JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 38

FEATURE additive manufacturing

Fig. 2: 3D-printed mandrel produced using ST130TM
material, halving production time and cutting costs
by 20%

Fig. 3: Obsolete air conditioning duct
for historic supercar that needed replacing

Fig. 4: Final air conditioning unit for historic supercar,
featuring 3D-printed air duct produced in Nylon 12CF
and ASA materials

Compositex has always invested significant resources in enhancing its production equipment and supporting its R&D
(currently averaging 10% of its annual
revenue). This approach has played a key
role in establishing the company as an
international leader in prepreg technology
for composite production. However, faced
with the challenge of meeting customers'
extremely high expectations in a more
cost- and time-effective way, the company
turned to additive manufacturing in a bid
to strengthen its production capability.

were able to use just one 3D-printed water-soluble mandrel to complete production. To put
this into context, with conventional composite
tooling, the creation of four female moulds
would have been required, as well as additional
milling and finishing operations. Not only did
we halve the production time and save around
20% in costs, but we were also able to fully
satisfy the customer's expectations in terms of
the finishing of the internal side of the duct."
Beyond the production of composite tooling, Compositex is also using the Fortus
450mc to directly 3D print customized
composite parts. These include aesthetic
components and structural parts that would
simply be too complex or cost-prohibitive
to produce using conventional methods,
such as the exterior body of remote-controlled aircraft and drones, air ducts for
automotive, and motorcycle handgrips for
motorsport. Having access to this capability
via the Fortus 450mc and high-performance
materials, such as ULTEM™ 9085 resin and
Nylon 12 Carbon Fibre, has been crucial
for the company in expanding its service
offering to meet the needs of this wider and
more diversified customer base.

Building upon success layer-by-layer
The Fortus 450mc is currently running
24/7 at Compositex's production site.
Those in charge of the 3D printing
department - a team of four industry
specialists - are keen on embarking on
new challenges and testing unprecedented additive manufacturing applications
for production. Furthermore, the team is
also exploiting the features of GrabCAD
Print software to further streamline the
workflow during design and development.
"The Fortus 450mc has changed our
approach to business and we fully intend
to continue pushing the boundaries of
composite production with this technology,"
explains Fanton. "In fact, when it comes
to finding manufacturing solutions for
our customers, we feel the only limit is our
imagination. Unlike other 3D printers we've
tried, the Fortus 450mc is suitable for the
most demanding production applications,
while the level of reliability and repeatability
it provides is essential for occasions where we
try and test unexplored solutions" (figure 4).

Reinventing traditional composite
production with additive manufacturing
Having explored a number of 3D printing
technologies, Compositex approached
Stratasys' local partner, Technimold, to
purchase a Stratasys Fortus 450mc - an
industrial-grade FDM 3D printer designed
to produce complex parts using high-performance materials. The added capabilities
made an immediate impression, particularly in the area of composite tooling.
The company now 3D prints a range of
composite tools, such as lay-ups, inserts and
mandrels - all key components within the
traditional prepreg production process. The
ability to manufacture these tools in-house
enables them to eradicate the need for
costly outsourcing, while also significantly
reducing production lead times. Even more
importantly, since using Stratasys FDM
additive manufacturing for composite
tool production, Compositex has reported
higher-quality results.
"We are currently using the ST130™ material
to 3D print water-soluble mandrels and the
results are outstanding," explains Fanton
(figure 2).
"For example, in order to manufacture a drone
duct for one of our established customers, we

38

"Stratasys FDM additive manufacturing
ensures we can quickly and cost-effectively
produce certain final parts, which means we
can now respond to customer requests that we
could not fulfill before," says Fanton. "We were
recently asked to produce an air conditioning
duct for a historic supercar which is no longer
in production. We reverse-engineered the
original duct and then 3D printed the part
using carbon fibre-reinforced Nylon 12CF for
the structural components and ASA material
for non-structural elements. The result was exceptional, far beyond our - and our customer's
- initial expectations. In fact, producing this
obsolete part with traditional manufacturing
would have been impossible" (figure 3).

jec composites magazine / N°137 November - December 2020

Fanton concludes: "There is no going back.
Working closely together with Stratasys' local
partner, Technimold, we have been able to
learn how to fully streamline and optimize
the use of the technology. Gaining this
knowledge and having local support have
been essential in identifying new applications
that can be enhanced with additive manufacturing. We very much see this technology as
an important part of future production and
a key driver for us in attracting new business
opportunities. So much so that we are
currently exploring the purchase of a second
system from Stratasys in the near future."
More information:
www.stratasys.com


http://www.stratasys.com

JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Human ressources - Skills requirements in the composite materials sector – the French example
Startup - Make lightness and performance affordable without compromising the environment
Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
MANUFACTURING
Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
Additive molding - From large-scale continuous thermoplastic composites to mass production
FEATURE AUTOMOTIVE - Is it possible to do better?
FRP - Fully coupled processstructure analysis for automotive center floor panel
Honeycomb - Composite materials for lighter vehicles
Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
EV - All-composite EV wheel moves to next development phase with pilot production
Security - The world’s fastest armoured car
Natural fibre - Sustainable composite solution for new Toyota LQ concept car
SOLUTIONS
Defence - Drones as wingmen
City - Composites for tomorrow’s cities
Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
TECHNOLOGY
Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
Inside the lab - The University of Southern Queensland - Centre for Future Materials
Method - Weight and cost reduction with double-double laminates
Index
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JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Human ressources - Skills requirements in the composite materials sector – the French example
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 12
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Startup - Make lightness and performance affordable without compromising the environment
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 16
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 18
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 22
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 26
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive molding - From large-scale continuous thermoplastic composites to mass production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - FRP - Fully coupled processstructure analysis for automotive center floor panel
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 31
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 33
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Honeycomb - Composite materials for lighter vehicles
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 36
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 38
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - EV - All-composite EV wheel moves to next development phase with pilot production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 40
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Security - The world’s fastest armoured car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 42
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Natural fibre - Sustainable composite solution for new Toyota LQ concept car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 46
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Defence - Drones as wingmen
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 48
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - City - Composites for tomorrow’s cities
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 51
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 56
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 59
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Inside the lab - The University of Southern Queensland - Centre for Future Materials
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Method - Weight and cost reduction with double-double laminates
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 68
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