From Hours per Part to Parts per Hour. Gary R Lownsdale Chief Technology Officer

Transcription

1 From Hours per Part to Parts per Hour Gary R Lownsdale Chief Technology Officer

2 CFC Entry into Automotive Off-shoot from Aerospace Autoclave Process Process Attributes High Quality Parts Process Limitations Slow Cure Cycle Thermally Inefficient N2 Atmosphere Labor Intensive Supports Low Volumes

3 Past and Present Business Chevrolet Corvette ZR1 Primed Fenders Painted and Exposed Hood Assembly Exposed Roof, Roof Bow, Rockers, Splitter Chevrolet Corvette Z06 Primed Front fenders Painted Roof, Rockers, and Splitter Dodge Viper ACR Splitter, Rear Wing, Dive Planes Ford Shelby GT 500 KR Painted Hood Assembly Exposed Splitter and Mirror Caps

4 Customer/Business Value Technology Development Matrix Thermoplastic 2 min cycle Lignin based Carbon Fibers New Resin Matrices 7 min cycle RTM Structures Pressure Press 17min cycle Out of Autoclave Technology Autoclave 90 min cycle Need to Focus and Deliver on Chemistry Solutions

5 Research & Development

6 Test Lab at the Heart of Research

7 Four Variable Equation for Solution Thermodynamic X-Y-Z Flow Transfer Pressure on Canopy Surface Time Discreet segments Resin Chemistry Tg and Curing Status By fixing Resin Chemistry a 3 dimensional carpet plot was possible for P, Th, and T

8 psi Autoclave Standard Run 70 Minute Cycle temperature pressure Temperature Ramp Hold End of Cycle

9 0:00 0:30 1:00 1:30 2:00 2:30 3:00 3:30 4:00 4:30 5:00 5:30 6:00 6:30 7:00 7:30 8:00 8:30 9:00 9:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13: Wixom - Cycle #51 Pressure Press 13 Minute Cycle Temp Press Vac F psi Time

10 Automotive Customer Development Center PCC Airport 24,000 square foot Facility ~ ½ Manufacturing Space Scale-up Facility for New Technology Production-Representative Focus on Market Penetration

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13 Pressure Press Economies Conventional Autoclave Pressure Press

14 New Press Technology for Sub 20 minute Production 1-Kit Cut 2 - Lay-up 5-Inner Sub-Assembly & Outer/Inner Bonding 3 - Press 4-Trim Balanced Process Cycle Time 6- Finishing 7-Prime

15 Globe Machine Manufacturing Company Calvin D. Bamford, Jr. Presents: Cutting Cycle Times for Pre-pregged Carbon Fiber Composites 701 East D Street Tacoma, Washington, USA Ph Fax Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

16 Company and Facilities Globe founded in 1917 in Tacoma, Washington, USA Lightweight Labs founded in ,000 square feet Engineering offices Manufacturing facilities R&D lab 170+ employees, including over 25 engineers First-class products known world-wide Demonstrated domestic and international professionalism in both product offerings and business approaches Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

17 Globe Finishing Lines for MDF and Particleboard Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

18 Globe Finishing Lines for OSB Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

19 Globe Robotic Roll Finishing Systems Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

20 Globe Tissue Paper Handling Systems Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

21 Globe Ultra High Pressure Presses for Light-weight Composite Armor Light- weight composite armor Up to 5,000 psi (12,000 ton) 5 x 10 and other custom sizes Full enclosed vacuum press Multi-daylight (10 opening shown) Heated and cooled platens Press Rams at Assembly Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

22 Class A Carbon Fiber Body Panels Complex Demonstration Part The Rapid Cure System today is production capable and proven to produce superior class A finishes for body panels, such as fenders, roofs and hoods Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

23 Timeline to Reach Common Objective Delivered first production system days from Agreement to proceed Delivered second production system to Plasan Customer Development Center days from Agreement to proceed Delivered third production system to Walker days from Agreement to proceed Today we have delivered a total of 7 Rapid Cure System work cells capable of 24/7 continuous operation for light weighting vehicles Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

24 What is the Rapid Cure System? The Globe Rapid Cure System is a nonautoclave carbon fiber component cure system that has reduced part-to-part cycle time from 90+ minutes to 17 minutes and better. Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

25 Temperature Temperature What is the Rapid Cure System? Autoclave (90+ minute cycle) Time (minutes) Globe Rapid Cure System (17 minute cycle) Time (minutes) Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

26 What is the Rapid Cure System? The Rapid Cure System was designed and engineered to be a highly efficient autoclave alternative by achieving significant time, energy, cost and space efficiency gains relative to autoclaves. Four Key Systems 1. High Pressure Consolidation System 2. Thermal Control System 3. Automated Machine/Tool Changing System 4. Precision Process Control Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

27 Precision Process Control Multi-Zone Temperature Control F Pressure Rate and Dwell Control 0 150psi Temperature Z1 (F) Temperature Z2 (F) Pressure (psi) Vacuum (inhg) Independent Vacuum Control 0 29 inhg Time (minutes) Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

28 What is the Rapid Cure System? Rapid Cure System Economies Conventional Autoclave Rapid Cure System Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

29 Class A Body Panels 17 Minute Cure Cycle In Action Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

30 Class A Carbon Fiber Body Panels Tooling Complex Demonstration Part Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

31 Class A Carbon Fiber Body Panels Tooling Complex Demonstration Part Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

32 Class A Carbon Fiber Body Panels Untrimmed Parts Complex Demonstration Part Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

33 Class A Carbon Fiber Body Panels Untrimmed Parts Complex Demonstration Part Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

34 Class A Carbon Fiber Body Panels Trimmed Part Complex Demonstration Part Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

35 Class A Carbon Fiber Body Panels Surface Quality Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

36 Class A Carbon Fiber Body Panels Surface Quality Cutting Cycle Times For Prepregged Carbon Fiber Composites PROPRIETARY + PATENTS PENDING + Copyright 2012 Globe Machine Manufacturing Company Technology by

37 Time (min) Plasan s Out-of-Autoclave Pressure Press Technology Total Cure Time Mold Time Reduced 75% Autoclave Cure Class A & Structural Parts Out of Autoclave Cure 1 Coat Primer Production Volumes of 30K-100K per Year Development Continues to Further Reduce Cycle Time Faster Cycle AND Improved Surface Quality

38 Pressure Press Economies Conventional Autoclave Pressure Press

39 What is a Pressure-Press? The Pressure-Press is an out-of-autoclave carbon fiber component cure system that has reduced part-to-part cycle time from 90+ minutes to 17 minutes and better.

40 New Manufacturing Facility in Walker, MI 197,000 square feet Manufacturing Incentives from the Michigan Economic Development Corporation (MEDC) Over Next 3 Years, to Generate almost $30M in Capital Investment & 202 New Jobs Geared to Higher-Volume Production Based on New Manufacturing Methods Plasan is Developing Plasan s CFC Processing Breakthroughs Supports 30K-50K Vehicle sets per Year Future Improvements to Reach 100K /yr

41 Out-of-Autoclave Pressure Press Technology Sub 20-Minute Production 1-Kit Cut 2 - Lay-up 5-Inner Sub-Assembly & Outer/Inner Bonding 3 - Press 4-Trim Balanced Process Cycle Time 6- Finishing 7-Prime

42 Current & Future Parts / Assemblies Class A Fenders Hood Assemblies Spoilers Deck Lid Assemblies Door Panel & Interior Parts Rocker Moldings Roof Assemblies Splitters Lift Gates Rear Wings/Spoilers Structural Roof Frame Pillar & BIW Substructure Inner Body Panels (hood, door, etc.) Engine Cradle Side Door Impact Bar Load Floor Battery Modules End Gate Assembly Seat Frames & Bases

43 Customer/Business Value Technology Development Matrix Thermoplastic 2 min cycle Lignin based Carbon Fibers New Resin Matrices 7 min cycle RTM Structures Pressure Press 17min cycle Out of Autoclave Technology Autoclave 90 min cycle Need to Focus and Deliver on Chemistry Solutions

44 Plasan Targeting Mainstream Automotive Out-of-Autoclave Pressure Press Accomplishments : Validated Cure Times < 20 minutes Modelled Cure Times < 10 minutes Next Steps: Reduce Cure Times to 2 minutes via the Chemistry Fiber Development: Low-Cost, Non-Petroleum Based and/or Tailored Properties Develop Reliable, Mainstream Predictive Engineering Develop Structural Processes Rapid Manufacturing

45 Automotive Customer Development Center PCC Airport 24,000 square foot Facility ~ ½ Manufacturing Space Scale-up Facility for New Technology Production-Representative Focus on Market Penetration

46 Thank You! SRT Viper