ACG Launches New DForm - Deformable Composite System (DCS)

A New Mass Production Part and Tooling Prepreg from the Leaders in Composites Technology (patents applied for).

The Advanced Composite Group (ACG), part of the Composites Division of Umeco plc, announces the launch of ‘DForm’, its latest innovation in prepreg technology.

This ground-breaking tooling and mass production component prepreg is ACG’s advanced Deformable Composite System (DCS), a time and cost-saving prepreg technology that combines the conformability of a short fibre moulding compound with the directional characteristics of a high performance, long fibre composite.   

This unique combination of characteristics is achieved through selective fibre slitting of a unidirectional prepreg precursor. Presented in a multi-layer configuration, DForm offers appropriate strength characteristics with no loss of stiffness. Moreover, it does not require detailed laminating or extensive vacuum debulking. On the contrary, it readily flows under press or autoclave pressure to replicate the precise details of a complex mould tool or components.

When compared to standard fabric-based tooling systems, DForm offers considerable savings, typically in the region of 20 - 30% reduction, in lay-up times through operational de-skilling, brought about through ease of application, as well as a readily achievable, superior surface finish. Furthermore, the directional nature of a DForm’s structure helps to maintain dimensional accuracy and performance predictability, thereby presenting a major advantage over random short fibre and resin infusion tooling systems. An added advantage is DForm’s ability to create an extremely flat, print-through free surface profile with no local thinning or loss of fibre orientation.

Like all of ACG’s prepregs, DForm moulds can be customised to suit customers’ specific requirements, and is particularly suited, because of its inherent strength and stiffness characteristics, to high volume secondary structural applications. As ACG strives to provide new technology and next generation products in advance of its competitors, the development of ACG’s DForm is continuous, and ACG is actively seeking parties that might be interested in collaborative working opportunities to examine applications for the technology.

Dr. John Nixon, Technical Marketing Manager at ACG, said: “This new, market leading technology is an exciting addition to our extensive product range. This product will allow customers to save money and improve efficiency whilst maintaining the high standard expecting of our products. We look forward to working with our customers to find and develop new and exciting applications for such a versatile technology.”

For further details contact ACG Sales Department.

Larger than Life Blades in Ireland's Strangford Lough - February 2008

Plans to install the world’s largest commercial scale tidal energy system in Northern Ireland’s Strangford Lough were recently published by tidal energy company Marine Current Turbines Ltd. (MCT). Strangford Lough is a large, shallow sea lough situated on the east coast of County Down.

The installation of MCT’s 1.2MW SeaGen tidal system, which is planned for March, will generate clean electricity for a thousand homes.

VTM®266, one in of series of Variable Temperature Moulding prepregs specially formulated by ACG, was selected for the manufacture of the 65mm thick structural spars, the elements that add strength and rigidity to the two 8metre long blades. It goes without saying that, at 8metres long, the spars had to be made using a material that possessed the requisite design and performance qualities and characteristics of high strength and stiffness, but with minimal mass.

As far as processing was concerned, VTM266’s chemistry resulted in a safe, low temperature cure processing route, making it ideally suited for this particular application, where overall composite thickness could, under other circumstances, result in severe exothermic reaction.

While VTM266 permits vacuum-only or autoclave processing cure options, the vacuum-only route was particularly suited for a component of this magnitude.

The scale of the project meant that excellent handling and out life characteristics were significant factors in choosing VTM266, as it provides good handling and processing characteristics on reinforcements ranging from lightweight veils to ultra heavyweight multi-axial fabrics and unidirectional tapes.

Aviation Enterprises Ltd., based in Lambourn, UK, which was responsible for manufacturing the colossal blade assemblies, also designed and installed a fully integrated fibre-optic stress sensing system into the blades to continuously monitor their life-long performance under the demanding environmental conditions that they are likely to endure. Taking stock of the enormity of the task, the entire project was seen as a fresh engineering challenge, one that the industry had not previously experienced, but one that was enthusiastically accepted.

A team of environmental scientists, drawn from Royal Haskoning, Queen’s University Belfast and St. Andrew’s Sea Mammal Research Unit, will closely monitor SeaGen’s operation and its interaction with marine life during the 12 week commissioning phase.

The UK Government’s Department of Business, Enterprise & Regulatory Reform (BERR) has provided valuable support to the SeaGen project. MCT has received grant assistance from BERR for the main part of the project’s development and has received a further £0.98million investment from the government-funded Technology Strategy Board to cover the additional installation costs and independent performance validation.

Martin Wright, Managing Director of MCT is reported to have said: “We have carried out extensive engineering and environmental studies to ensure the very best means of installation and operation. As long as the weather is good and there are no last minute operational issues to contend with, we should have SeaGen deployed by the end of March.”

“There is global interest in SeaGen as it will be the largest commercial tidal stream device to be installed anywhere in the world, and so we can expect its installation to be a springboard for the further development of the marine energy industry in the UK and the island of Ireland. Looking ahead, MCT intends to manufacture and deploy a series of SeaGen devices in projects off Anglesey, UK and on the Canadian seaboard within the next 2 to 4 years.”

ACG looks forward to partnering MCT in future projects and will continue to offer the same full technical support and materials formulation service that it offers to all of its clients.

Photos: Courtesy of Marine Current Turbines Ltd.

For further details contact ACG Sales Department.

‘Precimould Plus’ Partners Receive JEC Innovation Award for Software - February 2008

Ericsson Racing Team’s boat ‘Ericsson 3’, which was unveiled to the yachting press on the 12th February 2008, is the first one-off Volvo Ocean Race (VO70) challenge yacht to come out of the purpose-built Ericsson boatyard in Kista, Sweden. This is the first of two Ericsson yachts to be made using Advanced Composites Group’s (ACG) carbon prepreg materials; Ericsson 4 is in the boatyard right now. ACG, a member of the Composites Division of Umeco plc, has a proven track record in this and other challenging races, and is pleased to continue its association in this field, with sights firmly set of providing Ericsson Racing Team with customised materials and technical expertise to support them in this formidable venture.

With Juan Kouyoumdjian as the exclusive designer for Ericsson Racing Team, and Killian Bushe as construction manager, Ericsson 3 is unquestionably one of a kind, although embracing the strong heritage of the winning yacht ABN AMRO One, now Ericsson 2, from the 2005-2006 Volvo Ocean Race.

One of the final steps in Ericsson 3’s construction process was to provide it with its true identity - adding colour to the sleek black carbon hull, the product of employing VTM®264, ACG’s long out life, intermediate viscosity, epoxy resin matrix prepreg and its associated VTA®260 film adhesive, which is used to bond the honeycomb and foam core. With the finishing touches complete, Ericsson 3 is ready to take to the water and start serving the team as their main training boat, and be one of the race boats for the 2008-2009 Volvo Ocean Race.

While ACG’s VTM264 has logged a remarkable record of successes over the years, demands placed on these boats are severe. There is no dropping the anchor at the end of the day. During a leg or an in-port race the pressure is relentless. The Volvo Ocean Race is life on the extreme edge. Imagine a boat built for this. Well, based on previous experiences and the record of wins, ACG’s materials will give Ericsson Racing Team the best possible chance of making it to the finish line intact and as the winning team.

The first step in the construction technique adopted by Kouyoumdjian and Bushe is to build a plug, an outline of the hull, from precision-cut frames. Once the plug was made, a carbon fibre mould is built around it. The inside of the finished mould had to reflect the exact dimensions of the boat’s hull, so accuracy is of paramount importance.  The hull is then fabricated in two layers, with honeycomb core or foam sandwiched between them to add stiffness to the structure. In areas where extra strength is required, such as around the keel, high density foam or solid carbon fibre is used. Once fully laminated, the hull is slowly cured in an oven. The Kista yard has two ovens, one at 26 meters long, just big enough to accommodate the entire boat. The second, smaller oven is used to cure the carbon fibre prepreg deck, bulkheads, galley, navigational station, and toilet.

It has been said that the boat builders are crucial for the success of the project - and there are not that many of them around, but the same also applies to the crews and, of course, the construction materials. ACG trusts that they will be part of a winning combination that delivers when it really matters - when the race is on!

For further details contact ACG Sales Department.

Unveiled - 2008-2009 Volvo Ocean Race Yacht Uses Advanced Composites Group’s Prepregs - February 2008

Photo: copyright of Oskar Kihlborg/Ericsson Racing Team

Ericsson Racing Team’s boat ‘Ericsson 3’, which was unveiled to the yachting press on the 12th February 2008, is the first one-off Volvo Ocean Race (VO70) challenge yacht to come out of the purpose-built Ericsson boatyard in Kista, Sweden. This is the first of two Ericsson yachts to be made using Advanced Composites Group’s (ACG) carbon prepreg materials; Ericsson 4 is in the boatyard right now. ACG, a member of the Composites Division of Umeco plc, has a proven track record in this and other challenging races, and is pleased to continue its association in this field, with sights firmly set of providing Ericsson Racing Team with customised materials and technical expertise to support them in this formidable venture.

With Juan Kouyoumdjian as the exclusive designer for Ericsson Racing Team, and Killian Bushe as construction manager, Ericsson 3 is unquestionably one of a kind, although embracing the strong heritage of the winning yacht ABN AMRO One, now Ericsson 2, from the 2005-2006 Volvo Ocean Race.

One of the final steps in Ericsson 3’s construction process was to provide it with its true identity - adding colour to the sleek black carbon hull, the product of employing VTM®264, ACG’s long out life, intermediate viscosity, epoxy resin matrix prepreg and its associated VTA®260 film adhesive, which is used to bond the honeycomb and foam core . With the finishing touches complete, Ericsson 3 is ready to take to the water and start serving the team as their main training boat, and be one of the race boats for the 2008-2009 Volvo Ocean Race.

While ACG’s VTM264 has logged a remarkable record of successes over the years, demands placed on these boats are severe. There is no dropping the anchor at the end of the day. During a leg or an in-port race the pressure is relentless. The Volvo Ocean Race is life on the extreme edge. Imagine a boat built for this. Well, based on previous experiences and the record of wins, ACG’s materials will give Ericsson Racing Team the best possible chance of making it to the finish line intact and as the winning team.
                                                                                                                        
The first step in the construction technique adopted by Kouyoumdjian and Bushe is to build a plug, an outline of the hull, from precision-cut frames. Once the plug was made, a carbon fibre mould is built around it. The inside of the finished mould had to reflect the exact dimensions of the boat’s hull, so accuracy is of paramount importance.  The hull is then fabricated in two layers, with honeycomb core or foam sandwiched between them to add stiffness to the structure. In areas where extra strength is required, such as around the keel, high density foam or solid carbon fibre is used. Once fully laminated, the hull is slowly cured in an oven. The Kista yard has two ovens, one at 26 meters long, just big enough to accommodate the entire boat. The second, smaller oven is used to cure the carbon fibre prepreg deck, bulkheads, galley, navigational station, and toilet.

It has been said that the boat builders are crucial for the success of the project - and there are not that many of them around, but the same also applies to the crews and, of course, the construction materials. ACG trusts that they will be part of a winning combination that delivers when it really matters - when the race is on!

For further details contact ACG Sales Department.

ACG Integrates Primco Prepregs - February 2008

Image: 68-ft.-93-ft. (20.8m-28.3m) dia MSF radomes. U.S. Navy photo by JO1 Preston Keres, June 2003

ACG recently strengthened its position in the aircraft interiors business with the acquisition of Primco, a leading formulator and supplier of prepreg systems used in the aerospace, defence, medical, sporting and general industrial sectors.

The combined operation now offers outstanding synergisms; Primco augments the Group’s existing hot-melt capabilities through state-of-the-art solvent towers that meet stringent environmental regulations.

ACG now manufactures a range of cost-effective prepreg products, including epoxy, phenolic, cyanate ester, Bismaleimide (BMI) and thermoplastic resin systems in all formats and with all types of fibre reinforcement.

ACG Primco’s aircraft interior phenolic systems, qualified to Airbus specifications, exhibit superior surface finish, thereby reducing post-mould finishing while also contributing to reductions in both cost and weight. ACG also offers a range of self-extinguishing epoxy prepreg systems that are used in demanding applications such as flooring and seating.

ACG is forging ahead with the development of new aerospace systems for both structural and interior applications. The Group’s proven research potential was enhanced in 2006 with the opening of a modern Technology Centre, staffed by approximately 60 people.

Customers can expect to benefit from the high level service for which ACG and Primco are renowned. From its prepreg manufacturing facilities in the UK and the USA, the Group services the market by delivering bespoke products to short lead times. This is backed by a network of sales agencies around the world.

The acquisition of George Cole Technologies Limited, which traded as Primco, was made by Umeco plc through ACG.
Established for over 40 years, Primco's materials, manufacturing technologies and applications are highly complementary to those of ACG, and will further enlarge the Group's existing range of composite materials technologies and aerospace qualifications.

Clive Snowdon, Chief Executive of Umeco plc, commented: “The Primco acquisition further illustrates the progress Umeco has achieved in delivering complementary growth to the Group both in the UK and overseas. It will enable us to offer existing customers a wider range of material technologies, whilst allowing ACG to further consolidate its market leading position in a continuously evolving composite arena.”

Furthermore, “Primco offers good long term value-creating growth and we look forward to realising operating synergies as we integrate it into our existing business."

For further details contact ACG Sales Department.

ACG Official Supplier for one of the strongest teams in the Volvo Ocean Race 2008-09 - October 2007

Photo: copyright of Oskar Kihlborg

ACG, part of the Composites Division of Umeco plc, is proud to announce that it has signed an agreement to become Official Supplier of Composite Material to The Ericsson Racing Team in the run-up to the Volvo Ocean Race, which is scheduled to start in Alicante, Spain October 2008. While it may seem like early days, this is actually far from the truth. Ericsson Racing Team recently acquired the winning yacht from the Volvo Ocean Race 2005-2006, ABN AMRO One (ABN 1) for preparation purposes. It is currently being used to put the team through its paces for training and speed tests, extending the team’s commitment to develop a successful 2008-2009 campaign.

It is interesting to note, from a team and supplier standpoint, that ABN 1 also used ACG’s VTM®260 series prepregs and VTA®260 film adhesive. Even more remarkable is that Ericsson Racing Team is using the services of Killian Bushe as construction manager, i.e. the same person who headed the team that built ABN 1. It is no coincidence really, as this gentleman has yacht building in his veins. Moreover, the construction plan for the Ericsson boat is based on an exclusive design by Juan Kouyoumdjian, one of the world’s foremost designers of racing and cruising sailboats, and also the designer of ABN 1.

Born in Cork, Ireland, in 1955, Killian Bushe has been at the forefront of composite boatbuilding technology since the early eighties and has produced many high quality, light-weight-racing, cup-winning yachts, ranging in size from 40 to 85 feet. Among many successful projects is the Volvo 60 Illbruck, which was built in Leverkusen Germany, and went on to win the 2001-2002 Volvo Ocean Race. As we have seen, Bushe also built ABN 1, the winner of Volvo Ocean Race 2005-06, but he also built its sister yacht, ABN AMRO Two, which finished 4th in the same race. Killian also built the new version 5 Americas Cup yacht for Victory Challenge (SWE), which was manufactured in Gothenburg. Killian has been appointed as Ericsson Racing Team’s Construction Manager. Both Bushe and his team see this as a new and exciting challenge.

Ericsson Racing Team commenced building its two new VO 70 yachts this Spring, just 200 meters from Ericsson’s corporate headquarters outside Stockholm, thus confirming the company’s desire to share its race campaign with its staff, partners and customers. The first step was to build the female mould that would be used to form the composite carbon-fibre hull. This stage, which required great precision and attention to detail, was concluded in the Spring.

Killian Bushe is quoted as saying, “The build site is state-of-the-art. Since November, we have worked hard at putting the right team in place and getting all the necessary tools ready. This includes the two ovens - one of them as big as the boat (25 meters) - and a smaller one for all the components. It feels good to get started on the construction; we are looking forward to this new challenge.

After the build of the hull and the deck, the construction specialists will then add the systems, the electronics and thousands of other details that will allow the boat to sail around the world. The launch of the new Ericsson Racing Team yacht is planned for late 2007. ACG’s VTM260 series of epoxy resin matrices is a new generation of long outlife, flexible cure temperature formulations, which can be applied to a wide range of reinforcements and adapted to a variety of low cost vacuum-bag composite processes. This series offers extended outlife up to 30 days, an absolute essential characteristic for large-scale projects such as yacht building.

Ericsson Racing Team consists of two teams, one International and one Nordic. Anders Lewander will be the skipper of the Nordic boat, but following John Kostecki’s decision to leave, the skipper for the International boat has yet to be appointed. One senior team member is reported to have said, “We want the best people. We need sailors who have both the experience and the desire to compete in a hard environment and give it their all. But, more than anything, we want to be a real team and we want to work with people who have the ability to integrate themselves into a group.” Anders Lewander is a highly skilled sailor and sail maker, but has no experience in the Volvo Ocean Race. It is understood that Lewander and the rest of Ericsson Racing Team are convinced that, when the training period is over, the salty old veteran Volvo Ocean Race seadogs will have to watch out.

ACG is poised ready with the materials and technological knowledge to provide technically superior materials to ensure that the expertise of Team Ericsson Racing is given the best possible opportunity to win the Volvo Ocean Race 2008-2009.

For further details contact ACG Sales Department.

Alinghi – Another America’s Cup 2007 Success - Extract from ACG's Technology Centre Report - September 2007

Photos: copyright of Ivo Rovira/Alinghi

ACG is ‘doubly’ proud of its role as ‘Official Supplier’ of composite materials to Alinghi, the outright, back-to-back winner of the 32nd America’s Cup, which took place in Valencia, Spain between the 1st June and 7th July this year. This is the second time that Alinghi has won The Cup, having taken it by storm in the 31st America’s Cup in 2003, the first European team to do so in the 150-year history of this event. The count is now at two, each time with ACG as ‘Official Supplier’.

The winning yacht ‘SUI 100’, built in Vevey, Switzerland, used a range of ACG’s proven and tested LTF318, VTM®260 and MTM®49-3 materials. ACG’s ZPREG® LTF318 surfacing system and rapid lay-up technology offer very high surface quality tooling under vacuum-only processing, while VTM260 series prepregs and adhesives were used for the hull and deck.VTM260 offers optimised low pressure vacuum-only processing, flexible cure temperatures between a modest 65°C (149°F) and 120°C (248°F) with ‘step-ahead’ cure resin and controlled flow rheology to optimise fibre wet-out. This approach was used for all Alinghi yachts built by the Decision Yard.

Where rules permitted, ACG’s MTM®49-3, the 1st choice for Formula One chassis, was used for a number of key structural elements, where it provided superior compression performance.

Taking advantage of ACG's vast experience in the highly competitive and technical world of Formula One, Alinghi approached the development of their material and process specifications in a similar fashion to that of leading edge automotive companies; they were thorough and detailed, continually seeking optimum performance from structures that would ultimately provide the technical edge over the competition, which is exactly what they achieved this year.

The ACG and Alinghi alliance began in 2001, when they worked on an extensive programme of data generation, and test panel production, prior to the ultimate manufacture of the earlier SUI 64 and SUI 75 boats. This was followed through to the team’s success in the 2003 challenge, where ACG and Alinghi developed innovative ideas for tooling and structures on the new Version 5 Rule of the America's Cup Class yachts.

As the number one developer of innovative materials in the performance race yacht market, ACG was pleased to assist Alinghi by being part of the jigsaw that, together, constructed the winning team.

Drawing parallels with how ACG operates in the Formula One and performance yacht markets, ACG has provided Alinghi with comprehensive technical support direct from its new Technology Centre and, when required, right at the heart of the build.

It is ACG’s proactive approach to materials development and technical support that has seen it establish itself as the leading composites technology supplier in Formula One, the America’s Cup and other competitive environments and events.

For further details contact ACG Sales Department.

New VTM260 and MTM Series Matrix systems complete ACG range of Next Generation low pressure moulding systems - October 2007

With two America’s Cups and a Volvo Round the World race in the bag, the Advanced Composites Group’s (ACG’s) Variable Temperature Moulding VTM®260 series must be ‘the’ resin system of choice for the performance boat builder.

ACG, based in Heanor, UK, part of the Composites Division of Umeco plc, offers this notable series of prepregs with a blend of features. Ease of handling in the workshop, long freezer outlife and controlled flow combine with a broad processing window - offering 65°C low temperature initial cures or reduced total cycle, to make ACG’s VTM®260 series resins one of the most user-friendly prepreg systems available. Process innovations, such as ZPREG® partial impregnation technology for both surface and structural plies, plus a supporting range of adhesives and gelcoats, have further enhanced the usability of these products.

Experience gained working with the world’s premier boat builders has highlighted how ACG’s resins can be further improved. Late 2007 will see the launch of a new range of enhanced, next generation prepregs. VTM®267 and its variants will offer improved workshop handling through reduced temperature sensitivity and controlled tack levels, while optimised flow profiles will improve fibre wet out. This will reduce void levels to improve laminate quality and also allow the impregnation of much heavier reinforcement fabrics.  

For applications where the flexible cure profile of the VTM® system is not required, new 120°C curing matrix systems will also be made available. These will offer the same enhancements in ACG’s Medium Temperature Moulding (MTM®) systems, which are already popular with spar makers. The MTM®257 and MTM®58 variants complete the range of next generation of ACG out-of-autoclave, low pressure moulding systems now offered across the composite industry, including the aerospace, automotive and marine sectors.

For further details contact ACG Sales Department.

ACG successfully develops high performance carbon fibre composite MTM59 - October 2007

Advanced Composites Group (ACG) Ltd (Derby, UK), part of the Composites Division of Umeco plc, is proud to announce that it has successfully developed MTM®59, a revolutionary carbon fibre composite material that is set to benefit the medical sector.

MTM59, a 120°C curing matrix system has been combined with a recent development from ACG to provide a high performance composite system in addition to enhanced clarity, which is required for X-ray tables and plates.

The development of this carbon fibre composite not only represents a new hallmark of quality, but beneath the clear surface lustre there can be far more serious and technically demanding aspects to these exciting materials. Composite materials offer high strength, stiffness and low weight, but in the medical world it is their transparency to X-rays that makes these materials so attractive.

Surface clarity can, through innovative resin chemistry, translate into through thickness clarity and high definition X-ray images.

Presently under trial with a number of European manufacturers, MTM59 will set the standards for the construction of future medical imaging equipment.

Jon Mabbitt, Managing Director of ACG said: “We are constantly exploring new avenues for our innovative new products to service the growing needs of our customers. Until now there has never been a product like MTM59, and we believe it will prove vital to medical equipment manufactures the world over.

For further details contact ACG Sales Department.

Increasing In-Service Life with Insitu (Patch) Repairs - April 2007

The Advanced Composites Group Limited (Heanor, UK), part of the Composites Division of Umeco plc, is regularly called upon to assist in areas when direct replacement is neither feasible nor cost-effective. ACG considers this an important service to all market sectors and continues to respond to market demands, develop materials and techniques, and service this important aspect of composites applications. It is ACG’s philosophy is to keep an open mind on all composites applications and welcomes the opportunity to embark upon further projects of the nature and magnitude described herein.

Composite wet lay-up systems have their applications and associated advantages. When compared to prepregs, materials are relatively cheap and equipment requirements are minimal. However, the process attracts high labour costs, exhibits poor control of fibre fraction, has the potential for high void content, thickness is difficult to control, it is regarded as a ‘dirty process’ and has associated health and safety and environmental issues.

On the other hand, prepregs can, in certain circumstances, offer a more attractive solution, boasting better control of fibre fraction, low void content, superior control of laminate thickness, and definite improvements in quality and repeatability. From a heath and safety angle, prepregs offer a relatively ‘clean’ process, minimising the risks to laminators. Material and additional equipment costs are higher, but this is generally offset by a marked reduction in labour costs.

ACG has always manufactured ‘standard’ 120°C curing prepregs, but an early advancement was the development of a unique technology known as ‘step ahead’ curing. Prepreg technology is centered on ACG’s Low Temperature Moulding (LTM®) processing resins. These resins, which are formulated to cure at low temperature, can, in terms of mechanical and thermal characteristics, develop a state of cure that exhibit a much higher level of performance than can be expected from a particular curing condition. This enhanced stability allows hot curing to take place at 50 to 60°C. This concept was first exploited in Low Temperature Moulding (LTM®) tooling systems. The resins developed for this purpose exhibited resistance to extremely high temperatures. ACG’s determination to move forward in other arenas brought about further developments to this pioneering system, enhancing toughness and allowing low pressure processing, essential characteristics that have made prepreg technology a reality for repair systems.

That’s not to say these materials were not without their foibles; material is stored frozen to maximize life, but the reactivity of a particular prepreg system and its minimum curing temperature are inextricably linked. Therefore, low temperature curing means a short working life, which in turn limits the project size and complicates site logistics. This was less than ideal, but some projects have shown the potential for prepreg technology as the basis of a site repair.

With Low Temperature Moulding (LTM®) systems (Boots building project - discussed herein) having a limited outlife of 2 to 3 days, ACG developed its range of Variable Temperature Moulding (VTM®) systems, which have extended outlife of 30 days and a 65°C minimum cure temperature (Macintosh building and Cutty Sark projects - discussed herein). Obviously, there are benefits with both systems, each having their own particular applications.

Taking the civil and military aerospace, and Formula One industries as specific developments for composite repair, ACG has offered several methods of executing on-site repairs.

• Bonded pre-cured patch of doubler using paste adhesive.

• Scarf on repair using the same prepreg as the parent component. Typically performed using +120°C curing film adhesive co-cured with the patch.

• Scarf on repair using lower-temperature cure prepreg than originally used in manufacture. Applicable in repairs where it is not desirable to subject the parent material to high temperatures, e.g. composite repairs to civil airliners performed <30°C of the original component cure. Typically bonded with room temperature paste adhesive. Repairs using wet-resins make it particularly difficult for the user, especially for in-situ repairs on hard to reach areas.

Traditionally, to achieve the physical properties provided by the parent fibre reinforced composite, high temperature curing (+120°C) film adhesives need to be used; lower cure temperature adhesives fail to meet the physical performance requirements. ACG’s goal was to develop a high performance, rapid low temperature cure film adhesive.

The patch repair technology developed by ACG has the potential to replace two of the current scarf repair methods previously described.

• Low temperature rapid repair for in-situ repairs (in the field), where out-of-service time must be minimal. 

• For structural repair where it is not desirable to subject +120°C curing temperatures, but service temperature provided must be adequate.

A range of ACG prepregs and adhesive materials have been formulated and developed under two collaborative, funded projects, namely Patch Repair and FILMBOND.

Screening and data generation for these projects was handled by ACG, while durability and validation was performed by Aerostructures Hamble (now Smiths), with patch repair efficiency performed by QinetiQ.

A range of repairs was carried out on different components in a variety of market sectors:

• Formula One sector - low temperature repairs were carried out on several structural components (upper engine mount, front wing, and chassis) for Jordan GP.  

• Military aerospace sector - rapid low temperature repairs were carried out on the Eurofighter undertake scoop.  

• Civil aerospace sector – rapid low temperature repairs were carried out to a B747 rear underbelly fairing, where the patch accumulated >16K flying hours.

The patch repair process is outlined in the following simple sequence diagram.

Detail of damage	Damaged area dressed back	Damaged area filled with potting adhesive	Ply 1 - EF1803 (Pk13-350gsm) adhesive film	Ply 2 - prepreg ply	Ply 3 to 6 - prepreg plies	Vacuumed down and cured	Finished repair

Other areas where composite patch repairs have played a vital role in general preservation include ACG’s involvement in the Macintosh and Boots building projects and, more recently, an in-situ repair to the famous and faster ever tea clipper, the Cutty Sark, which is in dry dock in Greenwich, UK.

Cutty Sark

As part of the refurbishment of the structure of the Cutty Sark, the corroded inner wrought iron structure must be reinforced and, in some cases, totally re-established. Composite materials, comprising a combination of glass and carbon fibres in a polymer matrix, were proposed for this purpose and ACG personnel carried out a trial on the ship to demonstrate the technique using a low temperature curing prepreg method.

Cutty Sark in Dry Dock

Damaged Area

The ACG repair patch was successful and Cutty Sark Trust was left to carry out a series of tests on this patch to evaluate bond strength, etc.

The surface profile achieved by ACG reflected that of the original surface. In fact, the surface was improved where it was filled and faired.

Initially, the vacuum bagging process proved quite difficult, but initial obstacles were overcome and a vacuum tight surface to seal was achieved. Infrared heaters proved successful, but needed a higher level of control for large-scale usage. Heated rubber mats, used for drum heating or weld pre-heating, would be the easiest way to cure prepreg on a large scale. A number of mats of different sizes could be interlaced to accommodate varying structural geometry and would then only require simple insulation during the curing process.

The format of the prepregs used can be further optimised, perhaps with a VTF type surface ply, which would offer the benefits already highlighted, but also reduced tack and a higher level of adhesion. Similarly, a lower tack variant resin in the structural plies would make placement easier.

The Boots Building

The Boots building, which is located in Nottingham, UK, is an important Grade II listed building in pedestrianized area. Initially considered to have a zero-value asset on pension fund’s books, it was transformed, in collaboration with Taylor Woodrow, using ACG’s Low Temperature Moulding (LTM®) prepregs and is now valued at £8M.

Curved-in-plan rolled steel ‘I’ beam

The key features of this project were:

• Beam sizes not identified until Terra Cotta cladding was removed.

• Scaffolding would hinder crane access, which could only be granted for Sundays.

• Large crane required to access the damaged areas.

• Beam fabrication time 12 weeks, but strengthening with composites only 6 week.

• Bolted detail to be released for replacement, hence need to support adjoining members.

The solution was to wet lay-up ACG’s LTM® prepreg.

• Beam locations presented limited access, but application of the lightweight composites suited this.

• Only a small section of cladding had to be removed to gain access to the beams. Extensive dismantling would have been necessary for beam replacement.

• Based on experience, ACG selected the most appropriate composite material, thereby reducing the number of layers to be laminated.

The composite was vacuum-consolidated and heat-cured at just 65°C. ACG worked with its research partners to develop a low temperature moulding resin suitable for construction site applications.

The finished thickness of material added to the steel section was just 5 mm. Therefore, the Terra Cotta cladding was not displaced after restoration.

This award winning project, which was hailed as a resounding success, was based on the application of innovations from other industries, it fully demonstrated a new application of a particular format of composite, it used research and development to close knowledge gaps, restored rental income capability of the asset, and developed added value solution by shortening programme and saving time-related costs.

Column Repair

To facilitate a change of use to an old mill in Manchester, UK, a number of damaged structural, cast iron columns required repair and reinforcement.

The Scale of the Problem

A Fully Repaired Column

It was proposed that a carbon/glass fibre composite over wrap system be adopted for this purpose. A single column was then over-wrapped by ACG personnel to evaluate the process and demonstrate the technique to the client.

Building on the experience of the Boots project, and exploiting the material gains of VTM® systems technology, ACG’s Variable Temperature Moulding (VTM®260) series prepregs, the next generation of ACG’s prominent Low Temperature Moulding (LTM®) technology, were selected for this project. The extended, 2 to 30 day out-life of these prepregs removed the need for on-site refrigeration and simplified on-site logistics. Whilst the very low curing temperatures of the LTM® range are not available with VTM®260, it was felt that achieving the minimum cure of 65°C would not be difficult and this preliminary wrap was used to demonstrate the viability of on-site fabrication with the VTM®260 series.

The VTM®264 resin utilised for the prepreg materials mixed glass and carbon reinforcements. The glass offered electrical insulation between the column and the carbon reinforcement (carbon is galvanically active) resisting corrosion and providing some hoop strength through the thickness of the carbon reinforcement over-wrap, while also providing a final surface for subsequent over coating. An adhesive film was pre-laminated to some of the glass prepreg, which was then applied to the cast iron to ensure effective bonding and act as a compliant interlayer once curing was complete.

Bridge Repair

Surrey University carried out some research on the application of VTM® prepreg systems for bridge repair work. Further information on this project can be found in the research paper ‘ADVANCES IN ADHESIVE JOINING OF DISSIMILAR MATERIALS WITH SPECIAL REFERENCE TO STEELS AND FRP COMPOSITES, by L.C. Hollaway - School of Engineering - Civil Engineering, University of Surrey, Guildford, Surrey, UK.

Potential Future Work

ACG has performed investigative work on some major projects that would benefit, commercially, from the application of composites patch technology. One in particular is that of the repair of corroded train pillars.

Alstom Train Services, Eastleigh, UK (AKA Angel Trains) identified a number of corroded pillars on their fleet of Class 314 trains that could be repaired using advanced composite materials. With minimal disruption to service, simple pre-cured composite patches could carry service loads from the pillars into the train chassis. The application of such a patch would be a faster, more cost effective solution than a standard repair that involves the removal of surrounding panelling and flooring, followed by removal of the effected pillar and the subsequent manufacture of replacement ‘U’ shaped channel extensions that would be welding into position. Obviously, there are major issues associated with this technique. In particular, welding generates heat so there is potential for local distortion and heat damage to surrounding materials.

Corroded Interface Between Vertical Pillar and a Shear Plate

The composites patch option would enable the repair to be undertaken with minimal additional work. Following simple grit blasting and cleaning operations, the patch would then be fitted directly to the affected area, moulded into position and held there using a suitable clamping fixture for the duration of the curing process.

ACG’s Variable Temperature Moulding fire-retardant prepreg, VTM®264FRB, is ideally suited for this application. Material quantities are negligible, with calculations based on the pillar being corroded to a level of 25mm above the point at which it was originally welded to the chassis.

For further details contact ACG Sales Department.

Update on Out-of-Autoclave Processing - April 2007

ACG’s first generation of out-of-autoclave composite prepregs were developed to cure and de-mould in a stable condition after initial cure at temperatures as low as 60°C using low cost tooling and oven vacuum bag processing, but without need for the high temperatures and pressures of the autoclave normally associated with aerospace prepreg processing. One typical application of these prepregs is LTM®45EL, which was used in the construction of Scaled Composites’ SpaceShipOne space vehicle and its carrier plane WhiteKnightOne. Parts made from ACG’s LTM® prepregs are then post-cured, in a freestanding state, away from the mould to a higher temperature, thus completing the curing reaction and generating the required mechanical and thermal resistance properties.

In contrast, traditional composite prepreg materials, such as those typically used on the Lockheed/Boeing F-22 ‘Raptor’ stealth fighter aircraft or the Boeing 787 commercial airliner, require autoclave pressures of 6 or 7 atmospheres and high temperatures - typically 180°C - to bring about the cure. The composite or Invar mould tools required to withstand these conditions are expensive. This presents particular problems for one-off prototypes or limited production aircraft with only a small number of parts over which to amortize costs. This could result in the tooling constituting 75% of the airframe costs. A low temperature, oven vacuum bag cure resolves this problem, allowing the use of low cost tooling materials, as well as removing size limitations imposed by an autoclave.

First generation out-of-autoclave systems, developed during the 1990’s, had some success, but were deficient when compared to high temperature autoclave cured materials in a number of areas, specifically:

• mechanical performance.

• laminate quality

• damage tolerance.

Next generation out-of-autoclave prepregs and infusion systems exhibit none of these deficiencies and offer levels of performance, toughness and laminate quality comparable with high temperature/pressure systems, as well as improved handling and work-life at room temperature when compared to their predecessors.

MTM®44-1, MTM®45-1, MTM®46 and MVR444 (detailed below) form ACG’s new generation out-of-autoclave processing systems currently in use or under qualification for a variety of civil and military applications.

MTM®44-1 is a dual cure temperature (130°C / 180°C [266°F / 356°F]), high performance epoxy matrix developed for both resin film infusion (RFI) and prepreg processing. It has been optimised for low pressure vacuum bag processing and, in addition to resin film and prepreg formats, it may be supplied in partial or selectively impregnated (ZPREG®) formats to reduce lay-up time, minimise surface defects, and ensure very low internal void content. After a freestanding postcure, the system is capable of 150°C (302°F) wet Tg and exhibits a high level of damage tolerance. This, together with its low density, makes it a strong candidate for primary structures on aircraft, produced out of autoclave. The process cost savings can equally be applied to many less critical structures, such as fairings, which have, historically, been designed for autoclave processing.

MTM®45-1 is a variable cure temperature, high performance, toughened epoxy matrix, developed for both resin film infusion and prepreg processing. It has been designed for low pressure vacuum bag processing and, in addition to resin film and prepreg formats, it may be partially or selectively impregnated (ZPREG®) formats to reduce lay-up time, minimise surface defects and ensure very low internal void content. After a freestanding postcure, the system is capable of 150°C (302°F) wet Tg and exhibits a high level of damage tolerance. This, together with its low density, makes it a strong candidate for primary structures on aircraft, produced out of autoclave. The process cost savings can equally be applied to many less critical structures, such as fairings, which, historically, have been designed for autoclave processing. MTM®45-1 may be initially cured at temperatures as low as 80°C (176°F), allowing lower cost tooling materials to be selected for prototypes and very short production runs.

MTM®46 is a long outlife, flexible cure epoxy resin matrix for the manufacture of aerospace components using oven/vacuum bag moulding processes. The rheology of MTM®46 has been developed specifically for the production of high quality laminates using low pressure processes. The 60 day room temperature working life and excellent tack and drape properties facilitates the lay-up of very large complex structures. A full range of standard prepregs is also available autoclave processing. MTM®46 offers excellent hot/wet performance, making it the ideal candidate for the low cost primary and secondary structures in FAR23 aircraft. It is also suitable for secondary structures in civil aircraft and helicopters.

MVR®444 is a single component epoxy resin matrix for the manufacture of aerospace quality composite components using infusion processes such as VARTM (Vacuum Assisted Resin Transfer Moulding), RTM (Resin Transfer Moulding) or RIFT (Resin Infusion under Flexible Tooling). MVR®444 may be infused at temperatures as low as 70°C (158°F) and may be cured at temperatures between 90°C and 180°C (194°F and 356°F). It also exhibits excellent performance after hot/wet conditioning.

For further details contact ACG Sales Department.

New Product Development – TB720 Epoxy Tooling Block - April 2007

Following fast on the heels of the premium grade epoxy tooling block TB750, launched at the JEC Show 2006, the Advanced Composites Group Limited (Heanor, UK), part of the Composites Division of Umeco plc, announce the introduction of a new product ‘ACG TB720’.

As with TB750, TB720 has been developed in partnership with Huntsman Advanced Materials (Huntsman) as part of an on-going 5-year collaboration and distribution agreement with ACG. TB720 is an easily machined, lower-cost master model material that exhibits a good blend of mechanical and physical properties and is fully compatible with ACG's existing range of ancillary adhesives and sealers. To meet market demands, as ever, TB720 will be available in a range of sizes and on short lead-times from ACG factories in Europe and the USA.

For further details contact ACG Sales Department.

New Product Selector Guides and Data Catalogue - April 2007

The Advanced Composites Group (ACG) Limited (Heanor, UK), part of the Composites Division of Umeco plc, recently completed a major overhaul of its Product Selector Guides (PSGs) and updated the presentation and delivery of its Data Catalogue.

ACG’s market-specific PSGs, previously only available in paper or PDF formats, are now available as web-based suites on CD and via the Catalogue link on ACG’s web site (www.acg.co.uk). These new PSGs are uniquely designed to guide the user to the most suitable product for the intended end application, while still leaving the experienced composites professional the opportunity to browse at leisure.

Initially designed to accommodate all of the market sectors that ACG serves, PSGs are presented as a suite covering the Marine, Aerospace, Automotive, Motorsport, Tooling, Sport and Leisure, and Construction markets, they can also be supplied in bespoke formats for individual markets. The full PSG suite also incorporates a Fabric selector guide and a comprehensive catalogue of ACG’s products and general supporting literature and component images. The Catalogue includes product data sheets, technical data sheets, sales information, and general instruction documents. In addition, to assist the newcomer, the suite also contains a General procedures document detailing typical prepreg processing routes.

For further details contact ACG Sales Department.

Applying Advanced Gaming Technology to Deliver Novel Composite Manufacturing Techniques> - April 2007

A joint project, featuring technology transferred from the serious computer games industry, aims to develop a low-cost, high-performance physics-based software product for the visualisation and simulation of complex composites manufacturing systems.
This venture, called ‘PhysVis’ and led by AMTRI, will include the ACG and Innoval Technology, an independent materials and process technology consultancy.

The nineteen-month project, which started in October 2006, qualified for nearly 50 percent funding under the DTI Technology Programme via the Fast Track route, with the remainder being made up of contributions by the partner companies.

The PhysVis initiative promises to unlock the door to more innovation and new business for manufacturers in rapidly developing sectors such as the aerospace, motorsport, marine and automotive industries where ACG already delivers bespoke prepregs and novel material and process technologies to numerous OEMs on a worldwide basis. The proposed visualisation and simulation system is intended to offer, at far lower cost, the high levels of performance and capability only likely to be found in the application modules of far more expensive CAD suites from major vendors.

Phil Sholl, managing director of AMTRI, explained: "The high performance and low cost of PhysVis will represent a profound opportunity for a range of specialist companies in fast-growing, high-technology sectors like the production of carbon fibre-based composite components. These specialist manufacturers will be able to design 'right-first-time' production systems and assess investment and operational risks before they commit to procurement and implementation. This can only be done now with the resources available to larger companies".

AMTRI will develop the new product based on extensive work with the so-called 'serious computer games' technology developed by US company AGEIA and its new PhysX Accelerator and a low cost but sophisticated PC-based digital factory simulation system from Finnish company Visual Components.

The role of ACG in the project is that of end user or the first customer for PhysVis. ACG will provide the application domain, i.e. that of aerospace composite manufacture. Innoval's role is to categorise the material (carbon fibre) using their fabric modelling approach. The simulations start with an individual fibre and model the fabric weave in all its detail to create an accurate mechanical representation of the woven carbon fibre material. The output of the simulations is a constitutive material model that represents a 'unit patch' of the material; AMTRI will then map the unit patch to AGEIA's PhysX Accelerator and simulate both the material and the robotic manufacturing system to achieve accurate process and product interactions so that the best manufacturing techniques may be determined.

For further details contact ACG Sales Department.

OASIS in Sight for ACG and Partners to Optimise Materials Processing and Modelling - March 2007

ACG and its partners, Airbus UK, QinetiQ and the University of Manchester, recently embarked on a two year, DTI funded, collaborative research programme entitled ‘OASIS’ (Out-of-Autoclave Simulation of Induced Stress).

Briefly, Oasis will apply multi-scale materials and processes modelling to optimise cure schedules for an innovative out-of-autoclave fibre reinforced polymer composite fabrication process called ‘Quickstep’.

In addition to validating this process for the manufacture of typical aerospace components, manufacturing costs relative to conventional autoclave cure will be reduced by predicting and minimising residual stress and distortion, thereby reducing the need for expensive reworking of parts, while also lowering waste generation through ‘right first time’ manufacture.

The multi-scale modelling will start from the fundamental resin chemistry and proceed to structural finite element analysis of a generic component.

In addition to providing process and property data and supporting the predictive modelling work at QinetiQ, ACG will supply the selected prepreg material (MTM®44-1) for the programme.

For further details contact ACG Sales Department.

New Commercial Director Appointed - January 2007

ACG is pleased to report the appointment of Nigel Blatherwick as Commercial Director for the Group over-viewing the strategic sales and marketing direction of the company by co-ordinating the divisional commercial activities.

Nigel joined the Sales department in 1991 as Sales Engineer and has progressed, through UK Sales Manager to Group Sales and Marketing Manager, the position he has held for the past 6 years.

Jon Mabbitt, Managing Director, and the rest of the company wish Nigel every success in his new appointment.

For further details contact ACG Sales Department.

New Managing Director Appointed - January 2007

Advanced Composites Group (ACG), a Umeco Composites company, which manufactures a range of advanced composite materials for use predominantly in the aerospace, motorsport, automotive and wind energy markets, announces that Jon Mabbitt will succeed Alan Moore as Managing Director with effect from 1st January 2007. Alan Moore will remain on the Board until his retirement on 30 June 2007.

Alan Moore has been Managing Director since December 1998, during which time the business has developed into a highly successful industry leader. In 2004 he managed the sale of the business and its subsequent integration into Umeco Composites. Alan has led the recent major investment programmes both in the USA and UK, culminating in the newly-opened £7m technology centre in Heanor, Derbyshire.

Jon Mabbitt joined ACG in a sales position in 1988 and, following a number of management roles, became General Manager of the UK operations and subsequently joined the ACG board in 2001. Earlier this year he was promoted to the role of Director and General Manager of ACG and became responsible for both the UK and US operations.

Andrew Moss, Chief Executive of Umeco Composites, said:

"I am delighted that Jon is assuming this new role. In his various positions he has played an integral role in ACG's development and is a well respected figure in the industry. He will undoubtedly continue the success that ACG has enjoyed under Alan's leadership.

"When Alan retires, it will be with our wholehearted good wishes. He has been an inspirational force behind ACG's growth, and the market leading position that the company now enjoys is very much his legacy. Everyone at ACG and at Umeco Composites is grateful for the tremendous energy and enthusiasm that he has put into the business."

For further details contact ACG Sales Department.

European Sales Manager Appointed - January 2007

ACG is pleased to announce the appointment of Rob Wilder as European Sales Manager effective as from 1st December 2006.

Rob will be responsible for the Management of the ACG employed European Sales Team and will also continue in his role as Market Sector Manager for the Marine market.

Rob is wished every success in his new role.

For further details contact ACG Sales Department.

New Vice President Sales and Marketing

As part of the expansion and development of the management team in Tulsa, ACG Inc is extremely pleased to be able to announce the appointment of John Price to the role of Vice President, Sales and Marketing with immediate effect. John joined the company in 2004 from Northern Fibreglass and since that time has made a substantial contribution to the management of sales in the NE region.

John will be office based in Tulsa and will in time relocate fully to the area. The company joins Adrian Potts, President of ACG Inc, in wishing John well in his promotion.

For further details contact ACG Sales Department.

China Composites Exhibition

ACG again attended the China Composites Expo with Bernard Twist, Export Sales Manager, being present on the Shanghai Leadgo stand.

China Composites 2006 was larger and more professional than in previous years. The show venue was split over 2 floors and ACG shared the custom-built stand of Shanghai Leadgo-Tech with Aerovac Systémes France on the larger and busier of the two floors. Didier Gal and Mike Cooke were in attendance from ASF and Umeco respectively. The Shanghai Leadgo-Tech show stand followed last year's design very closely, but unusually, neither ACG nor ASF had individual entries in the exhibitor's catalogue and the only mention of our two companies was within the text accompanying the Leadgo entry. This will be addressed for 2007 when the Show moves to Beijing.

There was a significant increase in the number of overseas companies exhibiting and of the 207 companies exhibiting, 41% were from outside China - an increase of more than 100% on 2005.

China Composites is fast becoming a significant show for suppliers and customers in South East Asia.

For further details contact ACG Sales Department.

ACG Opens £7m Composites Manufacturing Centre - September 2006

Brian McGowan, Chairman of Umeco plc, accompanied by Peter Chivers, UK Vice President of Airbus, have today (21st September 2006) officially opened Advanced Composites Group's (ACG) new composites manufacturing facility in Heanor, Derbyshire.

ACG, a subsidiary of Umeco Composites, has been based at its Heanor site for 28 years, manufacturing a range of advanced composite materials for use predominantly in the aerospace, motorsport, automotive and wind energy markets.

This new development represents a £7m investment in additional manufacturing and warehouse facilities as well as a new technology centre. The expansion involves the addition of over 30,000ft² to the existing facility, combined with major investments in new resin mixing and prepreg manufacturing equipment. It will increase the manufacturing capacity by approximately 80% and once fully utilised will create employment for an additional 50 people. The manufacturing operation has been designed to comply with the latest quality standards dictated by aerospace and automotive customers.

ACG has, since its foundation 31 years ago, based its success on technical innovation. The new technology centre provides world class facilities for its research and development engineers, enabling them to continue to develop, leading edge composite materials, providing value solutions to its customers worldwide.

Alan Moore, Managing Director of ACG said:

"The opening of this facility represents a major milestone for ACG and the culmination of a lot of hard work for all of our employees. We can now move into the next stage of ACG's development with cutting edge facilities allowing us to offer our customers a wider range of advanced composites."

For further details contact ACG Sales Department.

New Office in Italy for ACG

As of today our Italian Sales office will be located at the new address below in Milan. Federico Pettenello is pleased to announce the move to the new premises, which are ideally located in one of Italy's major cities.

Please note that although the postal address, telephone and fax information is new, the email address for Federico remains the same.

New Address:

ACG Sales Office, Via Barbiera 32, 20153 Milano

Phone: +39 02 4891 3932 Fax: +39 02 4891 9821

Email Federico Pettenello: acgitalia@comm2000.it

For further details contact ACG Sales Department.

'Quiet Revolution' Wind Turbine - July 2006

A compact, robust, elegant wind turbine that incorporates a display screen - sounds like a good pitch, right? Well it's not just good, it's real and it's coming to a roundabout, a street lamp, a building or any space near you.

The 'quietrevolution' wind turbine was designed and developed by XCO2 in conjunction with ACG's customer Aviation Enterprises Ltd. who was able to offer full aerodynamic design, composite engineering and manufacturing expertise.

ACG worked closely with AEL providing light weight oven curing VTM® prepregs tailored to the nearest % of resin and curing as low as 65°C. Keeping the weight of the blades to a minimum was critical due to centrifugal forces of up to 200 G. Spinning the blades at 300rpm in testing, the blades required virtually no balancing at all proving the consistency and accuracy that ACG prepregs offer the customer.

The rotating section is 5m high and 3.1m in diameter and is designed to withstand maximum wind speeds of 120mph. XCO2 claims the design performs more efficiently as it does not have to keep changing direction with the wind as a traditional turbine would, this decreases vibrations and cuts down on aerodynamic noise, all of which are very important for use in urban areas.

Further advantages are that the cylindrical structure with the vertical 'S' blades occupies less space than the average turbine, the structure is robust, and practically as well as aesthetically can integrate easily into the urban environment.

Rotation of the turbine drives the 6kw generator and can be mounted on either a 9m or 15m high tower or on a 3m mast on a roof.

The 'quietrevolution' turbine also comes in a display model, the first site for which will be in Bristol on a roundabout in the Temple Meads area. By embedding flashing LED's into the blades, clients will be able to use the turbine to promote eco friendly products and raise awareness of climate change. At the same time as generating renewable energy.

Please also visit www.quietrevolution.co.uk

For further details contact ACG Sales Department.

ACG Acquires Aerodyne Advanced Composites - July 2006

ACG acquires Aerodyne Advanced Composites, supplier of advanced composites components for McLaren Automotive.

Advanced Composites Group, a subsidiary of Umeco plc's Composites Division, has announced the acquisition of the entire issued share capital of Aerodyne Advanced Composites (Proprietary) Limited ("AAC") from Aerodyne Industries(Proprietary) Limited.

AAC, who will trade as Advanced Composites Group SA (Pty) Limited with immediate effect, are based in Cape Town, South Africa, employ around 130 staff and manufacture advanced composites component parts principally for McLaren Automotive.

AAC has a contract with McLaren Automotive in relation to the sole supply of specified component parts to the Mercedes-Benz SLR McLaren super sports car. The contract is for the lifetime of the SLR programme and will form part of a strategic relationship between McLaren Automotive and ACG from which further business is expected to materialise.

The AAC business is highly complementary to ACG's materials business which currently supplies McLaren Automotive and other high performance automotive and motorsport customers including Koenigsegg, Porsche and Formula 1 racing teams including Team McLaren Mercedes.

ACG's total initial investment in this project is estimated at around £1.5 million and conclusion of the acquisition is subject to the satisfactory completion of all related legal proceedings.

Clive Snowdon, Chief Executive of Umeco plc, commented: "The acquisition of AAC cements our relationship with McLaren Automotive and further underlines our position as a leading supplier of advanced composites solutions to the new genre of super-cars. AAC will sit alongside ACG's existing composites engineering business to provide a low cost base to help demonstrate the use of composites and their applicability within the mainstream automotive industry. Vehicle technology is demanding lighter weight more cost-efficient designs and we are now well positioned to support this growth area."

For further details contact ACG Sales Department.

ACC Renamed to ACE - June 2006

ACC to ACE - What's in a Name? Quite a lot really!

The trading name of ACG's hardware division, Advanced Composite Components (ACC), has been in existence now for approaching 20 years, but things are about to change. In future ACC will become known as ACE (Advanced Composites Engineering). The reasons for the name change are simple, but quite significant for both ACG staff and ACG customers.

The two most important factors behind the move from ACC to ACE are organisational changes that see the Group's Applied Technologies and Design functions assimilated into what was the existing ACC structure. The inclusion of these two key customer support functions will mean an increased emphasis on the new ACE's ability to offer "turn-key" technology solutions to the Group's materials customer base, supporting a vast range of development programmes from design, through project management, to production.

The clear remit of ACE is to support, develop and promote Advanced Composite Group's novel materials and technologies across the globe - and to ensure the company's products are always employed to the optimum technical and commercial benefit of the customer.

For further details contact ACG Sales Department.

ACG to Distribute Huntsman Materials - May 2006

Advanced Composites Group Ltd (ACG), a member of UMECO plc's Composites Division, and Huntsman Advanced Materials (Huntsman) signed a 5 year agreement in May 2006 naming ACG as Huntsman's major global distributor of epoxy based master model materials.

In the first phase of the collaboration, ACG has launched a new epoxy model modelling board, the ACG TB750, that has been specially moulded for them by Huntsman and was released to the market in June. The TB750, a derivative of Huntsman's well established BM5055 product, will be supplied to existing ACG specifications along with an extensive ancillaries range.

Commenting on the agreement, Alan Moore, Group Managing Director of ACG, said: "Both ACG and Huntsman are renowned for their product quality and innovation in composite tooling. This collaboration will allow both our companies to work more closely on future product development cementing our positions as world leaders in the field of composite tooling."

For further details contact ACG Sales Department.

Added Strength And Support for Sales Team> - March 2006

ACG is very pleased to announce that it has concluded agreements with two new representing companies in order to strengthen and support its overseas sales and marketing activities.

In New Zealand, ACG's technologies, products and services are now to be represented by Advanced Composite Technology Ltd. (ACT). This Auckland-based company will provide comprehensive technical and commercial support to all sectors of the New Zealand market for high performance composites and will also offer design and processing expertise as well as the full range of ACG prepreg materials and ancillary products. ACT's links with the UMECO group of companies is further strengthened by their agreement to also offer vacuum bag materials from Richmond Aircraft Products. For more information, please contact:

ADVANCED COMPOSITE TECHNOLOGY LTD.
39 Vestey Drive
Mt. Wellington
AUCKLAND
New Zealand
PO Box 22800 Otahuhu

Telephone: +64 9 573 1976
Fax: +64 9 573 1973
Website: www.acom.co.nz (currently under construction)
Contact: Mr. Paul Hackett , Managing Director
Email: paul@acom.co.nz)

In Korea , agreement has been reached with Duly Corporation to represent ACG's high performance products and technologies. Duly Corporation was established in Seoul in 1990 and its principal business activity is the promotion of foreign manufacturers' products to the Korean aerospace, airline and rail markets. Duly Corporation prides itself on its excellent business relationships and ability to provide specialized experience to its customers and the new agreement to work with ACG products will complement perfectly their activities representing the range of vacuum bag consumables from Richmond Aircraft Products who are also a member of the UMECO group of companies. For information please contact:

DULY CORPORATION
#1514 LG Palace Building
165 - 8 Donggyo-Dong
Mapo-Gu
SEOUL
121-754 Korea
Tel No: +82 (0)2 322 1121
Fax No: +82 (0(2 322 1122
Website: www.dulykorea.com
Contacts:
Ki Sup Yun , General Manager
Email: duly01@kornet.net
Kah Kyung Lee, Asst. Manager
Email: duly03@kornet.net

For further details contact ACG Sales Department.

Preview of JEC Composites Show> - March 2006

The JEC Composites Show completed three successful days with yet another increase in exhibitors and visitors.

ACG joined Aerovac and Richmond Aircraft Products as members of UMECO Composites, one of the divisions of UMECO plc. UMECO's stand location for JEC 2006 was M16/M17 Hall 1. ACG has been exhibiting at JEC for many years and still regards this event as one of the main meeting places for all contributors to the whole of the composites industry, including all market industries.

ACG was pleased to include a Koenigsegg CCR show car from Koenigsegg Automotive AB - ACG's materials are used solely throughout the vehicle from complete monocoque structure to exterior skin. Other key projects were highlighted in the graphics on ACG's stand, the Virgin GlobalFlyer and the Aston Martin DB9 and the Alinghi boat defending the 32nd America's Cup title.

For further details contact ACG Sales Department.

ACG To Create £7M Composites Manufacturing Centre - March 2006

In August 2005 Advanced Composites Group Ltd, a member of the Composites Division of UMECO plc, embarked on a major £7M expansion to create a new 'world class' composites Manufacturing and Technology Centre.

Since then the skyline around Heanor has changed considerably and the significance and scale of this investment is now very evident.

The expansion will see the addition of over 30,000ft² to the existing Heanor facility, combined with major investments in new resin mixing and prepreg manufacture equipment.

Completion of building work and commissioning of new equipment is scheduled for September 2006 when an Official Opening Day is planned.

Since its early days, ACG has relied heavily on the contribution of its R&D and Testing services to support the design and development of its prepreg materials. Without this facility it would not be possible to manufacture composites tailored to specific applications or to offer customers the back up data and technical support that can secure the success of a project.

The 'state-of-the-art' Technology Centre will house the Company's extensive technical support resource, incorporating resin formulation, testing, process engineering and structural design. This major investment, along with ACG's expanding workforce of over 350 staff worldwide, secures the Company's future growth plans and will ensure it remains one of the UK 's leaders in composites.

ACG customers have come to rely on a high level of service from ACG, short lead-times and rapid responses to technical queries are core to ACG's business philosophy. This investment allows ACG to continue to lead the market in quality of product, response times and customer service. Aerospace and Automotive markets will be major areas of growth for ACG over the next 5 to 10 years and it is developing this 'world class' manufacturing facility to meet the quality demands of these markets. ACG aims to offer quality and systems second to none in the composites industry.

For further details contact ACG Sales Department.

Time and Temperature Deliveries To Europe - March 2006

During its 30 years of composite material manufacturing and development ACG has won a considerable market for its products in Europe.

Throughout this time the partner of choice for ACG has been, and remains, Berlin Project Limited (BPL) of Gloucestershire, UK. "Our prepreg materials are of high value," reports Geoff Peach, Logistics Manager at ACG, "but are also perishable in nature, insofar as their useful shelf lives are time and temperature sensitive."

To ensure the materials are delivered in the best possible condition BPL, in conjunction with and on behalf of ACG, operate two 13.5 tonne Mercedes Atego freezer vehicles which service the majority of ACG's European customers outside of the UK. Steve White, Managing Director of BPL states, "This partnership works extremely well and offers ACG a very reliable bespoke freezer delivery and collection service without the responsibility of maintaining or supporting the vehicles and operatives themselves." ACG are more than happy to agree that this is a job best left to the experts at BPL.

Berlin Project Ltd
Unit 5
The Runnings
Kingsditch Trading Estate
Cheltenham
Gloucestershire
GL51 9NJ
Tel: 01242 541400
Contact: Steve White

For further details contact ACG Sales Department.