ON-DEMAND PRESENTATION
Nano Thickness Aluminum Film Coating on Carbon Fiber Composites​
Archal Shah, Composites Tomorrow

The carbon fiber composites have been increasingly used in advanced applications, owing to their superior properties. However, typically carbon epoxy has very little reflectivity. This becomes a challenge for products that require high reflectivity like equipment bay, reflectors, et al. The paper talks about the concept and technology to deposit a nano thickness layer of Aluminum on carbon epoxy composites to achieve high reflectivity. The latter portion of the paper discusses the equipment developed and application of the coating on 1.2m long carbon epoxy shell. The paper also shares the challenges faced in development. Finally, we conclude with measurement techniques and overall process stability.  

ON-DEMAND PRESENTATION
Carbon Fibre Based Composite Industries - Bright Future Ahead​
R.K. Singh, Composites Excellence Center of Asia

India is a rapidly growing center of composite industries and carbon fiber based composite materials.  The growth prospective in India is eminent.  Discussion will include the present status and future growth opportunities of carbon fiber based composite industries. India has the infrastructure, development potential , and support of the Government, Educational institutions,  and the Composites Excellence Center of Asia.

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Carbon Fiber NOW Agenda

Wednesday November 18th, 2020

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Thursday November 19th, 2020

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*Please note that all sessions, speakers and times are subject to change. 

​11:00 am 🔶Opening Statement 
Scott Stephenson, CompositesWorld

Opening statement of the event. 

11:15 am  🔶A View From Wall Street-The Outlook for Aerospace & Defense
​Ron Epstein, Bank of America

An outlook for both commercial aerospace and defense markets during the COVID-19 pandemic in a Presidential election year. 

11:45 am 🔶Aerospace Composites Market Outlook
​Peter Zimm, Charles Edward

Before the COVID-induced downturn earlier in 2020, composites were gaining share over traditional lightweight materials such as aluminum. As production rates stabilize at lower levels than 2019’s, what is the outlook now? Will COVID’s disruption accelerate, slow, or even reverse the tide of adoption by the aerospace industry? Lastly, what are the prospects for still further disruption?
This presentation will provide an outlook on air traffic (in this case highlighting the differences between CFRP intensive widebodies and narrowbodies), production rates (they’ve dropped, will they drop more?), and ultimately aerospace demand for composites, using Charles Edwards’ proprietary raw materials model, as well as commentary on trends that are driving the outlook

12:15 pm 🔶Trends in Composite Aerostructures
​Curtis Welch, Spirit AeroSystemes

Advances in composite aero structures are driven by three primary trends:
1) Advances in design, materials, and processes are enabling more integrated structures
2) Advances in materials and automation technologies are enabling lower cost fabrication processes
3) Implementing the digital thread to improve quality and lowering cost
Spirit advancement in composite aero structures is secured by leveraging fully integrated structures, advanced materials and continued optimization of the manufacturing systems. Examples over the last decade include 787 Section 41 and A350 S15 large assemblies with differentiated co-cured panel prepreg and automated fiber placement (AFP) technology. For the next decade it is anticipated a next level of architecture integration, performance and cost optimization will be required and therefore new range of technologies are being matured. These include resin infusion processes applied to next generation wing and fuselage structure and leveraging thermoplastics. Spirit’s progress on next generation fuselage architecture and technology as demonstrated by ASTRA (Advanced Structures Technology and Revolutionary Architecture) and how we are incorporating these industrialization improvements into current programs will be discussed. Examples for next level automation and industrialization optimization through exploiting our distinctive capability strategy will also be shared as applied to current products including progress on A320 RTM spoiler. 

11:00 am 🔶Opening Statement- Scott Stephenson, CompositesWorld

Opening statement of the event.

11:15 am 🔶Butterfield UAM

11:45 am 🔶Christensen 

12:15 pm 🔶Carbon Fiber meets Polypropylene: New Opportunities with CF in the field of Thermoplastic Composites
Dr. Christos Karatzias, Mitsui Chemicals Europe GmbH

Thermoplastic matrices for composite solutions are becoming increasingly popular in various markets like automotive, aerospace, oil & gas but also in consumer and sports. Thermoplastic composites materials with carbon fibres (CFRTP) based on polar matrices like PA6 have been well developed, whereas non-polar polyolefin based CFRTP (e.g. with PP matrix) still have issues on interfacial surface between carbon fibre and polyolefin matrices, resulting in low durability and low mechanical properties. 

However, CFRTP based on PP have a huge potential to contribute to manufacture an economical, high performance lightweight composite as CF-PP could offer lower densities and higher rigidity combined with a high weight reduction, higher workability for further processing steps as well as outstanding resistance to water absorption and hydrolysis.

With regards to the mentioned challenge of this material combination, a recent composite development of Mitsui Chemicals is focusing on unidirectional tapes based on carbon fibre and polypropylene (TAFNEXâ„¢ CF-PP UD).
 
Therefore, the first part of the presentation will describe the process and material development in which a special PP-compatible bonding solution for carbon fibers has been new-developed for improved fiber matrix adhesion resulting in higher mechanical properties. In addition, an own modified PP compound as matrix is used, so that the
bonding is further increased and higher application temperatures are possible for a short time. 

In the second part of the presentation developments will be presented where TAFNEXâ„¢ CF-PP UD has been used in hybrid solutions (e.g. with injection moulding compounds or GF-based organosheets) to enable a cost-effective solution for semi-structural applications. A simulation approach has been developed together with our subsidiary ARRK Engineering using TAFNEXâ„¢ CF-PP UD to predict the crash behaviour and improve the lay-up of the UD tapes in the part.

12:45pm Coffee Break Sponsored by Harper

12:45pm Coffee Break Sponsored by Harper

1:00 pm 🔶Economic and Environmental Assessment of Recycled Carbon Fiber  
​Frazer Barnes, ELG Carbon Fiber

Over the last few years, the use of recycled carbon fibers in applications in the wind energy, electronics, rail and automotive industries has markedly increased. The original driver was usually reduced material cost, but now the additional economic benefits that these bring as a result of their particular properties are being more widely recognized. This, coupled with an increasing awareness of the environmental benefits of using recycled materials, creates a strong foundation for the next phase of growth of the industry. These topics will be covered in the presentation/discussion.

1:30 pm 🔶Sustainable Carbon Fiber  
​Stephen Rawson, R&M International 

Industry panel discussion with representatives from key suppliers/manufactures of carbon fiber to address the needs of the industry for sustainable carbon fiber.  The panel will address the key challenges facing the industry some new technologies on the horizon and the state of the industry in recycling.

2:00 pm 🔶Cimarron 

1:00 pm  🔹CrossTalk: Brent Strong, Tulinda Larsen, Gov. Herbert   

Future for Utah’s Advanced Materials and Advanced Manufacturing

1:30 pm 🔹Crosstalk: National Manufacturing Trends / Manufacturing USA Update 
Mike Molnar, NIST

As the Director of the Office of Advanced Manufacturing at the National Institute of Standards and Technology (NIST) within the U.S. Department of Commerce, Mr. Molnar will address national trends in manufacturing along with new developments with the Manufacturing USA program. 

2:00 pm 🔹Crosstalk: State of the Composites Industry 
​Jeff Sloan, CompositesWorld

As the editor-in-chief for CompositesWorld Magazine, a B2B technical trade publication that serves the global composites manufacturing industry, Mr. Sloan will discuss the state of the composites industry along with the latest developments and trends.

2:30pm Coffee Break Sponsored by Harper

2:30pm Coffee Break Sponsored by Harper

2:45 pm 🔶Implementation, Use, and ROI of IIoT and AI Technologies in Composites Manufacturing for the New Now​  
​Avner Ben-Bassat, Plataine Inc. 

Facing unprecedented times of global uncertainties, advanced manufacturers must examine methods to support complex programs at lower costs. Smart factory, where cyber-physical production processes and systems are automatically communicating with each other using the Internet of Things, opens a new horizon of possibilities for these advanced manufacturers. 

3:15 pm 🔶Optimization and Evaluation of Hybrid Composites Process Routes by Advanced Simulation Approaches  
​Benedikt Fengler, SIMUTENCE GmbH

Carbon fiber reinforced composite materials reveal a particularly high lightweight potential, due to their excellent weight-specific material properties and their capability to be tailored to specific applications. Thereby, thermoforming of thermoplastic tapes and the combination with thermoplastic back-injection molding, reveal great potential for large volume production of structural components, due to low cycle times, recyclability, and material efficiency. The manufacturing of composite materials, however, involves different challenges. These challenges can be met within the developments of Industry 4.0 through a continuous and functional virtual process chain, which includes a digital twin of production processes employing process simulation.

In this presentation, it is initially outlined how the manufacturability, as well as manufacturing effects of different thermoplastic process routes, can be predicted through process simulation. Subsequently, it is presented how manufacturing effects can be considered in downstream simulation steps, such as warpage or structural simulation, based on a functional virtual process chain (cf. Figure 1). This includes the presentation of novel simulation approaches for thermoforming of thermoplastic PA6-CF tape laminates in combination with back-injection molding. A focus is laid on the prediction of the interaction between the tape laminate and the LFT.

3:45 pm🔶 Large Scale Additive Manufacturing - Scaling for Production Tooling Applications 2020  
​Rick Neff, Rick Neff LLC

One of the key technologies to manufacturing is quality tooling.  In applications like composites or precast concrete, tooling often dictates the cost and schedule of a project.  Additive manufacturing has the promise of reducing the cost and the lead time significantly over traditional tooling.  The path has not been easy as there have been challenges along the way.  There has been an evolution in machinery, materials and methods that have resulted in a robust process for quickly making low cost tools that can meet the demanding needs of production. 
Additively Manufactured tooling has been used in the boating industry for both plugs and production molds.  Boat molds and plugs can be 3D printed.  There are a few examples of 3D printed watercraft as well.  A variety of projects highlight the different methods that have been tried.  
Printed tooling is making an impact on the architecture world with durable, low cost tools impacting the precast concrete industry.  
Aerospace has been working to qualify processes, materials and methods for both production and prototype tooling.  Years of research between leading companies, research laboratories and OEMs have continuously yielded new results.  See examples of work done by Oak Ridge National Laboratory, Tru-Design, Boeing, Lockheed Martin, Airbus, IACMI, Techmer PM and Thermwood Inc.  Large Scale Additive composite tooling can have vacuum integrity, low coefficient of thermal expansion (CTE) and durability.    
Companies can routinely process a variety of materials from room temperature materials like ABS and Polycarbonate to high temperature materials such as PPS, PSU, PESU and Ultem.  Each has its advantages and limitations. Materials with a lower glass transition temperature are easier to print, especially at large scale.  Higher temperature materials cool quickly so you need to print fast to make large parts.  The latest equipment can print quite large parts out of even high temperature materials like PESU.  
AM for composite tooling has forged past the challenges and can truly be implemented today for both prototype and production.  Composite manufacturers really can implement 3D printed tooling to reduce the cost and lead time of their production.  

2:45 pm 🔹Crosstalk: ​Graphene Enabling Advanced Material Applications  
​Terrance Barkan, The Graphene Council 

As the Executive Director of The Graphene Council, Mr. Barkan will provide an overview of the current range of graphene materials and examples of commercial applications such as: composites (thermosets and thermoplastics), coatings and related applications for increased strength, lightweighting, EMI shielding, heat spreading and more. 

3:15 pm 🔹Crosstalk: ​Composite Adoption Trends in Transport and Energy
Julia Atwood, Bloomberg NEF

Low-cost wind power and electric vehicles are accelerating demand for composites. But carbon fiber production has been hit by Covid-19, with its most lucrative clients in the aerospace industry cancelling contracts. This talk will discuss which industries have been the most resilient, and where we expect volumes and prices to go from here.

3:45 pm 🔹Crosstalk: The Role Of Engineered Compounds And 3d Printing In Support Of Industry 4.0 And Manufacturing Competitiveness  
​Tom Drye, Techmer PM

Tom Drye is Vice President of Emerging Markets, Innovation, and Application Development for Techmer PM, a materials design and solutions provider of custom engineered compounds. Mr. Drye will address the role that engineered compounds (in collaboration with large part additive printers) have played in US manufacturing.  Aspects discussed will be: design freedom, speed, cost, tool management, size, customization, autoclavability, and end-of-life recycling. 

4:15 pm 🔶Closing Announcements 
​Scott Stephenson & Jeff Sloan , CompositesWorld Magazine

Closing announcements for the event, given by our hosts for the week. 

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4:15 pm 🔶Closing Announcements 
​Scott Stephenson & Jeff Sloan , CompositesWorld Magazine

Closing announcements for the event, given by our hosts for the week.