Machining Composites
Much like other materials can be machined, so can composites. Everything from basic fiberglass fabrications to advanced composites materials can be machined to add details and features.
This can be accomplished using hand-held tools guided by fixtures and measurements. Hand tools such as air routers, drills, and saws. A disadvantage is that the operator can commit errors and must be protected from safety hazards. These hazards include airborne dust, bending strain, lifting strain, and physical cuts.
For high volume or high precision applications, there are CNC routers that can be employed. These are fast, efficient, and safe. They may be expensive though.
Several manufacturers make CNC routers, and Thermwood is one as shown below.
This video shows several different applications and parts that can be routed with this large machine.
UK Promotes Composites Manufacturers
I ran across an interesting video demonstrating case studies of composite manufacturers in the United Kingdom. This video paints a very pretty picture of companies that use these materials to manufacture a wide range of items including: aerospace, bicycles, bridges, auto racing parts, etc.
This video has some great video footage of automated composite manufacturing using advanced composites materials. Automating these processes has long been a challenge and hurdle to using composite materials for commercial applications.
This video seems to be done by a UK government agency called the “Department of Business Innovation & Skills” promoting a national strategy for composites industry growth. It supposedly demonstrates companies working together to develop new composites technology.
NASA Composite Crew Module
NASA, the space agency for the U.S. government, has investigated the use of advanced composites for use in future vehicle programs. The Composite Crew Module (CCM) has been designed and built as a travel vehicle for astronauts in future space programs to travel. Drawing parallels to the Apollo program, this module will be launched on a rocket and break away as a module.
This technology and material are undergoing testing and evaluation before it is officially accepted for the Orion program. As a partnership between government agencies and public companies, this technology aims to reduce weight and improve performance of the manned vehicles.
From NASA’s website “Led by the NESC, the project team is a partnership between NASA and industry, including design, manufacturing, and tooling expertise. Partners are civil servants from nine NASA Centers – ARC, DFRC, GRC, GSFC, JSC, JPL, KSC, LaRC, and MSFC; the Air Force Research Laboratories; and contractors from Alcore, Alliant Techsystems, Bally Ribbon Mills, Collier Corporation, Genesis Engineering, Janicki Industries, Lockheed Martin, and Northrop Grumman. The CCM team operates in a virtual environment, electronically connecting participants across the country.”
This full-scale structure has strain gauges attached to monitor loads on the structure. It was announced on January 25 that it has passed a battery of stress tests to prove viability.
The structure appears to be made with carbon fiber materials, maybe with some graphite reinforcement and an epoxy resin system. Mention of aluminum honeycomb can be found in the online reading materials. The main pieces are autoclaved, while bonding of the large sections (upper and lower shells) is accomplished outside of the autoclave.
Composites technology is being developed for future space exploration structures and vehicles, and this is good news for the composites industry!
Machining Composites CNC Video
Much like other materials can be machined, so can composites. Everything from basic fiberglass fabrications to advanced composites materials can be machined to add details and features.
This can be accomplished using hand-held tools guided by fixtures and measurements. Hand tools such as air routers, drills, and saws. A disadvantage is that the operator can commit errors and must be protected from safety hazards. These hazards include airborne dust, bending strain, lifting strain, and physical cuts.
For high volume or high precision applications, there are CNC routers that can be employed. These are fast, efficient, and safe. They may be expensive though.
Several manufacturers make CNC routers, and Thermwood is one as shown below.
This video shows several different applications and parts that can be routed with this large Computer Numerically Controlled machine.
GE Building Michigan R&D Center
General Electric recently announced plans to build a new R&D Center in Michigan, near Detroit. While portions o the Center will house Software Engineers, much of it will relate to advanced composites for renewable energy, aircraft engine, gas turbine and other high-technology products. The further development of composites, machining, inspection, casting and coating technologies will be pursued to benefit GE’s Aviation and Energy businesses.
This move generally marks a change in direction for GE’s growth in the United States. Prior to this announcement, most of their new operations were opening in Asia and India. There is a potential for a large number of new jobs should this plan reach fruition. Heavy tax incentives and a large number of unemployed engineers have helped make this plan make sense.
The locating of such a large composites R&D center near the automotive heart of America shows how important composites are to the future of American automobiles. Traveling by cars, planes, and trains consume mass amounts of energy, which is only going to become more expensive. Reducing the amount of energy consumption will improve the cost effectiveness of new materials and technologies.
GE is aligned very closely with the Federal Government, who now owns two car companies that also happen to be in Detroit. I would expect to see a lot of collaboration amongst all of these parties as time goes forward.
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