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1
5° Forum dei Materiali Compositi
presso MiCo - Milano Congressi
12 - 13 Ottobre 2016
Dr.Adalberto Horak,
President of BlackSun Partners Consulting
Business Development Director, carbon fiber applications, COMEC Innovative s.r.l.
2
Founded in 2009 thanks to a deep
technical know-how and wide network of
business relations, to supply consulting
services with focus on composites
applications, targeting carbon fiber
supply chain. BSP is preferred partner of
leading Company producers of fibers,
chemicals, materials, technology and all
what is referred to the manufacturing of
semi-finished and intermediates goods,
parts and components and end products
for the advanced composites and
defence. We supply M&A and logistics
services for composites Company but
also for side and other various business.
3
Located near Milano-Italy, BSP is working on three different levels:
Services
 Start-up and M&A
 Business consulting & development
 Manufacturer’s representative
Engineering
 Process tailoring
 Process integration and automation
 Composites parts design and prototyping
 Technical consulting and training
Logistics
 Supply chain management
 Logistic integration
 New suppliers and materials search
4
Main manufacturing partners:
High Strenght Carbon fibers and derivates
Intermediate and High Module and Strength
carbon fibers
Automation, robots and process integration
for composites parts manufacturing

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5
Composites repair materials and equipment
Non-destructive testing equipment for
composites structures
Technologies for composites textiles
manufacturing
6
Italian Politecnico of Milano-Italy (included
Lecco branch related to Composites Design)
Centro Tessile Cotoniero Busto Arsizio-
Italy (testing, research, technical support,
experimentation, and training Center)
Center for Research and Technology,
Aerospace cluster, Brindisi-Italy
BlackSun Partners is member of:
EuCIA (European Composites Industry
Association)
Assocompositi (Italian Composites
Association)
7
 Carbon fibers are extremely fine fibers
(typ. 5-7 µ in dia.) consisting mostly of
carbon atoms
 HS Carbon fiber is >95% carbon
 Carbon fibers are produced in tows
)yarns( ranging from 1.000 filaments
(1k), to 3k, 6k, 12k, 24k, 50k, etc.
 Properties of Carbon Fiber: high
stiffness, high tensile strength, low
weight, high chemical resistance,
high temperature tolerance and low
thermal expansion
human hair .
(50-70 μ)
carbon fiber
(5-7 μ)
WHAT IS CARBON FIBER?
8
Wind Turbine
Blades
Pressurized
Vessels
Civil Infrastructure
Automotive Oil and Gas Power Transmission
Marine
Sporting Goods
Aerospace
Defense
CARBON FIBER APPLICATIONS

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9
A key feature for the success of filament winding and composite
materials technology combinations is the improvement of the
manufacturing process to reduce costs and to increase the overall
quality.
10
One of the main manufacturing
disadvantage to overcome, is the
fiber impregnation method in open
bath. The main drawback of the
open bath is that a wide resin
surface is affected by the
exposition to air moisture. On top
of that, the temperature variations
in the resin bath and the change of
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impregnation quality and the final
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11
Comec has developed an innovative impregnation low pressure
process by applying a low hydrostatic pressure on the resin and
wetting the fibers exploiting a capillary pressure effect.
This patented process allows to avoid the resin backflow and the
fibers’ abrasion caused by the high compaction rate of the fibers.
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12
Mass production Towpreg line
High volumes Towpreg line

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13
CUSTOMIZED MACHINES AND
PROCESS INTEGRATION
FOR SMART COMPOSITE PRODUCTION
TOWPREG: an innovative approach to CF converting
Comec Innovative Quality Management
System is certificated ISO 9001:2008
regarding “design, manufacturing of
special machine for automatic
application, machine tools, industrial
maintenance, retrofitting”.
The certification is not just a slogan for us
but a working method and a business
system.
Comec Innovative is an Italian SME ( Small
and Medium Enterprises) of 50 employees.
Comec Innovative has a mechanical design
department, an electrical design
department, a software design department
and an after sale service department.
Comec Innovative designs with the last
versions of mechanic 3D CAD’s and
software tools for advanced analysis.
The after sale service has a large stock of
spare parts to manage the critical
maintenance activities, a department for
"on-site services" and a department for
comprehensive phone support.
Comec Innovative is able to equip its
machines with telecontrol & teleservice for
remote diagnostic.
Comec Innovative offers service agreements
with specific SLA (Service Level
Agreement).
These are some of our R&D partnerships:
 NOVOTECH ADVANCEDTESTING
 (GROUNDVIBRATIONTEST – GVT, NOISE TEST AND
LANDING GEAR DROP TEST)
 CETMA RESEARCHPARTNER
 THE UNIVERSITY OF MANCHESTER
 UNIVERSITA’ POLITECNICA DELLE
MARCHE
 ELANTAS CHEMICALR&D CARBONFIBER
DIVISION
These are some of our expertise:
 FANUC ROBOTICS
 KUKA ROBOTICS
 COGNEX VISION DEVICES
 SICK PROCESS CONTROLDEVICES
 ROBATECH GLUE SYSTEMS
 MITSUBISHI ELETRIC
 SMC PNEUMATICCOMPONENTS
 SIEMENS
 NETZSCH PROCESS CONTROLDEVICES
 NEUGART HIGH PRECISION GEARBOX
Integrator expertise

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TOWPREG: an innovative approach to CF converting
PRE-PREG
TAPE MACHINE
SLIT TAPE
MACHINE
PRE-PREG TOW FOR
HIGH SPEED FW
PRE-PREG
CUTTING MACHINE
• CleanRoom
• Hot-melt technology
• Tow, U-D Tape, Fabric Carbonand
NaturalFibre
• Width 1400 mm
• Moisture/ temperaturecontrol
• Indipendentdelivery systems
• CleanRoom
• Qualitative inspectionwith vision
deviceand Eddy Cus CF technology
• Differentkinds of materials and
width
• CleanRoom
• Moisture/ temperaturecontrol
• Indipendentdelivery systems
• Impregnationspeed from 5 to 130
mt/min
• CleanRoom
• Ultrasonic Cutting 20KHz
• Working Capacity 10m x 2m
• MaterialThickness20 mm
FILAMENT WINDING
ROBOT
AUTOMATIC TAPE
LAYER ROBOT
ATP LINEAR SYSTEM RTM SYSTEM
• Clean Room
• Complexgeometries
• Dynamic control shoot
• Impregnation resinscontrol
• CleanRoom
• Advancedcontrolof automatic
deposition
• Complexsurface
• Kuka RobotAccuracy 0,3 mm
• CleanRoom
• Compacting Load400 Kg
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materiali avanzatiricercainnovazione
RTM
SYSTEM
HANDLING SYSTEM FOR
CARBON FIBER
COMPONENTS
INNOVATIVE
INDUCTION WELDING
FOR THERMOSETTING CF
JIGS AND
MEASURE
TECHNOLOGY
COMPACTING PRESS
• Automatic handling system for
compositeparts and row materials
• Scadasoftware
• Innovativecontinuous
• inductionwelding machinewith a
controlledcoolingsystem
• Modularsystem
• High precisionwith zero point
• 3D measurerobot
• Clean Room
• MechanicalDrive
• Applied Load 160 ton
• Dinamic PositionControl
Automotive application
The system is designed for the automatic assembly and on-
line testing 100% of electrical connectors.
The system consists of:
• 1 precision rotary table with 8 positions
• 8 manipulation stations
• 16 axis
• 2 vibrating units
• 1 vision system for testing
The manipulations of the components are made through
specific mechanical modules, managed by the same
synchronous transmission that moves the rotary table.
Cycle time: 50 pcs / min.
Rotary Synchronous assembly
Automotive application
Example of stations of total assembly and testing lines
AUTOMATIC THERMAL
PROTECTION PAINTING
OF ROCKET
ROCKET SOLID
PROPELLENT CUTTING
MACHINE
AUTOMATIC DEPOSITION
THERMAL PROTECTIVE
TAPE OF ROCKET
LAMINATION
MACHINE
• Clean room
• ATEX
• Volumetric control
• Dinamic Position Control
• Clean room
• Speed control
• Temperature control
• Compaction press control
• Continuous prodution from
raw material to packaging of
the final products
• High speed / automatic
change of raw materials
• Clean room
• ATEX
• High precision
• Automatic load/unload
system
ROCKET SOLID
PROPELLENT CUTTING
MACHINE
AUTOMATIC DEPOSITION
THERMAL PROTECTIVE
TAPE OF ROCKET
LAMINATION
MACHINE

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a.horak@blacksunpartners.com
Tel.:+39 031 881 170
Cell.: +39 334 78 66 506
www.blacksunpartners.com
horak.adalberto@comecinnovative.it
Tel.:+39 0871 58531
Cell.:+39 334 78 66 506
www.comecinnovative.it
29

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TOWPREG: an innovative approach to CF converting

  • 1. 1 5° Forum dei Materiali Compositi presso MiCo - Milano Congressi 12 - 13 Ottobre 2016 Dr.Adalberto Horak, President of BlackSun Partners Consulting Business Development Director, carbon fiber applications, COMEC Innovative s.r.l.
  • 2. 2 Founded in 2009 thanks to a deep technical know-how and wide network of business relations, to supply consulting services with focus on composites applications, targeting carbon fiber supply chain. BSP is preferred partner of leading Company producers of fibers, chemicals, materials, technology and all what is referred to the manufacturing of semi-finished and intermediates goods, parts and components and end products for the advanced composites and defence. We supply M&A and logistics services for composites Company but also for side and other various business.
  • 3. 3 Located near Milano-Italy, BSP is working on three different levels: Services  Start-up and M&A  Business consulting & development  Manufacturer’s representative Engineering  Process tailoring  Process integration and automation  Composites parts design and prototyping  Technical consulting and training Logistics  Supply chain management  Logistic integration  New suppliers and materials search
  • 4. 4 Main manufacturing partners: High Strenght Carbon fibers and derivates Intermediate and High Module and Strength carbon fibers Automation, robots and process integration for composites parts manufacturing
  • 5. 5 Composites repair materials and equipment Non-destructive testing equipment for composites structures Technologies for composites textiles manufacturing
  • 6. 6 Italian Politecnico of Milano-Italy (included Lecco branch related to Composites Design) Centro Tessile Cotoniero Busto Arsizio- Italy (testing, research, technical support, experimentation, and training Center) Center for Research and Technology, Aerospace cluster, Brindisi-Italy BlackSun Partners is member of: EuCIA (European Composites Industry Association) Assocompositi (Italian Composites Association)
  • 7. 7  Carbon fibers are extremely fine fibers (typ. 5-7 µ in dia.) consisting mostly of carbon atoms  HS Carbon fiber is >95% carbon  Carbon fibers are produced in tows )yarns( ranging from 1.000 filaments (1k), to 3k, 6k, 12k, 24k, 50k, etc.  Properties of Carbon Fiber: high stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion human hair . (50-70 μ) carbon fiber (5-7 μ) WHAT IS CARBON FIBER?
  • 8. 8 Wind Turbine Blades Pressurized Vessels Civil Infrastructure Automotive Oil and Gas Power Transmission Marine Sporting Goods Aerospace Defense CARBON FIBER APPLICATIONS
  • 9. 9 A key feature for the success of filament winding and composite materials technology combinations is the improvement of the manufacturing process to reduce costs and to increase the overall quality.
  • 10. 10 One of the main manufacturing disadvantage to overcome, is the fiber impregnation method in open bath. The main drawback of the open bath is that a wide resin surface is affected by the exposition to air moisture. On top of that, the temperature variations in the resin bath and the change of viscosity of resin itself affect the impregnation quality and the final quality of the parts.
  • 11. 11 Comec has developed an innovative impregnation low pressure process by applying a low hydrostatic pressure on the resin and wetting the fibers exploiting a capillary pressure effect. This patented process allows to avoid the resin backflow and the fibers’ abrasion caused by the high compaction rate of the fibers. Moreover, in most cases, the parameters of the impregnation can not be adjusted while the fibers are being drawn in the impregnation bath.
  • 12. 12 Mass production Towpreg line High volumes Towpreg line
  • 13. 13 CUSTOMIZED MACHINES AND PROCESS INTEGRATION FOR SMART COMPOSITE PRODUCTION
  • 15. Comec Innovative Quality Management System is certificated ISO 9001:2008 regarding “design, manufacturing of special machine for automatic application, machine tools, industrial maintenance, retrofitting”. The certification is not just a slogan for us but a working method and a business system. Comec Innovative is an Italian SME ( Small and Medium Enterprises) of 50 employees. Comec Innovative has a mechanical design department, an electrical design department, a software design department and an after sale service department. Comec Innovative designs with the last versions of mechanic 3D CAD’s and software tools for advanced analysis. The after sale service has a large stock of spare parts to manage the critical maintenance activities, a department for "on-site services" and a department for comprehensive phone support. Comec Innovative is able to equip its machines with telecontrol & teleservice for remote diagnostic. Comec Innovative offers service agreements with specific SLA (Service Level Agreement).
  • 16. These are some of our R&D partnerships:  NOVOTECH ADVANCEDTESTING  (GROUNDVIBRATIONTEST – GVT, NOISE TEST AND LANDING GEAR DROP TEST)  CETMA RESEARCHPARTNER  THE UNIVERSITY OF MANCHESTER  UNIVERSITA’ POLITECNICA DELLE MARCHE  ELANTAS CHEMICALR&D CARBONFIBER DIVISION These are some of our expertise:  FANUC ROBOTICS  KUKA ROBOTICS  COGNEX VISION DEVICES  SICK PROCESS CONTROLDEVICES  ROBATECH GLUE SYSTEMS  MITSUBISHI ELETRIC  SMC PNEUMATICCOMPONENTS  SIEMENS  NETZSCH PROCESS CONTROLDEVICES  NEUGART HIGH PRECISION GEARBOX Integrator expertise
  • 17. S wrap Long Impregnation Surface Calander Control of pressure Control of gap Impregnation unit Volumetric unit
  • 21. 3D Coordinate High Accurancy Measuring Technique
  • 23. PRE-PREG TAPE MACHINE SLIT TAPE MACHINE PRE-PREG TOW FOR HIGH SPEED FW PRE-PREG CUTTING MACHINE • CleanRoom • Hot-melt technology • Tow, U-D Tape, Fabric Carbonand NaturalFibre • Width 1400 mm • Moisture/ temperaturecontrol • Indipendentdelivery systems • CleanRoom • Qualitative inspectionwith vision deviceand Eddy Cus CF technology • Differentkinds of materials and width • CleanRoom • Moisture/ temperaturecontrol • Indipendentdelivery systems • Impregnationspeed from 5 to 130 mt/min • CleanRoom • Ultrasonic Cutting 20KHz • Working Capacity 10m x 2m • MaterialThickness20 mm
  • 24. FILAMENT WINDING ROBOT AUTOMATIC TAPE LAYER ROBOT ATP LINEAR SYSTEM RTM SYSTEM • Clean Room • Complexgeometries • Dynamic control shoot • Impregnation resinscontrol • CleanRoom • Advancedcontrolof automatic deposition • Complexsurface • Kuka RobotAccuracy 0,3 mm • CleanRoom • Compacting Load400 Kg • Mechanicalcutter • Hydraulic Drive • Max Applied Load 20 KN • Synchronizedmotion • Volumetric pump
  • 25. RTM SYSTEM HANDLING SYSTEM FOR CARBON FIBER COMPONENTS INNOVATIVE INDUCTION WELDING FOR THERMOSETTING CF JIGS AND MEASURE TECHNOLOGY COMPACTING PRESS • Automatic handling system for compositeparts and row materials • Scadasoftware • Innovativecontinuous • inductionwelding machinewith a controlledcoolingsystem • Modularsystem • High precisionwith zero point • 3D measurerobot • Clean Room • MechanicalDrive • Applied Load 160 ton • Dinamic PositionControl
  • 26. Automotive application The system is designed for the automatic assembly and on- line testing 100% of electrical connectors. The system consists of: • 1 precision rotary table with 8 positions • 8 manipulation stations • 16 axis • 2 vibrating units • 1 vision system for testing The manipulations of the components are made through specific mechanical modules, managed by the same synchronous transmission that moves the rotary table. Cycle time: 50 pcs / min. Rotary Synchronous assembly
  • 27. Automotive application Example of stations of total assembly and testing lines
  • 28. AUTOMATIC THERMAL PROTECTION PAINTING OF ROCKET ROCKET SOLID PROPELLENT CUTTING MACHINE AUTOMATIC DEPOSITION THERMAL PROTECTIVE TAPE OF ROCKET LAMINATION MACHINE • Clean room • ATEX • Volumetric control • Dinamic Position Control • Clean room • Speed control • Temperature control • Compaction press control • Continuous prodution from raw material to packaging of the final products • High speed / automatic change of raw materials • Clean room • ATEX • High precision • Automatic load/unload system ROCKET SOLID PROPELLENT CUTTING MACHINE AUTOMATIC DEPOSITION THERMAL PROTECTIVE TAPE OF ROCKET LAMINATION MACHINE
  • 29. a.horak@blacksunpartners.com Tel.:+39 031 881 170 Cell.: +39 334 78 66 506 www.blacksunpartners.com horak.adalberto@comecinnovative.it Tel.:+39 0871 58531 Cell.:+39 334 78 66 506 www.comecinnovative.it 29