fibers, Hexcel Corporation
An Overview of The Current State of The Carbon Fiber Environment and What We Might Expect in The Future
Click here to read the latest CompositesWorld article featuring Spirit Aerosystems
9:30 Insights into The Carbon Fiber and Composites Value Chain Daniel Pichler, Managing Director, Carb Consult GmbH
A view on the current state, the opportunities, the barriers, the leaders, the innovators, and the potential reward-reapers. A (hopefully) thought provoking view of the carbon fiber and composites world from a long time participant and observer.
10:00 Refreshment Break
Enjoy a Coffee and Visit our Carbon Fiber Exhibitors! Sponsored by:
10:30 The Revolution in Commercial Carbon Fiber Applications Steven Carmichael,Dir. of Sales & Marketing, Carbon Fiber Division, Mitsubishi Chemical Carbon Fiber and Composites, Inc.
This presentation provides an overview of existing and emerging commercial applications that utilize carbon fiber. The varied applications in aerospace and recreational products that launched the CF Composites industry in the 1970’s and 1980’s are well known and developed. We’ll take a fresh look at the current and developing carbon fiber applications that will drive growth in the coming decade. In particular, carbon fiber technology is impacting how we generate energy and optimize how we use it efficiently. The carbon fiber story is unfolding in the real world and is focused on enhancing human flourishing … and it’s a great story.
11:00 Disrupting the Thermoplastic Aerostructures Paradigm David Leach, Director, Business Development, ATC Manufacturing
Thermoplastic Composites have held promise for reducing cost, increasing performance and enabling high rate in aerostructures for many years. The adoption of thermoplastic composites has been slow due to many real and perceived barriers. For example, beliefs that thermoplastics did not have adequate environmental resistance or temperature performance, could not be painted or bonded, could not meet adequate dimensional requirements, that unidirectional tapes could not be formed successfully and that parts were limited to small simple shapes have been dispelled through steady development and in-service experience. In addition, many of the historical fabrication approaches did not realize the expected cost benefits. Thermoplastics composites are now realizing their potential. The supply base is expanding in both materials and fabricators, and the understanding of design for manufacturing is growing rapidly. From initial applications in aircraft interiors with fabric reinforcement, thermoplastic composites are now being used in primary structure applications with unidirectional tapes. This is being achieved in large volumes at high rates and the industry is now seeing the long-promised cost benefits. The presentation will cover the historical adoption limiters and examples of the progress achieved in recent years
11:30 Pultruded Carbon Fiber Spar Caps In Wind Turbine Blades Derek Berry, Director, Wind Turbines Technology Area IACMI/ National Renewable Energy Lab
The use of carbon fiber in the spar caps of wind turbine blades has enabled the design of longer, stiffer structures resulting in increased rotor swept area and lower levelized cost of energy. This presentation will examine the evolution of pultrusion as a manufacturing method for carbon fiber spar caps, and will look towards the use of textile carbon fiber to lower costs.
12:00-1:30 Featured Luncheon Presentation Donna Dawson, Senior Writer, Compositesworld Jill GoldsworthyGolden
Past To Present Composites Technology: A review of composites technology developments in aerospace from 1965 to the present, including a special section on innovations by Brandt Goldsworthy and Burt Rutan, presented by Jill Goldsworthy Golden.
Enjoy your Lunch! Sponsored by:
1:30 Comcarbon Technology - Melt Spinning Of A New Class Of PAN Copolymers For Carbon Fibers Dr. André Lehmann, Head of Fiber Technology, Fraunhofer Institute for Applied Polymer Research
About half the cost of producing conventional carbon fibers is incurred in the manufacture of the polyacrylonitrile (PAN) precursor fiber. PAN is not meltable and so the fibers have to be produced by expensive solution spinning processes. The development of an alternative PAN-based precursor that saves around 60 percent of the precursor costs will be topic of the presentation. This alternative is based on an inexpensive melt spinning process using tailored, meltable PAN co-polymers that were developed for this purpose. Once they are converted to an infusible state, these cost-effective precursor fibers can be processed into carbon fibers much in the same way as conventional wet-spun PAN precursors.
2:00 Bigger Is Better - Unlocking Carbon Fiber Capacity With Plasma Rob Klawonn,CEO, 4m Carbon Fiber Corp.
Finally, a process improvement which debottlenecks carbon fiber capacity, and a company willing to invest heavily to exploit it.
2:30 Automated Fiber Placement of Thermoplastic Materials Pursuit of Low Porosity Without the Autoclave Justin Merotte,Composites Technician, Coriolis Composites
This paper will present the latest development in the automation of manufacturing composite parts using Thermoplastic Materials. The advantage of this technology is the use of a COTS industrial robot, interactive engineering software and ability to manage key processing parameters (temperature, bonding, tension,…).
The paper will introduce the advantages of Thermoplastic materials (processing, mechanical properties etc, …) in comparison to the widely used thermoset composites. Subsequently the paper will demonstrate how the Automated Fiber Placement (AFP) process parameters influences the microstructure of the Thermoplastic parts produced.
Relying on the requisite technical introduction and background, the paper will then present the results achieved for in-situ consolidation while laying up with a Coriolis AFP machine. It will be shown through the fabricated panels’ non-destructive evaluation results that having high levels of control authority over the machine parameters is a crucial enabler of in-situ consolidation where panels can reach porosity levels lower than the original raw material (slit tape). Achieving high quality, low porosity parts via in-situ layup requires a reduction in layup speed with current material systems and technology. Lowered layup speeds for the in-situ process creates a productivity versus quality dilemma for the end users that focused on rate production. This is a major barrier to adoption of the in-situ process for rate production.
In the spirit of pursuing low porosity parts outside of the autoclave, the paper will also present an alternative approach that allows for higher speeds with the fabricated panels showing porosity levels same as that of the autoclave consolidated ones.
To conclude, thermoplastic composites offer great advantages in terms of mechanical properties and recyclability, but pose processing challenges when adapted to three dimensional parts. AFP is a good answer to these challenges due to its low buy to fly ratio and its accommodation of just about any type of post consolidation process required.
3:00 Refreshment Break and Coffee
Enjoy a Coffee and Visit our Carbon Fiber Exhibitors! Sponsored by:
The development of a sustaninable recycling industry is an important part of the development of the overall carbon fibre industry. This paper will show how the industry has developed through the presentation of a number of case studies, in which the business and technical cases for the use of recycled carbon fibres will be expained. The use of recycled carbon fibres in combination with virgin carbon fibres as a means of growing the overall carbon fibre industry will also be discussed.
4:00 “Advanced CLT" - Incorporating Recycled Carbon and Aramid Fibers into Mass Timber Construction Geoff Wood, Fellow & VP Innovation, Composite Recycling Technology Center
The Composite Recycling Technology Center has been developing applications that will enable use of lower-value timber in Cross-Laminated Timber (CLT) construction. One particular effort, amongst several, is the use of recycled carbon fiber prepreg as an internal reinforcement combined with using recycled scrap aramid fiber as an interlayer to enable thinner panels with greater stiffness. The combination of materials allows not only thinner, lighter panels, but also enables improved protection from severe weather such as tornados and hurricanes. The combined structural elements also support the use of thermally modified and stabilized timber which otherwise have issues due to their brittleness. The market is such that this is an ideal lead-in to ultimate usage of low-cost virgin carbon fiber. Market applications and volume potentials will be discussed in the presentation.
4:30 Sustainable 3D Printing With Recycled Carbon Fiber Alice Havill , COO, Vartega, Inc.
Vartega will highlight how additive manufacturing and sustainability work hand in hand to improve product design and reduce lifecycle impacts. Case studies will be provided to demonstrate the benefits of recycled carbon fiber in 3D printing. An overview of the newly formed Advanced Materials and Additive Manufacturing Infrastructure Development and Education (AMIDE) Alliance will also be presented.
5:00 Recycling Panel Discussion Frazer Barnes,Elg Carbon Fibre Ltd. Geoff Wood, Composite Recycling Technology Center Alice Havill, Vartega Inc.
This will be a panel discussion, and attendees will be able to ask questions.
5:30 Conference Adjourns
Our conference moderators will adjourn our conference and allow for any final questions.
5:30 – 7:00 Grand Cocktail Reception
Enjoy our Grand Reception! Sponsored by:
7:30-8:45 Registration and Continental Breakfast
Enjoy A Continental Breakfast and Informal Discussion with Your Colleagues Sponsored by:
9:00 Novel Carbon Fiber Composites For High Volume Structural Automotive Applications David Bank, Fellow, Dow Chemical Co.
Meeting the global requirement for reduced CO2 emissions and increased vehicle fuel economy requires new technology development within the transportation industry. The impact of these pressures is evident in the passenger car market where increased regulation of exhaust emissions and fleet fuel economy have led to the need for advanced power-train engineering to meet current and future regulations. Results of this work have led to clean diesel technology, hybridization, and electrification. However, even as powertrains evolve, it has become apparent that these changes alone may be insufficient to meet future performance requirements. While automotive manufacturers have made gains in fuel efficiency and reduced vehicle greenhouse gas emissions, meeting mandated fleet average fuel economies requires a step change in vehicle technology. Carbon fiber composites offer an efficient means of achieving mass reduction without sacrificing mechanical integrity. To this end, Ford, Dow and DowAksa partnered to develop VORAFUSE™ compression molding intermediate and advanced processing technology. These materials are designed to meet stringent critical to quality performance parameters required to commoditize the processing of light weight components.
9:30 Advancements in Carbon Fiber SMC Development Mike Siwajek, VP, Research & Development, Continental Structural Plastics – A Teijin Group Company
Carbon fiber composites are desirable for their high strength-to-weight ratio allowing for reduced weight in automotive components. Sheet Molding Compound (SMC) is an attractive format due to its efficient utilization of material and lower cost compared to other formats (e.g. prepreg, RTM, etc.). This paper describes recent improvements in the effectiveness and versatility of carbon fiber SMC for the automotive market.
10:00 How Advanced Composites Manufacturing Will Benefit from Artificial Intelligence Scott Blake, President, Aligned Vision
In 2018, a convolutional neural network (CNN) successfully generated an analysis algorithm to detect foreign objects and debris (FOD) on composite component surfaces. The immediate benefit of this CNN implementation is the replacement of painstaking hand-engineering of algorithms with self-generated analysis algorithms, which will lower developmental costs and speed up new applications of automatic inspection. Certainly, many other benefits are in the offing as CNNs and other Artificial Intelligence (AI) mechanisms are applied to many other aspects of automated advanced composites manufacturing. This presentation will discuss the areas to which AI may be applied and explore the benefits of these applications. Areas to be discussed include raw material inventory and property characterization, generation of process control instructions, population of the digital thread and digital twin generation, and deep learning-generated closed-loop process improvement both for an individual component and for manufacturing technologies and processes.
10:30 Refreshment Break
Enjoy A Refreshment Break and Visit our Carbon Fiber Exhibitors! Sponsored by:
11:00 Design to Cost for Composites: From Automotive Experience to Aeronautics Benefits Christophe Champenois, Composite Director, CETIM Group
The “Quilted Statrum Design QSD” a new software for optimizing the material cost, a new versatile process to produce at low cost, and short cycle time tailored part with different semi-products.
*Mr. Champenois will not be joining the conference due to a serious injury. However, he will be making his presentation available to registered attendees after the event. This file will be sent to you in a PDF by way of a password protected link approximately 2 weeks after our event has concluded.
11:30 CFRP Series Production for The Automotive Industry Lars Herbeck, Business Development, Voith Composites GmbH & Co. Kg
Abstract to follow.
12:00-1:00 Roundtable Luncheon Sponsored By: Izumi International
Enjoy your Lunch and Visit our Carbon Fiber Exhibitors! Sponsored by:
1:00 Innovative Production Technology for Mass production – the Novel, Automated solution for Sequential Preforming and Challenging Bonding Applications Christian Fais, President, Schmidt & Heinzmann North America Inc
Schmidt & Heinzmann GmbH has launched a novel machine technology enabling automated, flexible and low-cost production. The plant can be used for sequential preforming processes of fiber reinforcement textiles especially carbon fiber and also for joining operations (adhesive bonding). A unique characteristic are the flexible robotic arms in the working area of the press unit, which can carry out a variety of handling operations quickly and reproducibly. In the area of sequential preforming, multi-stage draping processes can be implemented in which foamed material cores or metal inserts are positioned on the preform by the handling units. Likewise, the gripper arms can be used for applying local tension during the draping process. With the flexible gantry system the adhesives can be applied directly to the part and the appropriate ultrasonic cutting technology is used for edge trimming and segmentation of preforms. Finally no robot is necessary for these steps.
1:30 The Advantages of Continuous Z-Axis Reinforcements on Down-hole Tool Components Marco Zvanik, Vice President Business Development, Seriforge
Down hole tools for the oil & gas market have replaced most of the metal components with composite materials due to their ability to drill out cleanly and quickly. However, the harsh temperatures and pressures required on specific components like slip rings make composites less effective than cast iron and other alloys. Seriforge has developed a new technology to manufacture large volume net shape preforms for both infusion and compression molding that require higher shear loading requirements that conventional composites, with their Continuous Z-axis Reinforcement (CZR) technology.
2:00 Automated 3d Fiber Layup Concepts Based on Fiber Patch Placement Technology John Melilli, President, Composite Automation-Presented for Cevotec
Fiber Patch Placement (FPP) is the advanced technology for the automated fiber layup of geometrically complex composites and reinforcements. The process uses a pick-and-place robot with a flexible patch gripper to precisely place defined fiber patches, automatically cut from a tape, on a 3D mold mounted on a tool manipulation robot. This allows for a discrete orientation of each patch and eliminates scrap as well as additional forming processes through additive, 3D net-shape preforming – either with dry-fiber or thermoset prepreg tape. Through individual orientation of each patch along load paths, mechanical properties like stiffness and strength improve up to 150% while the additive, individual fiber placement saves up to 30% of the precious material.
2:30 Refreshment Break
Enjoy A Refreshment Break and Visit our Carbon Fiber Exhibitors! Sponsored by:
3:00 Additive Manufacturing of Carbon Fiber Reinforced Composites Hilmar Koerner, Senior Research Chemist, Air Force Research Laboratory
Additive manufacturing of carbon fiber reinforced resin systems including epoxies via Direct Write and polyimides via Fused Deposition Modeling and Selective Laser Sintering. This paper describes approaches to 3D print composite parts for Air Force relevant applications.
3:30 Composites Tooling Via Large Scale Additive Manufacturing – Advances and Challenges Vlastimil Kunc, Team Lead for Polymer Materials Research, Oak Ridge National Laboratory
It has been demonstrated that composite tooling can be produced with lower lead time and at lower cost via large scale additive manufacturing (AM) techniques compared to traditional manufacturing methods. In this talk, we highlight examples of AM tooling used for hand layup, vacuum infusion, autoclave and compression molding of composites. Features beneficial for AM tool production will be discussed along with design strategies will be discussed in light of recent advances and remaining challenges of this technology.