Modern Composites, The Composite Prototyping Center & “STEAM” Powered High Schools Jim Karanik Director of Training Composite Prototyping Center Presentation to Nassau BOCES STEAM Powered High Schools May 24, 2016
COMPOSITES Composite materials are made from two or more constituent materials with significantly different physical or chemical properties that when combined, produce a material with characteristics different from the individual components. The new material is stronger, lighter, and more cost efficient.
Benefits of Composites • Carbon fiber construction offers exceptional strength and stiffness at a lower density than traditional metal materials. • The high temperature epoxy resins with which the fibers are cured are highly resistant to water, fuel, anti-freeze, and solvents which might cause wear or deterioration, and they can be protected from ultraviolet radiation using the same paint finishes used on metal airplane components. • Composite parts are qualified for use in weather and climates found anywhere in the world and at all certified altitudes.
Industrial markets where advanced composite materials are used: • Aerospace (commercial & military planes/helicopters/UMV Drones, space vehicles) • Racing Cars • Sporting goods Wind Energy equipment such as wind blades • • Oil drilling • Infrastructure projects such as bridges, tunnels, skyscrapers • Tanks such as CNG tanks, waste tanks, etc.
Composites Serve as Primary Structural Material Boeing 787 Dreamliner Other 5% Steel Carbon laminate 10% Carbon sandwich Composites Titanium 50% Other composites 15% Aluminum Titanium Aluminum Titanium/steel/aluminum 20%
The global market for carbon fiber composite material and products reached over $15 billion (US dollars) in 2013, with an annual growth rate of more than 7 %.
Composite Prototyping Center (CPC)
Our Mission CPC’s core mission was developed in recognition of the growing demand and opportunities in advanced manufacturing using composite material such as carbon fiber, fiberglass and aramid. It is: To take the best assets available to form a core manufacturing competency in the rapidly growing composite market, while providing companies access to essential training /workforce development, process technologies , prototype manufacturing and test capabilities. Thus enabling these companies to meet the rapidly growing advanced composite manufacturing supply chain needs of prime contractors and OEMs.
Our Primary Objectives • Establish premier resource for composite prototype production for application across diverse markets, from aerospace, automotive, energy, infrastructure, transportation and leisure goods. • Equip the CPC with essential production line technologies and staff the center with expert technologist. Assist companies to become qualified suppliers to the OEMs and prime contractors • for composite components / assemblies. • Continue to secure government grants and private funding to facilitate CPC’s future growth and development. By working closely with universities and community colleges, help develop multilevel • certificate and degree programs consisting of advanced composite technologies for post secondary and undergraduate students thereby creating a highly-skilled workforce. • STEM training with local high schools.
Composite Training and Education CPC’s training classroom is equip with: Dell Workstations (seven) • • Software Tools : • CATIA v5 CAD/CAM with composite module • Siemens CAD /CAM (Nastran (FEA) /ANASYS) • Fibersim Composite Design • Pro-E Wildfire SolidWorks s/w • • Video Conferencing & Webinars • Mfg. process equipment networked to enable easy up/down loading of programs and of line programing Education Curriculum and Certificate Programs: • CPC offers introductory and composite design training courses for industry CPC is currently developing a Composite Technician Certification program • CPC has launched a STEM Composites Initiative with local high schools which includes credit • from Vaughn College
Software Design & Analysis Tools: CATIA, Pro-E & Nastran, Fibersim, etc.
CPC Manufacturing Floor CPC will support the following processes & functions: Automated Fiber Placement RTM / VaRTM 5 Axis CNC Routing Cell Autoclaves , Ovens Compression Molding, Heated Hand Lay-Up with Laser Press projection assisted templates and kitting capabilities Clean Room (Class 100,000) Single Ply Cutting System with Test and inspection – NDT and nesting s/w CMM tools and instruments 3D Printer Walk-in Freezer
Site Specifications • Building: 121 Express Street, Plainview N.Y. • Total sq. ft . = 25,500 sq. ft. 1 st floor: 20,000 sq. ft. ; 2 nd floor 5,500 sq. ft. • • Electric power: 2,500 amps /480 volts & 1,200 amps /208 volts • Other utilities: Natural gas, N2, compressed air, vacuum, water • Ceiling height: 20 ft. (clear under roof structure) • Fully air conditioned • Shipping dock and drive - in entrance for large deliveries • High efficiency LED high bay lighting • Secured controlled access
Automated Fiber Placement (AFP) Machine Manufactured by Automated Dynamics • Mfg. parts up to 90” long by 48” cross section/diameter Thermo-set Heads, 4 - 1/4” tows • • Thermo-plastic Heads, 1 - 0.25” /0.50” tape • Flat panel capable (48”x 96”)
Automated Fiber Placement Laser Head Prototype Pressurized Tank Proof of Concept
THE CURRICUL URRICULUM UM INTRODUC ODUCTIO TION N to COMPOS POSITE ITE This course is a 15 hour, four-week program TECHNOL HNOLOG OGY Y taught by the engineering facility from Vaughn College and CPC Personnel. The EDUCATION TION PRO ROGR GRAM AM curriculum consist of both classroom lectures and hands-on lab experience. Students that successfully compete the course will receive one college credit from Vaughn College. Introduction to Composites Design with Composites Analysis with Composites Composite Materials and Processes Manufacturing with Composites Hot Bond Repair
STEM HS COMPOSITE TECH PROGRAM STUDENTS COMPOSITE PANEL FABRICATION PROJECT
STEM HS COMPOSITE TECH PROGRAM STUDENTS COMPOSITE PANEL PROJECT REPAIR
STEM HS COMPOSITE TECH PROGRAM STUDENTS COMPOSITE PANEL PROJECT REPAIR
COMPOS POSITES ITES TECH CHNOL NOLOG OGY Y VET ETERANS ERANS TRAI RAININ NING
STUDENTS FROM EASTERN SUFFOLK BOCES’S STEM HIGH SCHOOL PROGRAM ATTENDED THE 2015 MANUFACTURING DAY AT THE CPC
SENATOR KIRSTEN GILLIBRAND ANNOUNCES NEW LEGISLATION SCALE-UP MANUFACTURING INVESTMENT COMPANY ACT OF 2015
Composite Prototyping Center Wins National Designation as the Department of Energy’s Institute for Advanced Composites Manufacturing Innovation’s Designated Center for New York and the Northeast Corridor Plainview, NY… (October 15, 2015) The Institute for Advanced Composites Manufacturing (IACMI) today signed a Memorandum of Understanding with the Composite Prototyping Center (CPC, Plainview, NY CPC) outlining a collaborative arrangement in which both will work to bring advanced composite materials and technologies to the marketplace. It is a major achievement for the CPC which has earned this national recognition as the IACMI’s designated center for commercializing advanced composites manufacturing on Long Island, New York State and the broader Northeast corridor. The agreement provides the framework for collaboration in research, product development, commercialization, workforce training and STEM (Science, Technology, Engineering and Math) education.
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COMPOSITE PROTOTYPING CENTER 121 Express Street , Plainview, NY 11803 1-516-597-5445 www.compositepro.org https://www.facebook.com/CompositePrototypingCenter https://www.linkedin.com/groups/Composite-Prototyping-Center- Consortium-CPC-3109255 https://plus.google.com/105156980143836753864/posts Jim Karanik Composite Prototyping Center Director of Training jkaranik@compositepro.org
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