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The Marine Innovation Service<br />Consultancy and knowledge/technology transfer service for the marine industry<br />ERDF...
Existing processing methods<br />Hand built<br />Open moulded chopped strand mat and woven rovings of E-glass, hand consol...
Why change processing methods?<br />Legislation<br />Elusive proposed EU Regulations on styrene exposure<br />Environmenta...
Why change processing methods?<br />The market for the established range doesn’t necessarily lend itself to higher technol...
Study outputs<br />Pre-pregs were discounted on grounds of cost – both materials and processing (oven)<br />Wet lay/vacuum...
Current wet lay/hand consolidation<br />Low material cost, high labour cost per unit<br />High structural weight<br />Resi...
Hurdles/changes/implications<br />Capital investment<br />Mould  design to accommodate vacuum system<br />Vacuum pumps and...
The learning curve<br />Understanding key processing principles is one thing, but practical application is another!<br />H...
Summary<br />Driver to change processing method has to come from a sound business plan<br />Choice of processing has to be...
Summary<br />Resin infusion offers the lowest financial outlay for laminate quality and working environment improvement as...
Alex Whatley<br />Marine Innovation Service Manager<br />alex.whatley@cornwall.ac.uk<br />07771907266<br />www.marineinnov...
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Making the Move to Closed Moulding Processes

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Making the Move to Closed Moulding Processes

  1. 1. The Marine Innovation Service<br />Consultancy and knowledge/technology transfer service for the marine industry<br />ERDF funding can underwrite some/all of the cost of consultancy for Cornish businesses<br />Initially focussed on composite materials, but all aspects of the marine industry covered<br />www.marineinnovationservice.co.uk<br />
  2. 2. Existing processing methods<br />Hand built<br />Open moulded chopped strand mat and woven rovings of E-glass, hand consolidated in polyester resin<br />Bespoke, hand built joinery made by time served craftsmen<br />
  3. 3. Why change processing methods?<br />Legislation<br />Elusive proposed EU Regulations on styrene exposure<br />Environmental<br />Less material, less waste, more easily driven hull forms – lower fuel consumption under power<br />Better working environment for shop floor staff<br />Cleaner<br />Lower styrene emissions<br />Business plan<br />Business plan requires greater efficiency:<br />High volume production required to cope with predicted demand and a good number of boats needed to establish racing class<br />
  4. 4. Why change processing methods?<br />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...<br />However - new models are for new markets and the business model has to be most important driver for adoption of new technology<br />Risk associated with introduction of new processing methods minimised by concentrating on one project<br />
  5. 5. Study outputs<br />Pre-pregs were discounted on grounds of cost – both materials and processing (oven)<br />Wet lay/vacuum consolidation does not give significant enough differences in working conditions from the existing processes to be considered<br />This leaves resin infusion and resin film infusion, including the SP Sprint system<br />A cost and weight comparison was carried out, based on the specific boat (a yet to be developed 37ft model)<br />
  6. 6.
  7. 7. Current wet lay/hand consolidation<br />Low material cost, high labour cost per unit<br />High structural weight<br />Resin Infusion<br />Higher material cost, lower labour cost per unit<br />Lower structural weight - 56.1% of current lay-up<br />Resin Film Infusion<br />Much higher material cost than resin infusion and no reduction in labour cost<br />Lowest structural weight - 49.8% of current lay-up<br />Wet lay-up<br />Nett Weight of composite structure 8,231kg<br />Projected Weight inc 10% margin 9,055kg<br />Cost of composite Materials £25,036<br />Projected cost including margin £27,539<br />Labour (GBP) 535hrs @ £30/hr £16,050<br />£68,625<br /> Cost/weight = 100%<br /> <br />Resin infusion<br />Nett Weight of composite structure 4,620kg<br />Projected Weight inc 10% margin 5,082kg<br />Cost of composite Materials £35,517<br />Projected cost including margin £39,069<br />Labour (GBP) 400hrs @ £30/hr £12,000<br /> £86,586<br /> Cost/weight = 126%<br /> <br />Resin film infusion<br />Nett Weight of composite structure 4 098kg<br />Projected Weight inc 10% margin 4,508kg<br />Cost of composite Materials £41,570<br />Projected cost including margin £45,727<br />Labour (GBP) 400hrs @ £30/hr £12,000<br />Amortized oven cost £2,000<br /> £101,297<br /> Cost/weight = 148%<br />
  8. 8. Hurdles/changes/implications<br />Capital investment<br />Mould design to accommodate vacuum system<br />Vacuum pumps and monitoring equipment<br />Consumables cost<br />Vac bags, sealing tape, pipe work etc<br />‘Clean space’ on shop floor amongst other ongoing projects<br />Staff development<br />Getting the details right<br />
  9. 9. The learning curve<br />Understanding key processing principles is one thing, but practical application is another!<br />Help and support is available<br />Marine Innovation Service<br />Other industry specialists e.g. Morley Composites<br />Supply chain e.g. SP/High Modulus, resin supply companies and firms such as Composite Integration<br />Small section trials and practice runs<br />
  10. 10. Summary<br />Driver to change processing method has to come from a sound business plan<br />Choice of processing has to be relevant to the end product <br />You don’t need to make sweeping changes... incremental introduction of process change allows analysis of impact<br />Bolting on higher technology can work, but new projects with technology built in from day one give greater flexibility<br />
  11. 11. Summary<br />Resin infusion offers the lowest financial outlay for laminate quality and working environment improvement as no oven needed<br />However – developments of low temperature pre-pregs continue to bring these materials within reach of the most basic ovens (500C)<br />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<br />
  12. 12. Alex Whatley<br />Marine Innovation Service Manager<br />alex.whatley@cornwall.ac.uk<br />07771907266<br />www.marineinnovationservice.co.uk<br />Next event:<br />Closed moulding practical workshop 15th March<br />

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