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News

Summit: Composites for Mass Production

JEC Composites : 03 February, 2011  (New Product)
JEC has announced that the agenda has been set for the 2011 2nd I.I.C.S
(Innovative International Composites Summit), which will take place on 29-31 March at Porte de Versailles
Following the first IICS (Innovative International Composites Summit), which took place during the JEC Show Asia Singapore (12-14 October 2010), the second edition will outline how composites for mass production are ready for take-off.

“Human population has increased three-fold over the past 50 years”, says Mrs Frédérique Mutel, JEC President and CEO. “Manufacturers are to meet more and more production demands. The composites industry is changing from low volume to high volume mass production. Composites design and process simulation are an essential part. And also, at the manufacturing stage, automating and accelerating production times with lower and faster temperatures and pressures
processes”.

“While the focus is on automating and producing more, we are also aware that our planet has a finite capacity and that we must change our entire energy structure. Key to composites is Carbon fibre. Biomaterials are now accepted and pervasive throughout the economy. Nano Materials have also some outstanding mechanical, electrical and thermal properties”.

During the IICS 2nd edition, all these trends will be explored in all application sectors in order to provide 12 high-quality end-users and cross-industries forums and also technical and strategy conferences to all players in the composites industry.

End-user Industry forums
Almost 26,000 new passenger and freighter aircraft valued at US$3.2 trillion will be needed between 2010 and 2029, to satisfy demand according to Airbus’ Global Market Forecast (GMF). This demand is primarily driven by replacement of aircraft for newer more eco-efficient models in mature markets, dynamic growth in new emerging markets, low-cost carriers particularly in Asia, further market
liberalisation and capacity growth on existing routes. In order to meet this need, the two Aerospace giants Airbus and Boeing have already announced increased production rates in the coming months and years. Despite the tremendous increase in composites use in aerostructures in the past years, there are still many issues to improve upon in order to prove benefits compared to metallic
structures. In the aerospace forum, you will discover advancements for a wide range of applications for the next generation of integrated composites aerostructures. The topics cover the spectrum of aerostructures including fuselage and airframe barrels, doors with advanced stitched performs and
main landing gear fittings with ultra thick laminates.

• Aeronautics: Introducing next generation integrated composites aerostructures
A One-Shot Infused Fuselage/Airframe Barrel • A Door Composite Structure with Advanced Stitched Preforms • Ultra Thick Laminates for Main Landing Gear Fittings • Next Generation Non Crimp Fabrics For All Structural Parts • New Possibilities in Automation •


• Automotive: How far away is composite for mass production?
With OEMs increasing focus on sustainable mobility and alternative energy sources - as well as energy saving and CO2 emission reduction - the search for new technologies to bring massive weight reductions and new structural solutions is intensifying. Composite technologies are not new to the automotive industry. Glass and polyester have been used in mass production for a long time.
Recently many companies are developing new processing techniques and high performance materials. Polymer composites have a lot of advantages such as lower cost, design freedom, high production speed and so on. Long fiber reinforced thermoplastics (LFT) molding is also one of the best technologies which can reduce both part cost and weight simultaneously. Renewable materials
are already in series production. The use of carbon fiber reinforced plastics for mass-produced cars is starting to be a reality, finding a reliable, competitive environmentally friendly material able to deliver 400 to 800 cars per week. In this forum OEMs and Tier 1 companies will discuss their choice and strategy.

• Construction & Civil Engineering: Widening the use of structural composites
Now, at the beginning of the twenty-first century, the structural engineering community is about to enter a stage in which structural design with fibre reinforced polymers composites is poised to become as routine as structural design with classical structural materials such as masonry, wood, steel, and concrete. In this forum, projects will highlight cost-effective integrated processes enabling the maximum capability of industrialization of components both for the Construction and Civil Engineering markets.

• Wind Energy: Producing high quality in a high quantity
Wind energy has seen exponential growth. The challenge now is to build rotor blades which are highly efficient and durable. In parallel the industry is changing from low volume manufacturing methods to high volume mass production. This forum will present 100% automated production processes, preventative maintenance actions and in-situ structural repairs of these composite structures, making this industry more productive, while increasing product quality, energy efficiency and minimizing pollution.

Cross-Industry forums
• Automation Forum: Gaining productivity in industrial processes
Increased production rates, both for Aerospace and Automotive, unprecedented market growth for wind energy — nearly 30 percent per annum over the past five years — is pressuring manufacturers to turn out more parts, more quickly, at a lower cost. Industry stands at a tipping point where automated production is a must if manufacturers are to meet future production demands. In the Automation forum, flexible and affordable way of automation will be presented, such as Automated Fiber Placement (AFP) for the production of fuselage sections of the Boeing 787 dreamliner and also the Airbus A350XWB, automated preforming processes and automated RTM/ injection/infusion processes for all industries.

• Bio-based Materials: When performance meets sustainability
The Green movement is now accepted and pervasive throughout the economy. In composites, many have seen the potential with strong investments in the sector though sales, at times, have not met expectations. Major reasons for using natural fibers are reduced weight, superior environmental balance, reduced costs and the possibility to manufacture complex structural elements. There are questions about the cost benefit of natural alternatives in addition to the added challenges of consistency in quality control. In this forum, we will see that Bio-based materials composites can now be produced with strongly improved stiffness and strength. Fibres such as flax, hemp, typha have penetrated the automotive, construction, sports and leisure industries and further opportunities exist with continued innovation.

NEW! • Nano Materials: Enhancing the mechanical and physical properties of composites
CNT have some outstanding mechanical, electrical and thermal properties, which make them one of the most interesting new materials for industrial applications. The challenge is to integrate this specific set of properties into various matrix materials, e.g. thermosets and thermoplastics, leading to new and enhanced materials. This session gives an overview on selected developments and
applications researchers developed within the last few years.

Composites Design in partnership with Stanford University: A new composites design methodology to reduce weight and cost
We must overcome many current design practices so the true potentials of composites can be realized. Stephen W. Tsai, Professor Research Emeritus and its speakers will present the best available theory and also design tools. Four major steps will be presented to overcome barriers: Innovative use of anisotropic, homogenized laminates, Excel-based tools with micromechanics to guide design, rational damage tolerance to avoid prohibitive penalty and engineered NCF and VaRTM offer the best of all worlds.

Composites Simulation in partnership with ESI Group: Predicting composite behaviour
Despite great advances demonstrated by the academic world and some spectacular industrial successes, the Manufacturing Process Simulation (MPS) and the Composites simulation in general are still in their infancy. The second edition of this conference will start with a study about how simulation can assist product development from both a manufacturing and a structural analysis
perspective with example parts across composites intensive industries. An advanced example developed in a German project involving composite will show that simulation can be used not only for manufacturing and design but also for virtual material design. Then, a real life case study about the SAFRAN Open 60’ race yacht will demonstrate how a digital approach to crashworthiness can
contribute to the competitiveness of a high performance yacht. Finally, the material properties driving the design and the simulation are nothing else but the results of the manufacturing process where the raw materials experience deformation, heating and cooling, curing, residual stresses, etc. Many defects arise during the component production that modifies the nominal properties traditionally used in the design department. The last part of the forum will cover MPS, which is a high support to the process engineers, the right tool for robust virtual performance simulations as it provides the analyst with the right material properties.

NEW! • Non Destructive Testing in partnership with CETIM: Seeing through composites: industrial applications and trends
Composite components are now used in many mechanical applications, and have often a critical role, as in aircraft industry, of submarine applications, by example. Up to now, the Non Destructive Testing methods used in industry suffered from relative difficulties of application and complexity of interpretation. Nowadays, some methods based on industrial needs, allow the development of promising techniques, exploiting the response of the component under inspection.
So, Non Destructive Testing is now often used to assess the quality of composite components, and to guaranty its fitness for purpose on critical components.

NEW! • Global Carbon Fiber Market: Manufacturing large quantities of high quality, low cost, carbon fibre
The human population has increased three-fold over the past 50 years. In India 75% of the population is under 30 years of age. Our planet has a finite capacity; We must change our entire energy structure, decarbonising the world economy - introducing wind energy, nuclear power and low ‘mass’ transport. A 20th century definition of an advanced nation has been its ability to refine and manufacture materials - aluminium, polymers and nuclear. Key to composites is Carbon fibre. The Carbon fibre sector has shown recent growth of 25% of CAGR and the world will consume ~ 43,000 tonnes per annum carbon fibre in 2010. By 2020 we will need 340,000 tonnes per year. Most carbon fibre is manufactured from PAN - a wasteful process. This conference will discuss about how to manufacture large
quantities of high quality, low cost, carbon fibres.

NEW! • Economic: A global composite economy into a growth trajectory
Demand for more composite applications increases and composite materials are rapidly becoming a mainstream technology and material of choice within many industries and regions. This conference will provide a global overview of the composite market: Asia has emerged as the largest regional market in terms of composites shipments and is expected to maintain its leadership helped by the
growing economies of China and India, the second fastest growing economy after China, with an annual growth rate of 7-8%. The Brazilian Composite Materials Association (ABMACO) predicts 3% growth for the composites industry in Brazil in 2010. Russia has once again become a key player in the international arena and Western goods and expertise are in demand. Middle East ambitions include being part of the global Aerospace Supply Chain with the intentions of at least 2 countries to be building their own aircraft within the next 7 years. Stimulus packages in major economies such as the US and China are expected to put the global economy once again into a growth trajectory.

These conferences and forums will bring together about 100 papers from 15 nationalities with very prestigious confirmed names, such as: BMW Group • Dassault Aviation • Eurocopter Deutschland GmbH • Ford • Gamesa Innovation & Technology • Hyundai Motor• EADS Innovation Works • Latecoere • McLaren • NASA-Marshall Space Flight Center • Repower • Rolls-Royce Deutschland Ltd & Co KG • Safran Engineering Services • Siemens AG….Universities and Research & Development Centers: • Ecole des Mines de Douai • Institute for Machine Tools and Industrial Management (iwb) • Katholieke Universiteit Leuven • Kyoto Institute of Technology • Laboratoire Central des Ponts et Chaussées • Technical University of Athens (NTUA) • Stanford University • Technical University of Munich • Technische Universität Dresden, Institut für Leichtbau und Kunststofftechnik • The City College of New York • Université Lyon 1 • University of Manchester • University of Nottingham ….

To view the full agenda, register and book your hotel room, go to http://www.jeccomposites-visitors.com/ or contact: Martine Vesco, JEC Conferences and Forums Manager - (vesco@jeccomposites.com).
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