Capability Presentation 2010


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Capability Presentation 2010

  1. 1. Capability Presentation Composite Components - 2010
  2. 2. <ul><li>Index </li></ul><ul><li>Relative experience </li></ul><ul><li>Past and current works </li></ul><ul><li>Relative projects </li></ul><ul><li>Conclusion </li></ul>
  3. 3. 1990 First exposure to composites building and racing the 'unrestricted' sailing class International Moth. Four boats were built of which 2 won state championships   1998 Employed with Eagle Aircraft as a composite laminator building aircraft components, primarily responsible for the control surfaces (rudder, flaps, ailerons). Temporary placement in Malaysia training staff on correct procedure to manufacture control surfaces of the Eagle 150 when the moulds were transferred to Eagle Aircrafts‘ parent company CRTM in Melaka. 1999 Upon return to Australia, a request to transfer to composite assembly was successful and Glen worked in 'bay 1' responsible for the wing(s) to fuselage fitment and bonding.   2000 Working with a colleague on Perth's only V8 Supercar team - CAT Racing. Co-development of a resin infusion system which was a first for Perth and likely Australia as this technology was in its infancy in the US only. Composite Experience – Glen Oldfield, Manager
  4. 4. 2000 Design Acumen, designers of the first ‘flat bed in the sky' for British Airways, were shortlisted down to the final 2 companies working on the interior of the A380 'super jumbo' work done here was primarily model-making from detailed drawings. The full scale models were made from metal, alloys, wood, composites or high / medium density tooling boards machined and / or hand finished to close tolerances 2001 McLaren Composites - P7 project , Employed to work jointly between the R & D department; for resin infusion / RTM component construction and the clean room to manufacture first article components from pre-preg, or SP Sprint materials. The P7 project would later be known as the McLaren Mercedes SLR. McLaren Composites manufactured components for the McLaren Formula 1 racing team as well as being involved in composite component manufacture of the Beagle Mars Land Rover. Composite Experience – Glen Oldfield, Manager
  5. 5. 2002 DPS Composites – construction of tooling and the main chassis components for the Jordan F1 team, DPS was also contracted to manufacture smaller components for McLaren F1 team, British touring car driver safety cells and 2 Cadillac LeMans chassis. 2003 to present Composite Design was founded to design and manufacture ‘high end’ composite furniture for corporate and commercial clients. We had good results immediately with awards for our Linea range in the first year and an Australian Design Award for the ‘Lux’ table in 2006. Composite Design continues to manufacture furniture products with retailers Australia wide. Composite Components was created to specialise in advanced composite products and research and development into composite structures for all industries. The first major project was manufacture of tooling for the ‘S-Core’ surfboard project (based in Perth) for French Snowboard and clothing manufacturer Salomon. The tooling contract evolved into an extensive R&D phase lasting 3 years, where upon production was established in Thailand and Romania. Composite Components now concentrate on diversity, with clients in fields ranging from Medical, Defense, Automotive, Sporting goods and R&D projects for industry. Composite Experience – Glen Oldfield, Manager
  6. 6. Architectural Fire, smoke and toxicity-rated building cladding for the Perth underground train station and custom made lighting designed by renowned Australian designer Paul Morris from Join for a hotel lobby Past and current works
  7. 7. Medical Prosthetics (legs and upper thigh socket), custom fitted feet orthosis (or orthotics) and custom fitted seats for wheel chairs Past and current works
  8. 8. <ul><li>Unmanned Air Vehicles </li></ul><ul><li>Hoverpod - CAV (compact air vehicle) </li></ul><ul><li>Phoenix - Jet turbine powered target drone* </li></ul><ul><li>Cybird 5 - High speed jet powered drone* </li></ul><ul><li>Cybereye 2 - MALE surveillance drone* </li></ul><ul><li>*autonomous, contains a pre-programmed autopilot on board </li></ul>Past and current works
  9. 9. Production components Composite design furniture – manufacture and support for the Lux table (recipient of an Australian Design Award, 2006) and Linea range of occasional tables. The tables are sold Australia wide through commercial and corporate based retailers. Past and current works
  10. 10. Production components OKA Truck headlight surrounds – contacted to replace the traditional surrounds with a ‘new look’, we identified a rapid composite manufacturing process and proceeded to generate CAD models and master patters before sourcing a local manufacturer to manufacture the components for OKA. We also have been involved in components for a V8 dirt drag bike and ‘nitro Harley’ racing team Past and current works
  11. 11. Production components Vacuum chambers for pressure sensing, racing jet ski ride plate, vacuum forming moulding and sailing yacht rudder foils Past and current works
  12. 12. Production components Manufacture of light weight structural composite turret and camera housings and associated CNC machined carbon fibre flat plate for ‘UAV dedicated’ HD video cameras. Carbon fibre road bicycle frame repairs – we currently service every bike store in Perth requiring carbon fibre frame repairs and have done so for 2 years now. Carbon fibre reinforcement of cricket bats – a local manufacturer used carbon fibre to reinforce their cricket bats, unfortunately due to recent ICC laws the reinforced bats have been ruled illegal. Past and current works
  13. 13. Research & Development Salomon 's-core' project – a point of difference for the surfing industry, a ‘hollow’ board with 3 foam ribs for stiffness and an epoxy resin and glass / carbon fibre construction. The boards received excellent feedback and were even ridden by multiple world champion Kelly Slater (pictured). Starboard Windsurfing (the largest windsurfing company in the world) also conducted R&D based on the s-core technology, Starboard saw potential in the hollow board construction and a 100 board pre-production was subsequently initiated. Past and current works
  14. 14. Research & Development ‘ Bladerider’ hydrofoil computer analysis development - for high performance sailing and subsequent input into structural design and product development. Composite Components have been involved in Bladerider’s development since the creation of the company in 2005. Past and current works
  15. 15. CNC Machining / Model making We have undertaken all manner of machining jobs including 2 x 1:100 scale models of a 100m luxury motor yacht, water purifying components, a scale swimming pool and signage for local companies without CAD/CAM access Past and current works
  16. 16. <ul><li>Non Fragmenting explosive boxes Initial prototypes were created and a series of materials selected for a segmented box to transport detonators and small charges to blast sites for mining operations, the key benefits indentified: </li></ul><ul><li>Interlaminar Faraday cage to block external electric fields and electromagnetic radiation eg: radio signals </li></ul><ul><li>Box construction ensured no life threatening fragments were thrown in the case of an explosion </li></ul><ul><li>Lightweight construction to meet OH&S standards for single person lifting and carrying </li></ul>Relative works
  17. 17. Custom fitted composite seating Production for the Cerebral Palsy Association of a seating system that uses 3D scans of patients backs to generate a CAD model which is used to CNC machine a ‘sacrificial’ mould (with offset tolerances for padding) the mould is used to create the advanced composite seat using a proprietary resin infusion method. The seats were tested by Curtin University against a variety of traditional materials, only the composite seats reached the required CPA criteria. Relative works
  18. 18. UAV aircraft Cybertechnologies - Cybereye 2 (MALE) and Cybird 5 high speed drone Air Affairs – Phoenix target drone Relative works
  19. 19. UAV aircraft Relative works
  20. 20. Unmanned Air Vehicles Hoverpod and Mupod (scale version) project components. The hoverpod is designed as a one man personal flying device or a CAV – compact air vehicle. Relative works
  21. 21. Architectural components Construction of the cladding system for the two information 'pods' for the Perth Underground station. As the cladding was being installed in an underground environment it meant conforming to strict FST (fire, smoke, toxicity) regulations. We structurally designed the cladding to meet the regulations and ‘lifecycle challenges’ that public transport buildings can be subjected to. Relative works
  22. 22. Sub-sea buoyancy Recently we have completed large sub sea buoyancy units for a heavy work class deep sea ROV capable of over 1000m sea depth. The main block component weighed just under 800kg after CNC machining. In conjunction with the client we undertook pressure testing (to failure at just over +100 bar) to evaluate the SAN based foam material, the bondline between sheets and the shear strength of the secondary bonded threaded inserts. Relative works
  23. 23. Composite Components are a small operation with large experience. We continue to service companies large and small across a range of fields all over Australia. We are responsive due to our size and have the ability to source materials from all over the world and the expertise to deliver effective solutions for our clients.     Conclusion composite components engineered composite solutions 9a Morse Road Bibra Lake, Perth WA 6163