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Latest Manufacturing Technologies for Low-cost, Energy-efficient Manufacturing of Advanced Polymer Composites

Uday VaidyaChief Technology Officer

8th Annual American Manufacturing

Strategies Summit 2017

Manufacturing USA Integration

UT Lab:

precursor, digital

fiber

Automation

Workforce collaborationWorkforce collaboration,

Colocation

Workforce collaboration,

Modeling & Simulation

Recycling initiatives

Resins & AdhesivesFacility & Equipment

Networking; Testbeds

Composite AM,

Tooling

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Operated by Collaborative Composite Solutions Corp, an independent not-for-profit

Governed by a board of directors

A wholly owned subsidiary of the University of Tennessee Research Foundation

Headquartered in Knoxville, Tennessee

Over 155 member consortium, including more than 125 industrial entities across supply chain

$250M in funding with $70M from DOE and $180M from partners

What is IACMI?

Research and Development Partner for Industry

IACMI – A National Institute for Advanced Composites

OhioCompressedGas Storage

IndianaInnovativeDesign,

Predictive Modeling &Simulation

TennesseeComposite Materials & Process Technology

New YorkComposite Prototyping Center

MichiganVehicles

WashingtonComposite Recycling Technology Center & Peninsula College

ColoradoWind Turbines

Technical Goals:• Lower carbon fiber–reinforced polymer (CFRP) cost• Reduce CFRP embodied energy • Improve composite recyclability into useful products

150 partners

All 50 states

IACMI- The Composites Institute has partnered with ACMA, the premiere composites industry association and Composites One for workforce training capabilities.

IACMI-The Composites Institute Senior Leadership Team

Dale BrosiusChief Commercialization Officer

Cliff EberleMaterials and

Processing Technology Area

Director

R. Byron PipesModeling & Simulation

Technology AreaDirector

Lawrence DrzalVehicles Technology

Area Director

Derek BerryWind Turbines

Technology Area Director

Brian RiceCompressed Gas

StorageTechnology Area

Director

Uday VaidyaChief Technology OfficerRenae Speck

Chief Operations Officer

John HopkinsChief Executive Officer

Interim

IACMI-The Composites Institute Facilities

ColoradoIndiana

Michigan

Tennessee

Ohio

IACMI Focus Areas and Metrics

+ 500M Capital Investment

Confidential information-Do Not Distribute 8

Solutionspinning

line Carbon Fiber Technology

Facility Pre-preg

productionpilot/full

scale Pilot-scale

PCM 750 ton press

Full ScalePCM

4,000 ton press

Scale-up Across IACMI Core Partners

Materials

Production

Intermediates

Processing

Composites

Manufacturing

(Sub) System

Assembly

Composites

Recycling

Pro

du

ct

Fo

rms

Pro

cess T

ech

no

log

ies

Crosscutting Technologies and Shared Services

•Commercial PAN-CF

•Low Cost PAN-CF

•Low Cost PO-CF

•Low Cost Pitch-CF

•Low Cost Lignin-CF

•Biomass PAN-CF

•Glass Fiber

•Thermoplastic Resins

•Thermoset Resins

•Additives

•Woven Fabric

•Non-woven Fabric

•Braids

•Prepregs

•Towpreg

•Molding Compounds

•Tapes

•Pultruded Forms

(rods, beams)

•3D Parts/Preforms

•Sheet Products

•Tooling (molds, dies)

•Pultruded Forms

•Pressure Vessels

•Pipes

•Shafts

•Rollers

•Tubes

•Automotive

Assemblies

Bodies, Chassis,

Chassis

Interiors

•Gas Storage

Systems

CNG

Hydrogen

•Wind Turbines

Spars (Caps,

Shear

Webs)

Blade Skins

Blades

•Offal/Trim Scrap

•Chopped Fiber

•Roll Goods

•Preforms

•Fiber Spinning

Solution Spinning

Melt Spinning

Gel Spinning

Electro Spinning

•Fiber Conversion

Thermal

Plasma

Microwave

Ultraviolet

•Fabric Weaving

•Fiber Braiding

•Prepregging

•Compounding

SMC

BMC

•Extrusion

•Stitching

•Auto Tape

Placement

•Preforming

•Thermoforming

•Compression

Molding

•Injection Molding

•Transfer Molding

HP-RTM

VA-RTM

Other Variants

•Additive

Manufacturing

•Filament Winding

•Pultrusion

•Infusion/Compressio

n

•Resin spraying

•Infusion/Cure/Set

Cooling (TP systems)

Thermal

Plasma

Microwave

Ultraviolet

Induction

Infrared

Magnetic Field

Electron Beam

•Pyrolysis

•Solvolysis

•Modeling & Simulation

Supercomputing

Process modeling

Microstructure properties

Probabilistic failure

Analysis

Multiscale modeling

Rheokinetics modeling

Crash modeling

•NDE/NDI

Thermography

Fiber optics

Spectroscopy

Flurorescence

Attenuation/Reflection

High resolution

microscopy

Scanning lasers

•Materials

Characterization

Microscopy

X-Rays

Neutrons

Mechanical

Physical

Thermal

Chemical

•Joining

Adhesives

(Reversible, Curie

Limited Curing)

Mechanical

fastening

(For Multi-

Material

Systems)

•Innovative Design Concepts

Composite Tube Super-Light-

weight auto. body structure

Composite vehicle snap fit joints

Conformable auto CGS tanks

Segmented adhesive-bonded

wind blades

Key IACMI Capabilities (300,000 sq.ft, $200 million in replacement value investment)

Ways to Partner with IACMI

1. RD&D Research Project

A. Enterprise

B. Technology Collaboration

C. Topic-Specific

2. Membership

A. Charter

B. Premium

C. Resource

D. Consortium

Roadmapping Strategy

Integrated R&D efforts across IACMI Technology Areas toward 5-/10-year targets

Industry-led projects draw upon resources from one or more IACMI Technology Areas

Eight cross-cutting subtopics help address full range of enabling technologies

Global vehicle production is growing

Why Lightweighting?

“Excess weight kills any self-propelled vehicle. There are a lot of fool ideas about weight . . . Whenever anyone suggests to me that I might increase weight or add a part, I look into decreasing weight and eliminating a part!” – Henry Ford, 1922

Every automotive manufacturer is pursuing

lightweighting as a key strategy to reduce fuel

consumption—irrespective of the powertrain technology

pathway.

Weight reduction – Automotive, Mass Transit & Truck

Performance

Increased ‘customer value’ while staying within Corporate Average Fuel Economy (CAFÉ) limits

Long term increase in fuel prices

6-8% (with mass compounding) increase in fuel economy for every 10% reduction in weight, everything else being the same

DOE, Carpenter, 2008

Big Area Additive Manufacturing for producing large scale

composites – ground vehicle components, cars, bridges,

wind mill blades etc..

Leverage Computing Power to Enhance Design Confidence

Create Composites Virtual Factory HUB (cvfHUB)

Develop platform for hosting and integration of commercial software tools for composites

Provide end-to-end simulation for composites

Correlate at multiple scales prediction and reality

Make tools and knowledge available to entire value chain to enhance confidence and reduce cost

Implementation is underway, rollout commences mid-2017

• Facility is shared by IACMI-The Composites Institute and LIFT Innovation Institute

IACMI-The Composites Institute Facilities, Vehicle Scale Up Facility in Corktown Area of Detroit, Michigan

• Co-located with LIFT, 9300 m2 total

• Capitalization >$15M

Compression Press

Schuler Press: 4000T, 3.7m x 2.4m platen

Thermosets & Thermoplastic

Infusion, compression

Injection Molding Cell

Milacron Press: 3000T, 3m x 2.4m platen

1-10kg shot size, 3 – 275kg dryers

Robotic handling

*Courtesy of Xperion

CGS Manufacture State of the Art

Braid Offers Potential for Enhanced Safety and Reduced Mass

• High-performance simulation tools

• Wind resource assessment

• Wind forecasting

• Utility grid connectivity

• Economic analysis of turbine technology

• Full-scale structural testing

− Blades

− Dynamometer

− Field testing

National Wind Technology Center (NWTC)

Wind Blade Challenges and Opportunities

• Reduction in hands-on labor− Automated fabric laying− Automated tape laying

• Transportation logistics

− Segmented blades

• Recyclability

− Thermoplastics?

• Field reliability of blades

− In-process nondestructiveevaluation

− Structural testing

• Blade structural properties

− Pultruded spar caps

• Time to market

− Additive manufacturing―molds

• Manufacturing space focused on composite manufacturing innovation

• 55’ x 200’ – 10,000 sq. ft.

• Adjacent to blade test facility

• Full-scale blade component manufacturing

IACMI Wind TA Composites Manufacturing and Education Technology (CoMET) Facility

Full Scale Wind Blade Tooling

48.5m blade tip mold

Courtesy GE

Large shear web mold

Courtesy GE

Portion of 60m spar cap infusion mold

Courtesy DowAksa

Workforce Training

STEM Events

Hands-On Events

Intern Program

Online Training (CCT)

$70M - DOE

$189M - Other

123 - Member Consortium

6 Core Partner States

Strong Leadership

5 Technology Areas

Production capacity

Jobs

- 75%CFRP embodied energy savings

- 50%CFRPproduction cost

Greenhouse gas avoidance

- 25%

- 50%

- 50%- 75%

95%FRP recycled

and/or reused

80%

Federal Investment Will Catalyze a Composites Ecosystem

in the Heart of US Manufacturing

10/30/2017 Confidential information statement (go to INSERT>>HEADER & FOOTER) 27

Contact info:

Uday Vaidya

Chief Technology Officer

IACMI-The Composites Institute, managed by Collaborative Composite

Solutions Corporation

Email: uvaidya@iacmi.org