March 19-21, 2013 Long Beach (CA) Convention Center

Tuesday, March 19, 2013

Keynote Presentation on the Deck:
8:00am – 9:00am

Jens Gralfs, Vice President, Manufacturing Engineering Assembly & Installation, Airbus Operations GmbH

Morning Concurrent Technical Sessions:
9:15am – 11:00am

(NOTE: Conference fees include exhibit hall access and crossover privileges between the AeroDef and Composites Manufacturing events.)


Composite Processes

Session Chair: Dick Lofland, President, Richard Lofland & Associates


9:15 AM-9:45 AM
Large Integrated Bonded Structures-Challenges and Opportunities
Doug Decker, Tech Fellow, Northrop Grumman Corporation

  • How will the future factory look different?
  • What are the benefits of bonded structures?
  • What are the challenges in people, equipment and facilities?
  • What about certification?

9:50 AM-10:20 AM
A Practical Discussion of the Abilities and Limitations of Automated Fiber Placement
Bill Hasenjaeger, Product Marketing Manager, CGTech

  • Learn how part curvature, fiber direction, and material limits affect the layup strategy. See how the AFP process affects lay-down path, part quality and rate.

Driven by the need to produce large composite aircraft components at commercial aircraft production rates, Automated Fiber Placement (AFP) equipment has become significantly faster and more reliable in recent years, broadening its practical application into domains previously occupied by metallic parts or by hand layup and Automated Tape Laying (ATL) equipment. Additionally, the need to layup increasingly more complex and contoured parts has driven improvements in both AFP equipment and off-line programming software.

This presentation discusses the interaction between part programming and machine functionality, and how it is affected by part geometry, ply boundary shapes, lay-down path trajectory, material limits, and the physical behavior of the machine, the fiber placement head, and mechanics of the layup process. Using practical experience gained during AFP machine and process development for a variety of production parts, the presentation describes the challenges and rewards of using AFP for composite part production.

10:25 AM-10:55 AM
Improving CFRP Structure Fabrication: A Comprehensive Data Driven Approach
Tom Sharp, PhD, Principal, Etegent Technologies

  • Manufacturing data mining; Improved root cause analysis; Improved material disposition processes

The fabrication of carbon fiber reinforced plastic (CFRP) structures is generating more and more digital data. This data includes NDI data, dimensional data, thermocouple data, material properties data, and many other forms of process data. Currently, integrating all of this data into a global view of the process is very difficult. Typically each data set is analyzed in its own software package, limiting the ability to integrate the multiple data types. This paper discusses work being supported by the US Air Force and US Navy to develop a software package to collect, organize, archive, and analyze this data. The data is organized by automatically aligning the data to 3D models of the parts being manufactured. The software can then visualize and layer the process data on various 3D models, such as mold models showing mold seams and thermocouple locations, ply models showing ply drops, preform models showing individual preforms, etc. This enables performing detailed analysis to detect trends at specific locations on the model. These trends can be indications of process problems. This paper will discuss the successful application of this technology to improve first pass yield, reduce scrap, and lower risk associated with the CFRP structure fabrication process.

Composite Sporting Goods Applications


9:15 AM-9:45 AM
Volume Two: Structural Application of Bio Fiber in White Water Kayaks
Greg Osusky, Manufacturing Engineer, Antithesis Design

  • Selective recap of last years presentation
  • Design, Processes and Material Characterization
  • White Water Kayak Prototyping and Testing
  • Production, Continued Applications and Future Developments

This presentation further chronicles the benefits and drawbacks of natural fiber reinforcement in composites application. "Volume Two", a continuation of my previous presentation, (SME Phoenix 2012) is a more detailed characterization of designing and manufacturing structural parts with refined hemp. Utilizing hemp and resin transfer technology, first and second generation white water kayaks were constructed and tested. Among canoe and kayak type boats, white water kayaks are the most structurally and impact demanding. These production prototypes have, in many aspects, out performed traditionally built, market available boats. Material development and future applications of bio fibers will be examined.

9:50 AM-10:20 AM
The Use of Composite Materials in Sports
Herb Reyes, Business Development Manager, Aldila

10:25 AM-10:55 AM
Composite Materials and Manufacturing Processes for Sporting Goods Applications
Dodd Grande, PhD, VP of Global Product Development, K2 Sports

Wind Energy Composite Applications

Session Chair: George Bullen, FSME CPIM, CEO, Smart Blades Inc.


9:15 AM-9:45 AM
Aerospace Materials, Processes, and Technology Transferred and Used to Produce Highly Efficient Wind Turbine Blades
George Bullen, FSME CPIM, CEO, Smart Blades Inc.

9:50 AM-10:20 AM
On Demand Prepreg
Keith McConnell, President, Century Design Inc.

  • New technology to support small scale prepreg production
  • Costs and benefits of making Prepreg to support business case
  • Understanding of applications where small Prepreg production makes sense
  • An option to gain control of costs, logistics, schedule and technology for composite manufacturing

The composites market is driving towards faster time to market, lower cost of materials and operations and more operational flexibility. For certain Prepreg applications the solution is to make your own material except that the capital costs and required expertise have been prohibitive. Newly designed small Prepreg machines are now more than a research tool, but can meet certain production applications. This presentation will overview the benefits and limitations of operating a small Prepreg machine.

Lunch on the Expo Floor
11:00am – 1:00pm


Panel Discussion on the Deck
1:00pm – 2:00pm

The AeroDef Boardroom Executive Perspectives on the Future of the Industry

Concurrent Technical Sessions
2:15pm – 4:00pm

(NOTE: Conference fees include exhibit hall access and crossover privileges between the AeroDef and Composites Manufacturing events.)


Composite Processes

Session Chair: Dick Lofland, President, Richard Lofland & Associates


2:15 PM-2:45 PM
Tubular Structure Fabrication
Keith McConnell, President, Century Design Inc.

2:50 PM-3:20 PM
Recent Developments in Braiding Technology for Aerospace and Commercial Markets
Dave Kehrl, Senior Project Engineer, A&P Technologies

3:25 PM-3:55 PM
Supply Chain Complexity in Aerospace
Dave Arnold, Royal Engineered Composites

Automotive Composite Applications

Session Chair: David Krzyzanowski, Composites Engineer, Advatech Pacific


2:15 PM-2:45 PM
Opportunities for Advanced Composites in Automotive Transportation
Chris Red, Principal, Composite Forecasts and Consulting, LLC

2:50 PM-3:20 PM
Composite Graphite Drive Shafts Provide Torque Delivery with Lowest Mass, Maximum Safety, and Vibration Damping
Jim Leslie, Advanced Composites Products & Technology Inc.

3:25 PM-3:55 PM
Benefits of the Rapid-Clave® in the Curing of Aerospace CFRP Materials
Lyod Champion, Director, Aerospace & Industrial Sales, Globe Machine Manufacturing Company

  • Development of an autoclave comparable process in the production of automotive body panels for a 2014 base model car.
  • Reduced cure cycle times to process materials compared to the use of an autoclave
  • Existing materials & resins designed for autoclave cures utilized
  • Aerospace and other industrial sector applications, large and small components
  • Reduced production costs – increased profit per part

Out of Autoclave

Session Chair: Lou Dorworth, Division Manager, Abaris Training Services, Inc.


2:15 PM-2:45 PM
Fabricating a CFRP Race Car Hood; A Case Study In Proper Infusion Methods & Techniques
Lou Dorworth, Division Manager, Abaris Training Resources, Inc.

2:50 PM-3:20 PM
The Current State of Out of Autoclave Cure of Aerospace Grade Composite Materials
George Bullen, FSME CPIM, CEO, Smart Blades Inc.

3:25 PM-3:55 PM
Out of Autoclave BMI for Large Integrated Structures
Herb Reyes, Business Development Manager, Aldila

The presentation will focus on the work completed under Man Tech efforts as well as other programs demonstrating fabrication of large integrated structures using BMI out of autoclave materials. Work completed using VARTM, prepreg, new adhesives, BMI foam and tow placement will be presented. Both aircraft structures and tooling will be covered. Planned future developments and work will also be discussed.