Many inventors have worked to make smaller-scale windmills.  Vertical-axis equipment seems to rule the day with this scale of equipment.  The smaller vertical-axis wind turbines for home use are less expensive, less intrusive, and have fewer moving parts.

I found a great video from arturomoises64 of a demonstration of some vertical wind turbines in Santiago, Dominican Republic.

The author’s description is as follows:

These wind turbines are moved by low winds and even at high speed winds they will not go out of control. They are very high torque and very efficient. They measure 6 feet height by 11 feet wide and are made out of fiberglass and steel. This design is very safe for birds and do not need to be installed as high as other types of wind turbines. They are completely silent and are esthetically pleasing, a hypnotic blend of science and sculpture

The construction of the blades utilizes a composite material molded into a complex shape to catch the wind and turn the axis, which is undoubtedly connected to an electrical generator of some sort.  Simple design, great application for composite materials!

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I found a video from Eastbay Composites that demonstrates a method for making small molds in a very quick an inexpensive fashion.

As you see from watching this, the basic construction materials are tooling gelcoat and inexpensive bondo for the support structure.

This mold construction technique certainly has drawbacks, but also has several advantages.  None of the materials required spray equipment, which is messy.  Brushes are inexpensive and easily disposed.  A disadvantage of this method is that surface finish might suffer from a lack of consistency on the coating thicknesses for the gelcoat and the release agents.

Using bondo as the support structure is quick and easy compared to glass and resin, but can cause problems as well.  It is more likely to crack, and can warpage issues as it cures and may be hotter in some areas than others.  Bondo may have some difficulty maintaining dimensional tolerance as it shrinks during cure.  Industrial resins used to create molds have minimal shrinkage in their chemistry and are placed on slower to minimize heat from the chemical reaction.

For quick, inexpensive and easy parts, this method from Eastbay Composites may work well for you.  What has not been discussed yet is that the mold model can be the most difficult part.  Off the shelf items are easy, but custom ones may be difficult.  Creating a shape or surface is time consuming and tenuous.  After that is complete, you can make your mold and final production parts!

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-They can be built off-site in a controlled environment.

-They are lightweight for transport and lifting into place.

-They have a durable and usually have a one-piece design.

-The material allows for design freedoms that are more difficult with other materials.

The many advantages of fiberglass swimming pools in residential use are numerous.  They do have disadvantages as well, just like other materials.  The outdoor environment can be very tough on any fiberglass structure.  Proper cleaning and maintenance is very important to keep an appropriate appearance together.

Fiberglass pools can be easily delivered on-site with medium-duty shipping equipment and lifted in place with a crane.  I found a great Youtube video demonstrating a lift over a large two-story house.  The pool easily goes into place, ready for surrounding landscaping.

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Toyota Pickup Box

This Toyota pickup box has fiberglass sides to eliminate the corrosion problem.  The floor and front bulkhead are steel, as well as the missing tailgate.  Using composite surely eliminated the rust problems associated with these vehicles, especially since it was used in the most apparent cosmetic areas that are most visible.

This pickup bed is not on a truck, because the frames of these trucks were also extremely rust-prone as well.

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The advantages of using composites in this application include non-conductivity, protection from impact, and the ability to resist corrosion in tough environments.  This is why it has outlived it’s factory setting.

Composites enclosure

An item like this where it has a good surface finish on both sides is going to be made in a set of matched-mold dies in a high-pressure and high-temperature press.  It is likely to be manufactured with the Sheet Molding Compound (SMC) process, though Bulk Molding Compound (BMC) could also be at work.

Electrical panel enclosure

You can see on the front door all of the holes from its former installation.  Holes on the side were used as well.  It was customized for its application with all of the holes, and a new unit would arrive “blank,” without holes, as most applications are customized.  The composite can be cut and drilled with metal working tools such as drill bits, holesaws, and saw blades.

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SMC Truck Fender Extension

This SMC part is all one single molded piece, having very complicated geometry.  It can also be noted that there are not any undercuts, i.e. the mold can open and close without having to move around the part. It has a mostly constant cross section, is not supported by any metal struts, and is attached to the cab by three bolts.  The geometry and details to match the cab and hood styling are molded-in so that the part can be painted and bolted on the truck.

If a part needing this much complexity was manufactured with sheetmetal, it would have many more pieces of the assembly and much more bracing.  Metal would also not have the resistance to corrosion and impact that is enjoyed by this composite part.

This fender extension is from a truck that has been on the road since 1993, with over 270,000 miles on it.  This part has been in the wild for over 15 years, and has been exposed to tons of road salt, debris from the tires, and lots of other environmental exposures.  It has survived well, only needing an update in paint to refresh its look.

Another great application of composites!

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The main goal of this substitution is to reduce weight, which improves fuel efficiency.  Other positive side effects include fewer assembly operations, additional design freedom, dent and impact resistance, and the elimination of corrosion.  Several “green” resin formulations have been introduced that make use of bio resins, which use much more renewable resources such as soy products.  The fillers and reinforcements in this material can also be made from recycled and renewable materials.

SMC has overcome several hurdles in order to get to its present use and application.  General acceptance and education had to be proven to the OEM manufacturers and consumers.  Paint application and adhesion was one large consideration that had to be proven out.  There were issues with popping and blistering from the SMC surface.  Making sure the SMC parts held dimensions and aesthetics was also an important milestone.

SMC has become widely used today for many applications, and will find its way into many more.  The weight saving aspects are paramount for reducing fuel consumption.  The anti-corrosion and dent resistance are loved by consumers.

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Advantages of composite poles over wood are numerous.  Composite poles have a lifespan of roughly 80 years versus the 25-30 years for wood, due to rotting issues.  These rotting issues with wooden poles are combatted with chemical additives that are sometimes corrosive and toxic.  Composite poles have a weight advantage, as they weigh about two-thirds less than a wooden pole, which allows for easier transportation to the jobsite and reduced equipment requirements for installation.  Due to their controlled and known construction, composite poles have physical properties that are more stable and reliable over the duration.  Composites are intrinsically non-conductive, which is ideal in this application.

Replacing an existing material in a current application always brings hurdles and challenges for acceptance.  The wooden poles are known by purchasing, engineering, installation, and line utworker crews.  Composite poles have a higher upfront cost, though long-term savings are significant.  As the educational resources reach those affected, the transition will take place and composite utility poles will become widespread.

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One of the uses for military ground forces is in the segment of armored vehicles. Metal armor competes with composite armor with metal being less expensive but heavier. This weight advantage has required the use of composite armor for the “up armoring” of vehicle systems that were already near their max payload. This minimizes the amount of other weight sacrifices being made in order to add armor.

Weight and performance are becoming more important as military tactics transition towards fast and nimble. This will create many future applications for composite materials as acceptance and testing open new opportunities.

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Replacing steel and concrete, composite bridge decks claim several advantages. They can be built in a factory as opposed to onsite (better quality control) transported and lifted rather easily, and should be much more resistant to the natural elements of freeze/thaw. One of the big savings is on installation time. The on-site construction time is much less, which allows for cost savings from road closures, detours, and site crews.

There has been TONS of Research and Development money spent by several federal, state, and private entities in developing the technology, testing, and specification criteria for this application of composites to the real world. Hurdles that need to be overcome include the acceptance by engineering professionals, infrastructure managers, and the public.

As a Composites Engineer, it sure is neat to see new applications of composites. And as a taxpayer, if it can save some money, I am very excited. As a driver, it sure would be nice to see some of these road projects shortened up!

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