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8/14/2019 Evaluating the Performance and Cost of Infusion
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Evaluating the Performance and Cost
of Infusion
Ramesh Watson
8/14/2019 Evaluating the Performance and Cost of Infusion
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What will we cover today?
Introduction of DIAB
Brief from Client to DIAB
Past and current global DIAB infusion projects
Project recommendations
Weight Study
Proposed hull laminates
Cycle time study
Process study
Cost study
Implementation plan
DIAB marketing support How to market benefits of sandwich and infusion construction
SUMMARY
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Who is DIAB
1200 employees globally
World leader in sandwich structural cores
#1 in foam structural core manufacturing capacity
#2 in Balsa manufacturing capacity
#1 in sandwich technology #1 in core infusion technology
Brands include
Divinycell®
ProBalsaTM
DiviletteTM
DIAB Core Infusion TechnologyTM
DIAB TechnologiesTM
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Brief from Client to DIAB
Client will give DIAB all the necessary data required forthe 36ft Motor Yacht Hull and would like DIAB to:
Estimate what the current hand laminated hull should weigh
Put forward a proposal on converting manufacturing process toINFUSION using DIAB Core Infusion Technology TM .
Propose structural and laminate redesign for INFUSION for hull.
Propose infusion strategy, materials selection, build/labour timeestimates, build/labour/materials cost estimate.
When approved, Client will work with DIAB under contractto implement and supply technology, training andmaterials.
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Global DIAB infusion customers
“DIAB has converted more production boat manufacturers to infusion than any other company”
Company
Azimut
Gobbi Sunseeker
Fiart
Sealine
Nimbus
NuMarine
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Company:AZIMUT
Location: Italy Range: 39 to 116ft
No.of employees: 1000
Models infused: AZ40
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AZIMUT:
DIAB involvement:
Redesign of laminates and structure from single-skin hull to afully cored hull.
Training of production staff
Production implementation
AZ40 Model now in production
Marketing and dealer training support (never marketed coredhull)
Supply of pre-cut infusion core kits
Implement infusion of other models in range eg. 42, 50, 55, 62,65ft
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AZIMUT: Why infusion?
Employee benefits:
Solve OH&S issues
Improve skills of staff
Environment benefits:
Reduce VOC emissions
Brand benefits:
Improved quality and repeatability
Improved performance and marketability
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AZIMUT: Why infusion?
Financial benefits:
Improve staff retention
45% faster than hand lamination on 40 to 55ft range
25% labour reduction on 40 to 55ft range
Lift valuation of company
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AZIMUT: 55ft deck
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Company:Gobbi
Location: Italy Range: 39 to 55ft
No.of employees: 350
Models infused: 39 Atlantis
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Company:SUNSEEKER
Location: England Range: 28 to 105ft
No.of employees: 1400
Models infused: 65ft (Hull and Deck)
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Company:Nimbus
Location: Sweden Range: 28 to 42ft
Boats per year: 50 of Nova 35
Models infused: Nova 35 (Hull)
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Company:SEALINE
Location: England Range: 25 to 60ft
Boats per year: 400
No.of employees: 700
Models infused: S29 (Hull)
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Company:FIART
Location: Italy Range: 22 to 50ft
Boats per year: 500
Model infused: 38ft Genius (Hull)
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36ft Motor Yacht Hull
Findings and recommendations Proposed hull laminates
Weight Study
Cycle time study
Process study
Cost study
Implementation plan
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Laminate Comparison
PART ORIGINAL HAND LAMINATE DIAB INFUSION LAMINATE
Hull Bottom
900 CSM 900 Sprayed Rovings
600 CSM 750 Triaxial
1868 DUOMAT 600 Biaxial
600 CSM 26mm Divinycell H100
1868 DUOMAT 1050 Biaxial
900 CSM 750 Triaxial
Hull Side
900 CSM 900 Sprayed Rovings
600 CSM 750 Triaxial
2.5mm COREMAT 600 Biaxial600 CSM 15mm Divinycell H80
600 CSM 1050 Biaxial
800 QUAD 750 Triaxial
600 CSM
600 CSM
2.5mm COREMAT
600 CSM
Transom
900 CSM 1050 Biaxial
900 CSM 1050 Biaxial
800 WR 750 Triaxial
900 CSM 600 Biaxial
800 WR 1050 Biaxial
600 CSM 1050 Biaxial
19mm PLY 40mm Divinycell H130
600 CSM 40mm Divinycell H200 inserts
19mm PLY 1050 Biaxial
900 CSM 1050 Biaxial
1050 Biaxial
750 Triaxial
1050 Biaxial
1050 Biaxial
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PART ORIGINAL HAND LAMINATE DIAB INFUSION LAMINATE
Keel
900 CSM 900 Sprayed Rovings
600 CSM 750 Triaxial
1868 DUOMAT 600 Biaxial
600 CSM 600 CFM
1868 DUOMAT 1050 Biaxial
900 CSM 600 CFM
3368 50% Overlaps 1050 Biaxial600 CFM
1050 Biaxial
600 CSM
1050 Biaxial
600 CFM
1050 Biaxial
600 CFM
1050 Biaxial
750 Triaxial
600 CFM
Bulkheads
1200 CSM 800 Biaxial
12mm PLY 15mm Divinycell H80
1200 CSM 800 Biaxial
Laminate Comparison
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Preliminary Weight Estimate
Original Hand Laminate
1643 kg DIAB estimate
(1760kg actual avg)
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Preliminary Weight Estimate
DIAB Core InfusionLaminate
1024 kg
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Preliminary Weight Estimate – A GlobalComparison
DIAB Core Infusion Laminate
1024 kg
Original Hand Laminate
1643 kgWeight difference:
1643 – 1024 = 619 kg
(38% reduction)
17 components removed
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New Longitudinal Girder Structure
NewLongitudinal
Girder Structure
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Structural Arrangement – ProposedLongitudinal Girders
Dispose transverse floors
Structural efficiency Less weight for given strength
Provides direct support to panels AND contributes to thelongitudinal strength
Transverse strength provided by bulkheads and decks
Structural continuity
Minimises abrupt changes in stress levels
Utilisation of space Less interference
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Preliminary Weight Estimate – A Part ForPart Overview
TransomBulkheads
Hull
Bottom
Hull
SideKeel
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Preliminary Weight Estimate – A Part ForPart Comparison
Weight Comparison of Hull Panels
0
50
100
150
200
250
300
350
400
450
W e i g h t [ k g
Original Hand Laminate 341.10 420.00 140.89 66.54 186.84
DIAB Infusion Laminate 247.66 247.56 92.52 73.03 64.86
Hull bottom Hull side Transom Keel Bulkheads
Reduction 27% 41% 34% +10% 65%
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Preliminary Weight Estimate – A Part ForPart Comparison
Weight Comparison of Panel Components
0
200
400
600
800
1000
1200
1400
W e i g h
t [ k g
Original Hand Laminate 1155.37 359.77 585.06 173.22
DIAB Infusion Laminate 725.64 288.38 273.37 126.56
Total Glass Resin Core material
Reduction 37% 20% 53% 27%
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Weight Saving Benefits – Performance
Overview Original:
∆ = 9.50 tonnes
P = 472 kW (total installed)
DIAB Infusion:
∆ = 8.88 tonnes
P = 441 kW (total required)
V = 35.0 knots
(- 619 kg)
2 x 239 kW
MerCruiser @ 100% MCR
2 x 239 kW
MerCruiser @ 85% MCR
2 x 239 kW
MerCruiser @ 100% MCR
V = 37.4 knots
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Weight Saving Benefits – PerformanceOverview
Cummins MerCruiser 4.2L EI 320
0
50
100
150
200
250
0 1000 2000 3000 4000 5000
RPM
k W
0
10
20
30
40
50
60
70
80
l / h r
85% MCR100% MCR
Power
Fuel
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Weight Saving Benefits – PerformanceOverview
Original:
70 L/hr @ 3900 RPM, 236kW
90% Tank Capacity Per Engine = 360 L
Range:
333 km @ 35 knots
DIAB Infusion:
40 L/hr @ 3300 RPM, 220kW
Range:
583 km @ 35 knots
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Weight Saving Benefits – Summary
Less Weight means:
Lower fuel consumption
Longer range
More speed
Quieter operation
Better acceleration
Better maneuverability
Boat planes quicker
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Design Rules – A Brief Outline
Part AS4132 DNV ISO DIAB
Outer skin laminate g/m2 1580 2400 1260 2250
Inner skin laminate g/m2 1264 1600 882 1800
Core type -- H130 -- H100
Part AS4132 DNV ISO DIAB
Laminate S.F. 3.5 3.34 2 AS4132
Core S.F. 2.9 2.5 2 AS4132
Minimum Requirements
Safety Factors
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Process And Application – Original HandLay-up Day 2
Stage 7a 7b 8 9
Time 90 90 90 30
Men 3 0 3 2
7a Starboard side 2nd laminate
7b Wait for starboard side to dry8 Port side 2nd laminate
9 Bogging keel and strakes
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Process And Application – DIAB Infusion -Day 1
Stage 1 2a 2b 3a 3b 4 5
Time 30 45 90 60 90 20 285
Men 1 1 0 3 0 1 2
1 Preparation of mould
2a Gelcoat
2b Wait for gelcoat to dry
3a Application of tie layer
3b Wait for tie lay to dry
4 Grinding of dags off the laminate
5 Load kitted fabric for outer skin
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Process And Application – DIAB Infusion –Day 2
Stage 6 7 8a 8b 8c 9 10
Time 240 320 60 60 45 60 30
Men 2 2 2 4 4 3 2
6 Load kitted core materials
7 Load kitted girders and fabrics
8a Set out reusable resin feed and vacuumlines
8b Fit pre-fab vacuum bag to mould andconnect to catch pots and pump system
8c Drop test and leak finding, set upresin
9 Start infusion and fill part
10 Remove bag and lines
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Processing And Application – The BottomLine
Build time for hand laminate process
= 23.5 man hours (2 days)
Build time for DIAB infusion process= 28.4 man hours (2 days)
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Processing And Application – FutureOptimisation
Tie Layer Obsolescence
= Deduct 2.5 man hours
Optimal Infusion Time
= Deduct 0.3 man hours
Optimal Setup Time= Unlimited
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Polyworx Infusion Simulation - The Setup
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Polyworx Infusion Simulation - Open ResinLines
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Polyworx Infusion Simulation - 8.29 mins (35%filled)
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Polyworx Infusion Simulation - 14.3 mins (50.2%filled)
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Polyworx Infusion Simulation - 18.4 mins (75.1%filled)
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Polyworx Infusion Simulation - 42.1 mins(Complete)
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Cost Study
Assumptions Used provided cycle and labour times for current hull
Used material costs provided by Distributors
Used 5% wastage and labour @ $60/hr
Construction up to hull shell and bulkhead components
No rework costs for hand lay-up hull included No consumables for hand lay-up and infusion processes included
Current hand lay-up hull= ~$5,000
DIAB infusion hull= ~$13,500
Cost difference= ~$8,500
Weight difference= 619kg
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Cost Study – The important questions
How do you manage the cost differential between existingfabrication method and infusion method? Revise cost-to-weight targets for this model? What are acceptable trade-offs?
Revise material selection to achieve cost for weight target?
Reduce engine specification to maintain price point?
Utilise integrated benefits in the market place for differentiation?Lower running costs
Better performance (power-to-weight ratio, maneuverability)
Better build quality
Better end-user comfort
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Market differentiation
Features and benefits of Divinycell®
sandwich construction tothe end-user/owner:
Lighter weight construction allows either:
Reduced fuel usage for same power (lower fuel cost/greater range)
Greater fuel capacity (improved range)
Greater thermal and acoustic insulation. Eliminates condensation.Reduces heating and cooling energy requirements, while providinggreater comfort to the user.
Larger span between inside frame work, means more usable volume.
Improved safety from hull impact penetration due to double-skinconstruction.
Additional in-built buoyancy provided, adding to safety. Eliminates ‘structural timber-rot”, therefore improving long-term
retained value of the vessel for the owner.
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Implementation Plan - Hull
Next steps: Classification decision (Client)
Cost/performance targets (Client)
Cost/performance engineering (Client /DIAB)
Factory setup (Client /DIAB)
Materials qualification (Client /DIAB) Team training: Stage 1 (Client /DIAB)
Team training: Stage 2 (Client /DIAB)
Infuse hull#1 (Client /DIAB)
Implement plan for other parts (Client /DIAB)
Dealer training
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Single Skin Infusion – An Brief Overview
900 g/m2SprayedRovings
750 g/m2 Triaxial
600 g/m2Biaxial
26 mmDivinycell H100
1050 g/m2Biaxial
750 g/m2 Triaxial
DIAB Infusion Laminate
- Hull Bottom
Panel Size 1200 x 600 mm
Total Thickness 31.00 mm
Panel Weight 10.97 kg/m2
Mid-panel
Deflection
2.86 mm
Results
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Single Skin Infusion – An Brief Overview
Option A – Reduced PanelSize
Panel Size 600 x 600 mm Total Thickness 9.91 mm
Panel Weight 15.76 kg/m2
Mid-panelDeflection
10.92 mm
Results
900 g/m2Sprayed Rovings
450 g/m2CFM
750 g/m2 Triaxial
450 g/m2CFM
1050 g/m2Biaxial
450 g/m2CFM
600 g/m2Biaxial
450 g/m2CFM
1050 g/m2Biaxial
450 g/m2CFM
750 g/m2 Triaxial
450 g/m2CFM
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Single Skin Infusion – An Brief Overview
Option B – Equivalent Panel Size
Panel Size 1200 x 600 mm Total Thickness 12.46 mm
Panel Weight 19.91 kg/m2
Mid-panelDeflection
10.49 mm
Results
900 g/m2Sprayed Rovings
450 g/m2CFM
750 g/m2 Triaxial
450 g/m2CFM
750 g/m2 Triaxial
450 g/m2CFM
1050 g/m2Biaxial
450 g/m2CFM
600 g/m2Biaxial
450 g/m2CFM
1050 g/m2
Biaxial450 g/m2CFM
750 g/m2 Triaxial
450 g/m2CFM
750 g/m2 Triaxial
450 g/m2CFM
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Single Skin Infusion – Summary
Single Skin Infusion means:
More glass required to achieve required thickness
Additional weight from extra stiffeners (Option A)
Heavier panel
Greater deflection
Engineering overkill
