Archived General News - 2008
Demonstrating the Technology of our Tomorrows’ In one of the Palaces of our Yesterdays’ - December 2008
As a partner in the ALCAS (Advanced Low Cost Aircraft Structures) consortium, Andrew Shelton (ACG’s Applied Technology Technician), Alasdair Ryder (ACG’s Senior Design Engineer) and Xavier Gambert (ACG’s Aerospace Market Sector Manager) attended the Paris ‘City of Sciences Exhibition’ in late November 2008 to demonstrate - to the general public - the benefits and technology behind advanced composites and describe the impact that these materials are having on our everyday lives.
The demonstration, which took place in the ‘Aerospace Composites Factory’ booth in Paris’ Grand Palais, involved the press moulding of an astounding 240 miniature planes over 3 days to a constant stream of interested children and adults alike, all totally intrigued by the ‘industrial process in action’ that they witnessed.
The number of visitors that attended this exhibition was nothing short of astonishing, perhaps even totaling 20,000 per day, and all in the beauty and grandeur of the spectacular venue of the Grand Palais (Grand Palace), a large glass exhibition hall built for the 1900 Paris Exhibition and now the regular venue for the couture fashion house Chanel, which hosts many fashion shows within its walls.
The exterior of this massive palace combines an imposing Classical stone façade with an array of Art Nouveau ironwork, and a number of allegorical statue groups.
ACG to Play Major Role in Pioneering £2m Energy Research Projects - September 2008
Derbyshire-based Advanced Composites Group Ltd (ACG), part of the Composites Division of Umeco plc, is to play a major role in two ground-breaking research and development projects into turbine generators that could have significant impacts on energy efficiency and carbon dioxide emissions. The projects, worth over £2m, could lead to a recruitment drive offering exciting job opportunities for local and regional communities.
The first project is centred on improving the processes used to manufacture components for tidal turbine generators and improving overall operating efficiencies, while the purpose of the second project is to develop composite materials for power generating gas turbine applications.
Nigel Blatherwick, ACG Commercial Director, stated: “ACG is proud to be involved in these exciting and challenging research projects and to apply its expertise in an effort to reduce the environmental impact of emerging power generation programmes.” Furthermore, “in addition to our recent, successful recruitment drive and significant increase in operating profit, the Group continues to look to the future and is likely to offer further rewarding employment opportunities for the region in its drive to become ‘a world class composites solution provider’.”
As the Lead Partner in a project examining ‘New Materials and Methods for Energy Efficient Tidal Turbines’ (NEW-MMEETT), ACG and its partners will investigate optimising energy efficiency and return on investment. This will be achieved through the development of new carbon and glass fibre reinforced resin systems optimised to counter fatigue effects, which will then allow for reductions in the design allowables and, with the application of state-of-the-art aerospace technologies, to the design of more efficient tidal turbines. Aviation Enterprises Ltd, Materials Engineering Research Laboratory Ltd, and the University of Bristol, all prominent industrial leaders in their own right, are partnering ACG in this venture.
The second project, which will be led by Rolls-Royce plc, with ACG, Swansea University and the University of Birmingham as joint partners, will focus on the research and development of ‘Advanced Ceramic Matrix Composites for Energy Generating Gas Turbine Applications’. The project will develop a high temperature oxide/oxide-ceramic matrix composite for use in power generating gas turbine applications. This will provide a step change in temperature capability, thereby enabling higher operating temperatures, improving engine efficiency and reducing carbon dioxide emissions.
ACG’s projects are two out of a total of sixteen that are to receive investment of over £10 million from the Technology Strategy Board and Engineering and the Physical Sciences Research Council (EPSRC), while the estimated total of all the projects currently in planning in the UK is in excess of £20 million.
Artificial Lower Limbs - March 2008
Advanced Composites Group (ACG), a member of the Composites Division of Umeco plc, is pleased to announce that its MTM®28 series carbon fibre prepregs have been chosen by Blatchford Ltd for use in articfical lower limb products. Blatchford is a world leader in the design and manufacture of advanced, high precision components for artificial lower limbs.
MTM28 is one of a range of toughened epoxy matrix resins designed by ACG for the manufacture of components requiring high damage tolerance, and being particularly suited to the press moulding production technique employed by Blatchford.
ACG's MTM28 series carbon fibre prepregs are used in their world-leading ENDOLITE range of feet, including the 'Elite' and 'Esprit' models.
Advanced Composites Group (ACG), a member of the Composites Division of Umeco plc, is pleased to announce that its MTM28 series carbon fibre prepregs have been chosen by Blatchford Ltd for use in articfical lower limb products. Blatchford is a world leader in the design and manufacture of advanced, high precision components for artificial lower limbs.
MTM28 is one of a range of toughened epoxy matrix resins designed by ACG for the manufacture of components requiring high damage tolerance, and being particularly suited to the press moulding production technique employed by Blatchford.
ACG's MTM28 series carbon fibre prepregs are used in their world-leading ENDOLITE range of feet, including the 'Elite' and 'Esprit' models. The 'Elite' and 'Esprit' models provide optimum multi-directional movement to maximise the benefits for the end user; the shock absorbing reflex action e-carbon heel, provides active, responsive shock absorption and forward progression. The twin-toe feature adapts and conforms to rough and smooth surfaces with optimised energy return, while the Tri-pod system provides effective propulsion and controlled stability on all terrains.
As with all Blatchford products, specialist design and engineering talent is blended with ACG's individually selected carbon prepreg formats to give their feet the right functional characteristics, thereby enabling their customers to engage in rigorous, high impact, high energy activities like athletics, children's games and rugged work.
ACG's MTM28 series prepregs are also used in Blatchford's complimentary range of shin and knee options, which are designed to expand the potential for active living.
Photos courtesy of Blatchfords Limited
For further details contact ACG Sales Department.
ACG Appoints Carlos J. Simarro to expand its Spanish and Portuguese business - March 2008
Advanced Composites Group (ACG), a member of the Composites Division of Umeco plc, is pleased to announce the appointment of Carlos J. Simarro to assist in the promotion and management of its growing business interests in Spain and Portugal. Carlos will be part of the European Sales Team, reporting to Rob Wilder, ACG’s European Sales Manager.
Spanish born Carlos, a fully qualified civil engineer, fluent in Spanish, English and Portuguese, has considerable experience in civil engineering and composites, and holds a degree in Civil Engineering gained at the University of Madrid. His experience in the composites arena is significant, having worked for one of ACG’s prime contacts in recent years. This, and his youthful enthusiasm for composites and their application, will be expertly applied to promote ACG’s presence and product portfolio in the Spanish and Portuguese automotive, motorsport and marine markets. Carlos’ experience will be invaluable in an industry where short delivery times and bespoke - formulated for purpose - products require that proven, essential competitive edge over the competition. Similar attention will be given to other key market sectors requiring customised composites materials for high performance end applications. Carlos will apply his civil engineering expertise to encourage the use of composites in structural projects such as bridges, where ACG has experienced some success in recent years.
From a safety aspect, a vital element in all structural applications, Carlos possesses an official Spanish qualification as Risk Prevention Technician (Master Level) in Work Safety, Industrial Health and Ergonomics and Applied Psychosociology.
Rob Wilder, European Sales Manager, said: “We are delighted to welcome Carlos and look forward to working together to increase ACG’s reach across the Spanish and Portuguese markets.”
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 relating to prepreg materials for alternative energy projects, please contact the ACG Sales Department.
‘Precimould Plus’ Partners Receive JEC Innovation Award for Software - February 2008
Precimould (PRECIsion MOULDing), a combined distortion prediction software and database package aimed at improving tool design for the production of accurate composite components, won the Software category accolade in the JEC Group’s ‘Award Winning Innovation’ 2008.
Precimould is the result of a collaborative research programme called Precimould Plus, a project involving Advanced Composites Group Ltd (ACG) - part of the Composites Division of Umeco plc., Finite Element Analysis Ltd (FEA), BAE Systems and Bombardier Aerospace (Shorts). Funding support was provided by the UK Government under the Aeronautics Research Programme from the Department of Trade and Industry (DTI), with the project building on the output of a previous one initiated by ACG and supported by the European Commission as a BRITE/EURAM 3 project under Framework 4.
The aim of the project was to develop and validate a software package to define the accuracy of predicted laminate composite part distortion during processing, reverse engineer the surfaces and apply the simulation to complex structures. Benefits derived from the technology include design confidence to predict and remove distortion, thereby reducing scrap and reworking assembly costs.
In effect, the designer can use the information about part distortion and put this to good use by creating a mould or pattern that compensates for distortions during manufacture of the mould and the final manufactured part. The process starts with the manufacture of an ‘incorrectly-shaped’ tool that can then be used to manufacture ‘correctly-shaped’ parts direct from the mould or pattern. The key to this ‘distortion prediction’ software suite is the engine embedded within the finite element software ‘LUSAS’, developed by Finite Element Analysis Ltd. Supporting this software is a database of material properties describing a range of resin systems manufactured by ACG. Together, these elements provide the designer with the tools to manufacture ‘right first time’ parts.
It is estimated that, in airframe applications, 50% of the costs associated with composite parts occur during the assembly process. This is generally due to the cumulative distortion present on individual components and the time associated with the rework and shimming processes required to accommodate these errors and integrate the parts in an assembly. It is reported that up to 200 kg of shimming can be used to correct errors due to component distortion. Use of the Precimould simulation can lead to a significant reduction in costs and overall weight.
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 Launches New DForm - Deformable Composite System (DCS) - January 2008
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.