JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 50

KNOW-HOW Laser projection g…/… Recent innovations in laser templating the tool but, as long as the relative position remains the same, they do not need to be physically installed on the tool itself (Figure 2). Ply compensation on carbon-fibre parts Because composite materials are being used more and more in aircraft part construction, inconsistencies in material thicknesses have the potential to diminish the structural integrity of a given part and preclude it from satisfying strict engineering tolerance standards. In response to this, Magestic Systems, Inc. recently developed TruNEST™ Ply Compensation System (PCS). At final inspection, this system interprets a point cloud of “as-built” data that defines the thickness of the composite part off the tooled surface and compares it to the “as-designed” engineering model to determine thickness and structural integrity. TruNEST™ PCS detects zones on a composite part (such as a wing skin) that are out of engineering tolerance for thickness, and calculates the shape and quantity of compensation plies required to build the part back into tolerance. It automatically generates both the NC code to cut the new compensation plies and the laser projection files to place them accurately on the composite part. TruNEST™PCS allows manufacturers to increase savings and throughput by eliminating two major causes of waste: (1) discarding parts with minor defects and (2) milling down excess plies to bring a part into tolerance. can be de-skilled and accelerated with an improved end result. Hours of manual measurement and double-checking are required to ensure that the right dimensions of a design are transposed to the surface (fuselage, hull, etc.), and that the Fig. 3: Laser projection used to guide the kitting process. right “effect” is provided to give the desired look. If a 2D picture can be intersected through a 3D CAD model, then going from a 2D drawing to final projection on the real part is both fast and easy. No drawings or “hand measurement” are required after this. More information Magestic Systems, Inc., specializes in material and process optimization solutions across all CNC cutting and laser projection applications. Using a laser to guide the kitting process on a cutting table Cutting expensive materials such as carbon fibre requires optimized nesting for maximized material usage. Putting kits together for hand layup can often be an arduous task that can be error prone. Again, a laser projector is an ideally designed tool to direct a hand operator to the post-cut parts on a cutting table to assemble kits. Once parts are cut, the laser projector guides an operator to pick up each part. The projector can draw the part number and an outline of the required piece, practically eliminating the chance of error. The system can also guide multiple operators to pick parts and put kits together in parallel. Each kit is number coded to minimize the chance of error. A small retro-reflective piece of material on the operator’s wrist or coat sleeve can activate the system to move on to the next part. The system is simplicity itself and stands to save a lot of time at the kitting table, where it is possible to spend more than 80% of the total material preparation time just sorting out kits (Figure 3). Fig. 4: Transition from concept to projection to painted aircraft. Laser projection for paint masking and other operations While not directly linked to the composite process, using a laser projector to mask a surface for painting is an excellent example of how a time-consuming and difficult operation Using an accurate model of the item to paint and having a set of known good reference points to position projector targets ensures a laser projection as accurate for paint masking as it is for composite layup, even though this is rarely called for. This approach may be used for applying paint masking, guiding freeform painting (painting during projection requires explosion-proofing the equipment) or decal application. The end result is a more accurate job, completed much more quickly than ever before. LaserCAD and Virtek Vision International maintain this patented process. An example of the transition from CAD to aircraft is shown below (Figure 4). Lasers may be used safely when operated in conformance with the manufacturer’s specifications and operating requirements. Conclusion As the performance of laser projection systems continues to increase, more and more people are coming up with new ideas and jec composites magazine / No54 January 2010

JEC COMPOSITES MAGAZINE - Issue #54 - January 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #54 - January 2010

Cover
Editorial
Contents
NEWS WORLDWIDE
Companies
- Focus Aeronautics
- Jushi lets its ambitious plans out of the bag
- Dedienne Multiplasturgy Group marches on
Agenda of events
Equipment : Software
- SigmaNEST saves £70,000 in composites manufacturing
BUSINESS
Market survey
- A market with a rosy future
Niche market
- High-tech first at NASA: a crew module structure made of composite materials
Human capital
- The graduate with a degree in composite materials
FEATURE - WIND ENERGY
China
- China: No slown in global wind developments as country continues expansion
Fibre
- High-performance E6 glass fibre: Meeting the needs of the wind energy industry
Foam
- Infusion moulding structural panels
- New PET foams for wind turbine construction
Epoxy
- Blade length: Top-end limits are set by the materials
Manufacturer
- SHFRP: still limited as a player
Equipment
- Epoxy-resin infusion systems for wind-blade manufacturing
- Workflow optimization for rotor blades manufacturing
- New robotic wind-blade finishing system reduces work time by 90%
Small wind turbines
- An experimental study of rotor shapes: for small horizontal-axis wind-turbines
Maintenance
- Predictive maintenance in the wind energy industry
USERS’ PLATFORM
Composites in the world
- The world’s most environmentally friendly aircraft
- Bicycling enthusiasts can adjust bike parts themselves
- Champagne!!!
Successful partners
- High-pressure hydrogen storage tanks made by RTM
Application
- Lightweight, ultra-durable air cargo containers
- Solar Plane takes of
- First solar-powered speedboat
KNOW-HOW
Laser projection
- Recent innovations in laser templating
Nanochemicals
- LEO semi-solid resin film
Mould
- DEMOCRAT, an electrostatic process
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - Editorial
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 5
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 6
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Focus Aeronautics
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 8
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Jushi lets its ambitious plans out of the bag
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 10
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Dedienne Multiplasturgy Group marches on
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 12
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 15
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - SigmaNEST saves £70,000 in composites manufacturing
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 17
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - A market with a rosy future
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - High-tech first at NASA: a crew module structure made of composite materials
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - The graduate with a degree in composite materials
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 21
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - China: No slown in global wind developments as country continues expansion
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 23
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - High-performance E6 glass fibre: Meeting the needs of the wind energy industry
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 25
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Infusion moulding structural panels
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - New PET foams for wind turbine construction
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Blade length: Top-end limits are set by the materials
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - SHFRP: still limited as a player
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Epoxy-resin infusion systems for wind-blade manufacturing
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Workflow optimization for rotor blades manufacturing
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - New robotic wind-blade finishing system reduces work time by 90%
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 35
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - An experimental study of rotor shapes: for small horizontal-axis wind-turbines
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 37
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 38
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 39
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Predictive maintenance in the wind energy industry
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Champagne!!!
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - High-pressure hydrogen storage tanks made by RTM
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Lightweight, ultra-durable air cargo containers
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Solar Plane takes of
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - First solar-powered speedboat
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 47
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - Recent innovations in laser templating
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 49
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 50
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 52
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - LEO semi-solid resin film
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 54
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 55
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - - DEMOCRAT, an electrostatic process
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 57
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 58
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #54 - January 2010 - 60
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