Modern Composites, The Composite Prototyping Center Prototyping...Modern Composites, The Composite Prototyping Center & “STEAM” Powered High Schools Jim Karanik Director of Training

Modern Composites,

The Composite Prototyping Center&

“STEAM” Powered High Schools

Jim KaranikDirector 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

Composites

50%

Aluminum

20%

Titanium

15%

Steel

10%

Other

5%

Carbon laminate

Carbon sandwich

Other composites

Aluminum

Titanium

Titanium/steel/aluminum

Boeing 787

Dreamliner

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

Press

Hand Lay-Up with Laser

projection assisted templates

and kitting capabilities

Clean Room (Class 100,000)

3D Printer

Single Ply Cutting System with

nesting s/w

Walk-in Freezer

Test and inspection – NDT and

CMM tools and instruments

Site Specifications

• Building: 121 Express Street, Plainview N.Y.

• Total sq. ft. = 25,500 sq. ft.

• 1st floor: 20,000 sq. ft. ; 2nd 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

• 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 (AFP) MachineManufactured by Automated Dynamics

Automated Fiber Placement Laser Head Prototype Pressurized Tank Proof of Concept

THE CURRICULUMThis course is a 15 hour, four-week program

taught by the engineering facility from

Vaughn College and CPC Personnel. The

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

INTRODUCTION to COMPOSITE

TECHNOLOGY

EDUCATION PROGRAM

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

COMPOSITES TECHNOLOGY

VETERANS TRAINING

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 theDepartment 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.

25

Think Tank Vision

CompositesNanotechnologyGenetic EngineeringBiological WarfareInformation WarfareDirected EnergyCompositesRobotics

COMPOSITE PROTOTYPING CENTER121 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 KaranikComposite Prototyping Center

Director of Training

[email protected]