Forum Presentations for Thursday, January 27, 2022
Presentations for the Materials Innovation & Advanced Technology Leadership Forum on Thursday, January 27, 2022.
SESSION 1 — CHALLENGES
Air Mobility - Economy of Scale, John Geriguis and Nobuya Kawamura
Air mobility key factors : safety is north star, light-weight is central to achieve maximum range, production volume expected to be significantly higher than traditional aerospace, total cost of ownership of an aircraft is a key to success. Economy of scale needs: the lightest materials, the strongest materials, the toughest materials, the most economical materials, the most economical methods, the fastest processes. Reduce material cost: no waste, no material expiration, no out-time limitations, reduce material purchased by 50%. Reduce touch labor: automated processes, in-situ inspections, in-situ repairs, digital twin, eliminate the variables. Industry improvement opportunities : Improve quality inspection methods, improve lay-up time, improve material for AFP, improve weight saving, improve takt time. Working together to expedite disruptive technologies.
Recycling and Circular Economy of Automotive Composite Parts, Hendrik Mainka
Composite Material Opportunities and Challenges for Air Mobility and Unmanned Systems, Robert Yancey
The Advanced Air Mobility (AAM) market is emerging quickly as the next generation of efficiently transporting people and cargo in urban environments and underserved regions. The Unmanned Aerial Vehicle (UAV) market is growing rapidly for both defense and commercial applications. Both markets require advanced composite materials for lightweight and efficient operations. They also are challenging current material and manufacturing systems as they will require material and manufacturing systems that result in high-volume, low-cost, but reliable composite structures. This presentation will cover the structural material challenges, opportunities, and solutions for the UAV and AAM industries. It will include an in-depth discussion on the material selection criteria including cost, rate, quality, manufacturing process, supply chain, automation, and certification. Presentation content is applicable to companies in all stages of development and production for UAV/AAM vehicles.
SESSION 2 — SYNERGIES
Synergy of Aerospace and Wind Energy Composites Technologies, Wendy Lin
GE is a leader in the use of composites for aerospace and wind energy through the GE Aviation and GE Renewable Energy business segments since the introduction of composite fan blades in 1990s and acquisition of wind energy business in early 2000s. As the technologies in both industries advance, there is a drive to common goals of automation to manage limited skilled labor force and quality, thermoplastics for higher rate, and recycling. As a Principal Engineer at the GE Global Research leading programs on composite materials and process development, Dr. Lin was in a unique situation to work concurrently in both industries. She gained further depth as she continued her career as Consulting Engineer with GE Aviation Chief Manufacturing Engineering organization followed by her current role as Consulting Engineer with GE Renewable Energy Advanced Manufacturing Technologies organization. From her 20+ years’ experience working in both industries, Dr. Lin will provide overview of areas of synergy for development.
Pultrusion with Design Freedom, Matthew Parkinson
Pultrusion composites are known for their outstanding mechanical properties especially strength and impact. However, due to pultrusion’s linear section profiles it has limited product design adoption. Often engineers would prefer a pultrusion due to their excellent mechanicals and mass advantage but instead select structural metals due to geometry design freedom. At BASF we have innovated with our customer partner L&L Products a new concept that allows for design freedom with pultrusion better than what metals offer. In 2021, two separate OEMs, Toyota and Stellantis launched vehicles into production with innovative applications where thermoset pultrusion is overmolded with thermoplastics to leverage the advantages of both materials. This unique combination allows for 40% lower mass than previous generation steel and significant cost savings over aluminum die casting. This presentation will present an overview of the Toyota and Stellantis applications to promote the use of this technology in other industries and applications.
Advances in Manufacturing CarbonCarbon Composites for High Temperature Applications, Adam Rawlett
Alternate Methods For Increasing Composite Part Throughput, Sam Tollefsen
SESSION 3 — ADVANCEMENTS
Rapid Large-Scale Structural Thermoplastic Parts, Michael Assadi and Todd “TJ” Chace
NCC’s Digital for Composites (D4C) – From Right First Time to Right Every Time, Enrique Garcia
Aerospace Integral Structures by LRI Based in Automated Lamination of Fabrics with ADMP, Peio Olaskoaga
SESSION 4 — SIMULATION/SOFTWARE CONTRIBUTORS
AI-Based Production Scheduling And Process Optimization Drive Manufacturing Agility And Efficiencies, Avner Ben-Bassat
How Credible Simulation Significantly Reduces Product Development Time and Cost, Javad Fatemi
Software Platform Solutions for Composites Design, Manufacturing and Simulation 4.0, William Ramroth
Efficient Manufacturing for 21st Century Composite Structures, Alex Rubin
In this presentation, the author will discuss the role of design architecture, Model Based Engineering (MBE) integration, production system optimization, automated manufacturing processes, and other factors that have a direct impact on accelerating production rates required to meet current and especially future needs for composite aerospace components. An integrated MBE approach for various design and manufacturing steps of composite component development, fabrication and product support are necessary to maintain component quality requirements and cost goals throughout component lifecycle. New materials and manufacturing processes that enable these higher rates will need to be implemented, as well as critical in-line monitoring and in-line inspection techniques. Future aircraft may include different composite materials and processes options to achieve the performance/rate/cost/quality requirements for specific composite components at higher rates. The various analytical solutions are needed to integrate sensor data, Machine Learning and Physics Based process optimization models resulting in real-time closed loop control systems to adjust the process to meet multiple requirements, for Boeing internal manufacturing and at Suppliers.