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AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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For 25 years, the Awards for Composites Excellence

(ACE) have recognized the superior product and process

achievements that are the forefront of innovation to the

industry. This annual competition and product showcase

hosted by the American Composites Manufacturers

Association (ACMA) recognizes superiority in engineering

and design as well as improvements and innovation in

equipment and manufacturing. The products, equipment

and processes that receive this distinguished recognition

have significant impact within the market as well as a proven

understanding of composites.

Join fellow industry peers at the Innovation Park Theater

in the Exhibit Hall on Tuesday, September 12 at 2:00 PM

to celebrate the innovative companies that are shaping

composites as the 2017 ACE winners are revealed and

receive their awards.

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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DESIGN CATEGORYINNOVATION IN GREEN COMPOSITES DESIGN AWARDThis award is presented to the composites product that best exemplifies innovation that lowers/minimizes the environmental footprint or offers an attractive life cycle assessment (LCA) of the product. The product design should demonstrate application of new or innovative materials, or it should apply a unique design that contributes to efficient manufacturing, delivery, installation and in-service performance leading to energy savings.

MOST CREATIVE APPLICATION AWARDThis award is presented to the composites product that showcases composites use in a unique, new application or uses composites’ attributes in imaginative, innovative, or artistic ways. The composites product should show evidence of significantly replacing traditional materials, or show innovative use or refinement of existing composites materials that impacts current or new markets. Candidate product entries for this award include both production and prototype/research and development.

Composite Overwrapped Pressure Vessel made with Recycled Continuous Carbon Fiber Vartega Inc.

Carbon fiber recycled by Vartega and sized by Michelman has been provided to Steelhead Composites for incorporation into new pressure vessels and to close the loop on their manufacturing scrap. Steelhead Composites’ MicroForce diaphragm accumulators are a family of lightweight, 3,000+ psi (207 bar) accumulators currently available in 0.5 and 2.0 Liter internal volumes. These compact, lightweight composite accumulators provide unmatched form and functionality for any weight-restricted applications where mobility and strength are top priorities.

Biodegradable 3-D Printed Molds for FRP Tank Part ManufacturingDesign Tanks LLC

The common material to build FRP molds are steel, aluminum and fiber glass. After a while (normally 10 years), these molds need to be replaced and they are not bio degradable. In a research to use biodegradable mold, several materials were investigated. Polylactic acid (PLA) was used in a 3D printer and the obtained molds were used in producing molds. It was noted that the 3D printed molds take less time to make. For example, PLA anti vortex mold needs 1.5 hr. less than FRP made mold. The importance of the research is replacing non-biodegradable molds with biodegradable molds.

Large Scale 3D Printing Using 100% Bio-Composite MaterialsOak Ridge National Laboratory

Researchers at the Oak Ridge National Laboratory (ORNL), in collaboration with industrial partners, have developed and demonstrated large scale 3D printing using 100% bio-based and bio-degradable composites. These materials were used to 3D print a large portion of the world’s largest green printed pavilion structure which was exhibited at the Design Miami Exposition. The Pavilion structure with complex geometry largely consisted of a bamboo fiber-reinforced biopolymer formulation developed at ORNL. This innovative green formulation has 1/3 of the embodied energy and an order of magnitude less carbon footprint of carbon fiber –resin systems normally used in large scale additive manufacturing.

Carbon Fibre / Kevlar Hinge SystemTalon Technology

The product is a revolutionary hinge that utilizes the strength and fatigue resistance of Kevlar and the structural stiffness of carbon fibre to produce a hinge that is extremely corrosion resistant, lightweight, maintenance free and one of the thinnest hinges in the world. For its size and weight, it can hold considerable weight and the carbon fibre makes it highly compatible with other composite parts making it possible to bond the hinge in place which saves space, weight and makes for an extremely strong bond. Priced to be about 30% cheaper than quality stainless steel hinges.

Imitation Wood Composite Light PoleAppalachian Plastics

Imitation wood composite light pole used for parking lot lighting at theme parks in Florida, Texas and California. Designed to blend in with the floral and wooded landscape. An alternative to wood was needed due to the woodpeckers and termites damaging their current light poles. The pole was engineered by Appalachian Plastics and Alliance Composites. Mold was tooled off of a wooden pole. The core is filament wound with the outside being a poured polyurethane.

Rapid Manufacture of Ultra-High Quality Composite Mirrors The Aerospace Corporation

There is an increasing demand for lightweight mirrors made of composite materials, but their quality and stability have not been able to match those of glass mirrors in high precision applications. The Aerospace Corporation has developed a processing method to manufacture replicated composite mirrors with high optical quality and dimensional stability under varying hygrothermal environments. This was made possible by utilizing an optimized self-assembled monolayer as a mold-release and secondary processing of the UV curable epoxy utilized in the replication process.

Composites Lift the World’s First Electric Flying SurfboardStrongwell

Strongwell’s custom pultruded mast, co-developed with Lift Foils, provides the strong, lightweight backbone of the revolutionary Lift eFoil, the world’s first electric foil board. A hydrofoil (foil) board is a recreational “surfboard” with wings underneath it which lift the board and its rider out of the water as the board gains propulsion. Prototyped using metals, then resin transfer molding (RTM), the pultruded carbon and glass mast produced by Strongwell provides the greatest multi-axis strength at the lightest possible weight. Pultrusion also provides tolerance consistency during mass manufacture required to ensure the proper fit with additional components used in the eFoil.

DIY Phenolic GRP Composite Coffee TableICMC

Coffee table legs 4” x 4” x 17”, made of room temperature cure phenolic resin & glass fibre csm by hand layup process. Fire retardant with FST properties connected by brass studs & fasteners for elegance and durability. We deliver 4 legs in antique Burma teak finish, with long brass studs for a coffee table to be ready in 20 minutes; a DIY concept.

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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One-Piece Molded High Performance Carbon Fiber Triathlon Bicycle FrameCervelo Cycles/Vroomen White Design

The Cervélo P5X is a new concept in design and manufacturing for a high performance carbon fiber composite triathlon bicycle. It uses a radical new shape which allows the frame to be molded as a single piece, providing improved strength and stiffness relative to bonded tubular frames. The design has been optimized for aerodynamic performance along with rider comfort, which is of key importance in long distance Triathlon events. Also, the frame shape has been designed with significant internal storage, to allow athletes to carry food and drink within the bicycle for a full Ironman distance race, without affecting aerodynamics

Satellite Dishes Disappear from Residential and Commercial RooftopsHauk Technology

Hauk’s STS composite panel provides a SIGNAL transparent aperture for devices like satellite dishes, cell boosters, and wireless point to point devices. The composite material comes in a skylight frame that is placed on the south facing side of the home with the satellite dish placed underneath in the attic. STS is available in several forms to give the appearance of a skylight, slate, composite, tile and metal roofs. Placing the composite material in a skylight frame insures ease of installation and familiarity for builders, roofers, and inspectors. Target market includes residential new construction and multi-family buildings under 4 stories.

Golf Swing Training (LAG) DeviceTsunami Bar, LLC

The SwingBalance™ Laginator™is a 30” functional training device for golfers allowing them to take their hands on a direct path to the ball, when swinging the device, and at the same time train to retain the ‘LAG’. The practice of swinging this device, with its unique movable mechanism, offers vestibular feedback by combining the sensory systems of hearing, seeing and feeling. Pultruded composites are used with thermoplastic tubes to give unique bending characteristics that enables this training of a proper golf swing. It fits easily in a golf bag or the overhead bin on an airplane.

Composite Self-Driving Shuttle by Additive ManufacturingLocal Motors

The Olli self-driving shuttle is a low speed electric vehicle transportation solution for widespread application as a people mover. The use of large scale additive manufacturing of composite materials was employed in an efficient and elegant design that produces a structure comparable in weight and at significantly reduced cost and development time compared to an existing prototype design with an aluminum chassis. The design utilizes two main 3d printed components, the upper and lower chassis, connected together with aluminum extrusions and composite corner structures manufactured on 3d printed tooling. The simple design optimizes the use of composites and additive manufacturing.

Composite Overwrapped Pressure Vessel made with Recycled Continuous Carbon Fiber Vartega Inc.

Large Scale 3D Printing Using 100% Bio-Composite Materials Oak Ridge National Laboratory

Biodegradable 3-DPrinted Molds for FRP Tank Part Manufacturing Design Tanks LLC

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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Carbon Fibre / Kevlar Hinge SystemTalon Technology

One-Piece Molded High Performance Carbon Fiber Triathlon Bicycle Frame Cervelo Cycles/Vroomen White Design

Rapid Manufacture of Ultra-High Quality Composite Mirrors The Aerospace Corporation

Golf Swing Training (LAG)Device Tsunami Bar, LLCDIY Phenolic GRP Composite Coffee Table ICMC

Imitation Wood Composite Light PoleAppalachian Plastics

Satellite Dishes Disappear from Residential and Commercial Rooftops Hauk Technology

Composites Lift the World’s First Electric Flying Surfboard Strongwell

Composite Self-Driving Shuttle by Additive Manufacturing Local Motors

AWARDS FOR COMPOSITES EXCELLENCE

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MANUFACTURING CATEGORYEQUIPMENT AND TOOLING INNOVATION AWARDThis award is presented to the equipment, tooling, production aid, or software that is designed to improve manufacturing production, environmental sustainability, or product quality and performance in composites manufacturing. The entry must demonstrate improvement or efficiency in the manufacturing of a specific end-use composites product.

MATERIAL AND PROCESS INNOVATION AWARDThis award is presented for a material or process that best contributes to efficient manufacturing and product sustainability. The entries should demonstrate use of innovative materials, production techniques or methods that result in better quality, reduced production costs, increased production rates and volume, or reduced life cycle costs. The entry must demonstrate its application in the manufacturing of a specific, end-use composites product.

2017 ENTRANTS

Composite Material Roll and Kit Life Tracking SoftwareJETCAM International s.a.r.l

CrossTrack provides traceability of location and life from delivery of composite rolls or tapes, in and out of the freezer, the cutting room, layup and the autoclave. Due to tight integration with JETCAM Expert nesting software can also track life to individual ply level. If a ply needs to be scrapped it can be re-nested on demand and the kit life will be automatically recalculated. Dynamic nests can be easily picked from the cutting table due to integration with laser systems. Instant full life reports can be generated on demand or automatically.

Comprehensive Composite Manufacturing PlatformAutodesk

Autodesk provides a comprehensive tool set creating an end-to-end solution for composite manufacturers. Highly functional capabilities provide solutions to novice and expert companies alike. Design composites layups with material catalogs, orientations, plies, and layup sequences. Add manufacturing edges, swap surfaces, and splice geometry based on material packaging. Simulate composite shear, fatigue, impact, warpage, and PFA. Analyze the manufacturability of processes like HLU, AFP/ATL, RTM, and forming. Autodesk’s simulation provides early access to problems in design and manufacturing. Manufacture composite parts by creating 2D flat patterns, program laser projectors, nest, track materials, and program, edit, and simulate machine part programs.

Reusable Shipping and Storage Containers for High Value AssetsPRC Composites

PRC Composites is providing a family of composite shipping and storage containers for a large aircraft engine component supplier. Our reusable containers will replace large single use wood boxes. The elimination of the 1000’s of wood boxes that would have been required for life of the program will save thousands of trees as well as save our customer from wood related damage to the high value products that they are shipping. Replacing single use wood with reusable Vacuum Assisted Resin Transfer Molding (VARTM) containers using new innovated materials will minimize the environmental footprint and increase customer satisfaction.

Out-of-Autoclave Process: Low Cost, Low Cycle Time Motorcycle HelmetsVistex Composites, LLC

The motorcycle helmet is being produced in partnership with Impact Technologies’ Kirsch Helmets. Their revolutionary liner replaces traditional EPS foam for energy absorption. Due to the liner’s low profile and unique needs during impact, advanced composites were essential for providing both high stiffness and high toughness. The helmet is made from external layers of woven carbon fiber and internal layers of Innegra Tech’s high performance Innegra™ Solefin fibers. Additionally, the use of composites makes the entire helmet ultra-low profile and light weight.

Cyanate Ester Infusion System for FST Compliant Aircraft Interior PartsRAMPF Group, Inc

Cyanate Ester based system that is fully compliant to FAR 25.853. Inherently fire, smoke and toxicity (FST) compliant (no halogens or heavy metals) and meets the demands for an easy-to-process (no autoclave processing required) and affordable material (can reduce overall part cost 15-30% in most cases) for use in aircraft interior structures. The system has a viscosity of 150 to 300 centipoise at 104°F (40°C) facilitating quick infusion times and cures at 250°F (120°C). This system replaces difficult to process phenolic based systems (no volatiles verses 3-5% for typical phenolic) and other prepreg systems traditionally used for aircraft interior structures.

CFRTP Processing Technology Using Commingling, Fiber Laying, and Light MoldingGifu University

We propose a process, which provides a high flexibility of design, high fabrication yield, and easy shaping carbon fiber reinforced thermoplastic (CFRTP) molding product. This process consists of three independent technologies; commingling, fiber laying, and light molding. First, high performance polyamide N-XD10 (Mitsubishi Gas Chemical) was spun. The resin fiber was highly dispersed into a carbon fiber yarn without losing their textile working ability by Kajirene commingling technology. The commingled yarn was laid on a polyamide film by using Tajima fiber laying Machine. At the end, the laid commingled yarn was cured by D-MEC Amolsys system using near-infrared light.

Nanocalcite-Modified Thermosetting Resins for Lightweight, High Performance Fiber-Reinforced Composites3M Company

The product is an initial portfolio of nanocalcite-modified, low viscosity epoxy resins aimed at composite manufacturing processes (RTM, Pultrusion, VARTM, filament winding, solvent prepregging). The initial portfolio contains epoxy 3M Matrix Resins 883X (where x= 0-2.4.5) containing high levels of nanocalcite (50-60 wt %). These cost-effective resins offer simultaneous improvements in modulus and toughness, leading to fiber-reinforced laminates with increased laminate modulus/strength, impact resistance, compression strength/modulus, short beam shear, lower Z-axis CTE, and lower water uptake. Additionally, use of the resins in tubular structures results in composite tubes and driveshafts with higher torque capacity, offering significant lightweighting/cost-saving opportunities.

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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2016 ENTRY FINALISTS

Comprehensive Composite Manufacturing PlatformAutodesk

Composite Material Roll and Kit Life Tracking SoftwareJETCAM International s.a.r.l

Reusable Shipping and Storage Containers for High-Value Assets PRC Composites

Front Rail Car CabinABLE Mfg & Assy, LLC

Front Rail Cabin for light rail inner city passenger transport. The resin is AOC with ATH filler that exceeds stringent flame, smoke, and toxicity rail standards. Airex foam is encapsulated for strength and weight savings. Special waterbase paint and resin infusion is selected for low emissions consideration.

Significant Weight Reduction of Aircraft SeatOxeon AB

HAECO turned to TeXtreme® to help optimize their current seat design for weight, while still maintaining mechanical properties. TeXtreme® used calculation, simulation and manufacturing support to help HAECO reduce the weight of the aircraft seat by almost 20%. TeXtreme® wisely optimized the composite lay-up. Also, the TeXtreme® fabric has been judiciously used so that its specific architecture could help for a better bearing performance and resistance to cracks propagation. Not only has TeXtreme® achieved a significant weight reduction while maintaining the desired stiffness but it has also contributed to save some manufacturing labor by decreasing the number of patches used.

3D Foam Printing TechnologUniversity of Central Florida

The University of Central Florida (UCF) with its industry partner SegAna, LLC have developed a 3D Foam Printer and materials systems. This is a first successful demonstration of 3D printing of very flexible foam materials with a density as low as human lungs, ultra-low elastic modulus (10 times lower than elastomers) but ultra-high elongation. Using a patent-pending print head technology, UCF is able to create flexible foam parts by printing the proprietary reactive two-part polyurethane liquid precursors. The 3D foam printing technology can offer a variety of industrial applications such as space, aerospace, biomedical, footwear, and sports applications.

Epoxy SMC Seatframe DemonstratorHexion Inc.

Hexion EPIKOTE™ TRAC 06605 (resin), EPIKURE™ TRAC 06608 (curing agent) and HELOXY™ Additive TRAC 06805 (internal release agent) is a three component, epoxy resin system that is suitable for production of high performance epoxy sheet molding compound. This new epoxy was specifically formulated to eliminate styrene monomer exposure and is low in VOC and fog emissions throughout its manufacturing processes. The material can be compounded on standard equipment and is stable at room temperature for several weeks prior to molding. The low viscosity formulation enables complex molded geometry and a superior surface quality without a loss of cycle time.

Bio Material Spray-up and Dispensing UnitSunstrand

This novel bio material spray-up system by Sunstrand is designed to augment chopped fiber glass spray up systems. The system consists of a mechanized hopper/ feeder, and a pneumatic delivery tube. It can replace a significant amount of glass fibers when fibers are used as a bulking material to increase the thickness of a composite part. It can also be used as a core filler to replace commonly used balsa and foam sheets. As a core material, it can easily and quickly apply core material onto complex curved geometries at user defined varying thicknesses.

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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Out-of-Autoclave Process: Low Cost, Low Cycle Time Motorcycle Helmets Vistex Composites, LLC

Significant Weight Reduction of Aircraft Seat Oxeon AB

CFRTP Processing Technology Using Commingling, FiberLaying, and Light Molding Gifu University

Epoxy SMC Seatframe Demonstrator Hexion Inc.Front Rail Car Cabin ABLE Mfg & Assy, LLC

Cyanate Ester Infusion System for FST Compliant Aircraft Interior Parts RAMPF Group, Inc

3D Foam Printing Technology University of Central Florida

Nanocalcite-Modified Thermosetting Resins for Lightweight, High Performance Fiber-Reinforced Composites 3M Company

Bio Material Spray-up and Dispensing Unit Sunstrand

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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MARKET GROWTH CATEGORYINFINITE POSSIBILITY AWARDThis award is presented to the composites product that demonstrates the potential to significantly increase the use of composites in existing markets or generate the greatest impact to open new and emerging markets for composites. This product exemplifies innovation, creativity, and commercialization leading to market growth.

Lighter-than-Water, 0.98 Specific Gravity Sheet Molding CompoundCore Molding Technologies

Hydrilite(TM) SMC is a 41% glass thermoset, blended resin sheet molding compound (SMC) that offers one of the lowest density alternatives in the market today. The system is designed to offer an ultra-lightweight alternative to a variety of end markets including automotive, marine, and heavy truck. Offering a significant weight reduction, in some cases even below some thermoplastic systems, Hydrilite SMC with a nominal specific gravity of 0.98 achieves a tensile strength of 75 MPa, flexural strength of 155 MPa, impact strength of 850 J/m (notched), and a water absorption of less than 0.5% while maintaining a paintable surface quality.

Low Cost Carbon Fiber (LCCF)Oak Ridge National Laboratory

Carbon fiber is a strong, stiff, lightweight enabling material for improved performance in many applications. Historically carbon fiber has been a high-priced specialty material prohibiting its widespread use in high volume, cost sensitive applications. The Oak Ridge National Laboratory (ORNL) has successfully addressed this issue with the development of a novel fiber production method that reduces the carbon fiber cost by approximately 50% while also reducing the energy required for its production by a similar amount. LCCF technology is the first to meet the cost and performance requirements for main stream domestic automotive and other high volume cost sensitive applications.

Curved Pultrusion Process Applied to Highly Engineered Hollow ProfilesShape Corp

Shape Corp has developed a curved pultruded component that will start soon. This specific product is for an automotive application; however, the process and materials might be best served for many other industries and applications. The part will be made with a Urethane Acrylate resin system; however, the team has tested a variety of different Poly Urethane’s and Epoxy systems. This is the first ever curved pultruded “hollow section” profile that has been awarded for a production application. From material development, process and product innovations, and CAE methodology, this project exemplifies a holistic engineering approach for today’s composites.

Satellite Dishes Disappear from Residential and Commercial RooftopsHauk Technology

Hauk’s STS composite panel provides a SIGNAL transparent aperture for devices like satellite dishes, cell boosters, and wireless point to point devices. The composite material comes in a skylight frame that is placed on the south facing side of the home with the satellite dish placed underneath in the attic. STS is available in several forms to give the appearance of a skylight, slate, composite, tile and metal roofs. Placing the composite material in a skylight frame insures ease of installation and familiarity for builders, roofers, and inspectors. Target market includes residential new construction and multi-family buildings under 4 stories.

Flame Retardant Polyolefin Based Light Weight Reinforced CompositeHanwha Azdel

Flame-retarding performance is required in differing degrees for a number of composite applications, including building and construction, automotive, furniture and transportation, and others. Widely different test standards are used for these different applications. Recent developments in polyolefin-based, light-weight reinforced thermoplastic (LWRT) composites significantly improve the flammability performance of the material in different aspects. By proper selection of non-halogen flame-retarding additives for the intended end use, performance of the LWRT materials, as tested by ASTM E84 and SAE J369, can be significantly improved. In addition, the LWRT with flame-retarding formulation also shows potential for improved acoustic performance at relatively low thickness.

Ford/Magna Carbon Fiber SubframeAshland LLC

Lightweighting vehicles, in order to reduce emissions, is a well identified need for the automotive industry. Magna International Inc in cooperation with Ford Motor Company, have developed a prototype carbon fiber composite subframe that not only reduces the weight of the vehicle but also consolidates the number of parts needed in its assembly by over 80%. The part is manufactured with Ashland epoxy vinyl ester resin and carbon fiber SMC technology. Because the subframe is an integral part of the vehicle’s frame, it has greatly expanded the possibilities of composites use in a truly structural application for mass produced vehicles.

AWARDS FOR COMPOSITES EXCELLENCE 2017 ENTRANTS

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Lighter-than-Water, 0.98 Specific Gravity Sheet Molding Compound Core Molding Technologies

Satellite Dishes Disappear from Residen-tial and Commercial Rooftops Hauk Technology

Low Cost Carbon Fibe (LCCF) Oak Ridge National Laboratory

Flame Retardant Polyolefin Based Light Weight Reinforced CompositeHanwha Azdel

Curved Pultrusion Process Applied to Highly Engineered Hollow Profiles Shape Corp

Ford/Magna Carbon Fiber SubframeAshland LLC

www.acmanet.org

The American Composites Manufacturers Association

(ACMA) is the world’s largest composites industry trade

group. We are manufacturers, material and equipment

suppliers, distributors, academia and end users, dedicated to

growing the composites market. We serve our members and

the industry by promoting the competitive advantage and

versatility of composite materials. ACMA offers composites

industry educational resources through our CAMX show,

conferences and Certified Composites Technician (CCT®)

program. We develop standards and specifications that drive

preference for the use of composites in place of traditional

materials. We lead advocacy efforts via legislative and

regulatory channels to achieve a more viable composites

industry. Together, we are shaping the future of composites.