Making the Move to Closed Moulding Processes

Making the Move to Closed Moulding Processes

• 1.
  The Marine InnovationServiceConsultancy and knowledge/technology transfer service for the marine industryERDF funding can underwrite some/all of the cost of consultancy for Cornish businessesInitially focussed on composite materials, but all aspects of the marine industry coveredwww.marineinnovationservice.co.uk
• 2.
  Existing processing methodsHandbuiltOpen moulded chopped strand mat and woven rovings of E-glass, hand consolidated in polyester resinBespoke, hand built joinery made by time served craftsmen
• 3.
  Why change processingmethods?LegislationElusive proposed EU Regulations on styrene exposureEnvironmentalLess material, less waste, more easily driven hull forms – lower fuel consumption under powerBetter working environment for shop floor staffCleanerLower styrene emissionsBusiness planBusiness plan requires greater efficiency:High volume production required to cope with predicted demand and a good number of boats needed to establish racing class
• 4.
  Why change processingmethods?The market for the established range doesn’t necessarily lend itself to higher technology processing – owners respect ‘hand built’ style and are suspicious of cored structures...However - new models are for new markets and the business model has to be most important driver for adoption of new technologyRisk associated with introduction of new processing methods minimised by concentrating on one project
• 5.
  Study outputsPre-pregs werediscounted on grounds of cost – both materials and processing (oven)Wet lay/vacuum consolidation does not give significant enough differences in working conditions from the existing processes to be consideredThis leaves resin infusion and resin film infusion, including the SP Sprint systemA cost and weight comparison was carried out, based on the specific boat (a yet to be developed 37ft model)
• 7.
  Current wet lay/handconsolidationLow material cost, high labour cost per unitHigh structural weightResin InfusionHigher material cost, lower labour cost per unitLower structural weight - 56.1% of current lay-upResin Film InfusionMuch higher material cost than resin infusion and no reduction in labour costLowest structural weight - 49.8% of current lay-upWet lay-upNett Weight of composite structure 8,231kgProjected Weight inc 10% margin 9,055kgCost of composite Materials £25,036Projected cost including margin £27,539Labour (GBP) 535hrs @ £30/hr £16,050£68,625 Cost/weight = 100% Resin infusionNett Weight of composite structure 4,620kgProjected Weight inc 10% margin 5,082kgCost of composite Materials £35,517Projected cost including margin £39,069Labour (GBP) 400hrs @ £30/hr £12,000 £86,586 Cost/weight = 126% Resin film infusionNett Weight of composite structure 4 098kgProjected Weight inc 10% margin 4,508kgCost of composite Materials £41,570Projected cost including margin £45,727Labour (GBP) 400hrs @ £30/hr £12,000Amortized oven cost £2,000 £101,297 Cost/weight = 148%
• 8.
  Hurdles/changes/implicationsCapital investmentMould design to accommodate vacuum systemVacuum pumps and monitoring equipmentConsumables costVac bags, sealing tape, pipe work etc‘Clean space’ on shop floor amongst other ongoing projectsStaff developmentGetting the details right
• 9.
  The learning curveUnderstandingkey processing principles is one thing, but practical application is another!Help and support is availableMarine Innovation ServiceOther industry specialists e.g. Morley CompositesSupply chain e.g. SP/High Modulus, resin supply companies and firms such as Composite IntegrationSmall section trials and practice runs
• 10.
  SummaryDriver to changeprocessing method has to come from a sound business planChoice of processing has to be relevant to the end product You don’t need to make sweeping changes... incremental introduction of process change allows analysis of impactBolting on higher technology can work, but new projects with technology built in from day one give greater flexibility
• 11.
  SummaryResin infusion offersthe lowest financial outlay for laminate quality and working environment improvement as no oven neededHowever – developments of low temperature pre-pregs continue to bring these materials within reach of the most basic ovens (500C)The learning curve is steep – don’t try and reinvent the wheel as there is plenty of help out there, from other businesses to the supply chain
• 12.
  Alex WhatleyMarine InnovationService Manageralex.whatley@cornwall.ac.uk07771907266www.marineinnovationservice.co.ukNext event:Closed moulding practical workshop 15th March