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  • Home
  • Introduction to Composites
    • Fundamentals of composite materials
      • How Composites Differ From Metals
      • When to Use Composites
      • Composites design
      • Composites manufacturing
    • Systems approach to composite materials
  • Foundational Knowledge
    • Materials science
      • Material structure
        • Polymer (matrix) structure
          • Thermoplastic polymers
          • Thermoset polymers
      • Material properties
        • Basic Definitions of Material Properties
          • Thermal conductivity
          • Specific heat capacity
          • Thermal diffusivity
        • Polymer properties
          • Heat of reaction
          • Degree of cure
          • Outgassing of Polymer Resins
          • Viscosity (resin)
          • Glass transition temperature (Tg)
        • Reinforcement properties
        • Composite properties
          • Fatigue Limits
          • Failure Theories
          • Safety Factors
          • Macro-Mechanics
          • Micro-Mechanics
    • Processing science
      • Thermal behaviour
        • Heat transfer
          • Conduction
          • Convection
        • Thermal phase transitions of polymers
        • Cure of thermosetting polymers
    • Foundational method documents
      • How to measure curing time and degree of cure
      • How to measure gel time
      • How to measure reinforcement content (and corresponding matrix content)
      • Tensile Testing
  • Systems Knowledge
    • System parameters - inputs and outcomes
    • System interactions
    • Thermal and cure/crystallization management (TM)
      • Effect of material in a thermal management system
      • Effect of shape in a thermal management system
      • Effect of tooling in a thermal management system
      • Effect of equipment in a thermal management system
    • Materials deposition and consolidation management (MDCM)
    • Residual stress and dimensional control management (RSDM)
      • Effect of material in a RSDM system
      • Effect of shape in a RSDM system
      • Effect of tooling in a RSDM system
      • Effect of equipment in a RSDM system
    • Machining and assembly management (MAM)
    • Quality/inspection management (QIM)
    • Systems knowledge method documents
      • How to perform an experimental thermal profile
  • Systems Catalogue
    • The factory
      • Factory layout (where)
      • Objects in the factory (what)
        • Material
          • Cores & inserts
            • Foam
            • Honeycomb
          • Matrix
            • Fire Retardant Resins/Additives
            • Epoxy resin
            • Polyester resin
          • Prepreg
        • Shape
        • Tooling and consumables
        • Equipment
          • Autoclave
          • Oven
          • Room temperature transformation
          • Hot press
      • Factory cells (where and how)
        • Testing
          • Thermomechanical Analyzer (TMA)
        • Material deposition
          • Automated fibre placement (AFP)
          • Compression moulding
          • Hand layup prepreg (Autoclave/Out-of-autoclave) processing
          • Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)
          • Wet layup
        • Thermal transformation
    • Resources
      • Composites Courses at Canadian HEI
  • Practice
    • Integrated Product Development
      • Practice for Developing a Product
        • Composite Production Part Drawing
        • Selecting Functional Requirements
        • Shape Development
        • Material Selection
        • Practice for Identifying Process Steps
      • Practice for Developing a Process Step
        • Practice for Developing a Deposition Step
          • Resin degassing
        • Practice for Developing a Demoulding Step
        • Practice for Developing a Consolidation Step
          • Debulking
          • Consolidation of Thermoplastics
          • Vacuum Bagging
            • Vacuum Bagging for Prepregs
            • Vacuum Bagging for Vacuum Infusion
        • Practice for Developing a Receiving and Storage Step
        • Practice for developing a thermal transformation process step
          • Developing production scale tooling
      • Ensuring quality during curing of thick parts
      • Ensuring tooling choice meets part quality metrics
      • Ensuring quality during production of variable thickness parts
      • Maintaining equivalency during cure for different fibre architectures
    • Production Optimization
      • Process selection for production scale-up
      • Decreasing Cure Cycle Time
      • Increasing throughput by curing parts simultaneously
      • Maintaining quality when scaling-up from coupons to production-ready parts
      • Optimizing a cure cycle for improved production rates
    • Production Troubleshooting
      • Practice for troubleshooting a Light RTM step
      • Troubleshooting scaling issues from small to large parts
      • Transitioning tooling styles between different thermal transformation equipment
      • Troubleshooting when changing production tooling material
      • Troubleshooting a cure cycle for improved production rates
      • Troubleshooting tooling to achieve part quality
      • Maintaining part quality when changing curing equipment
      • Troubleshooting part quality during cure when changing the reinforcement
      • Troubleshooting scale-up issues from thin to thick parts
      • Ensuring appropriate resin flow and part consolidation for a new cure cycle
      • Troubleshooting scaling-up issues from coupons to parts
      • Ensuring appropriate resin flow and part consolidation for a new material
      • Troubleshooting quality issues during cure for different equipment types
  • Case Studies
    • Development
      • Lack of Requirements in Product Development
      • Conducting a thermal tooling survey on three complex tools of different materials
      • Developing for Future Production Scale Up
      • Use of Right Sized Simulation to Aid Decision Making in Thermoplastic Composite Manufacturing Systems
      • Feasibility of Using Composite Materials in Mobile Food Truck Tandoor Ovens
      • Automotive Battery Enclosure Material and Manufacturing Assessment
      • Product Development Stage Gate Methodology for a Composite Shroud
      • Process Selection for a Composite Transit Vehicle Door
    • Optimization
      • Optimization of a hot press process for bike components
      • Optimizing Cost vs Weight for Low Production Volume Parts
      • Cost Comparison Study of a GFRP Leisure Boat Hull Manufacturing Method; Spray Up vs Resin Infusion
      • Using Barcol Hardness Measurements to Correlate Hardness and Degree of Cure
    • Troubleshooting
      • Troubleshooting of room temperature processes for large recreational and industrial parts
  • Perspectives
    • Presentations
      • Dr. Anoush Poursartip's cdmHUB global composites expert webinar
    • Interviews
      • Interview with Prof. Kevin Potter
    • AIM Events - Webinars
      • Advanced x-ray imaging of carbon fiber microstructure
      • Implementation of Bolted Joints in Composites
      • Filament Winding
      • Introduction to Bolted Joints in Composites
      • Introduction to Damage and Repair of Composite Sandwich Structures
      • Introduction to Non-Destructive Testing of Composite Materials
      • Introduction to Repair of Composite Structures
      • Viscoelasticity and Composite Materials
      • Introduction to Adhesive Bonding - Part II
      • Introduction to Adhesive Bonding - Part I
      • Sandwich Panels in Aerospace
      • Introduction to Tooling for Composite Materials Processing
      • An Introduction to Composites Sustainability
      • Porosity in Composite Materials - Part II
      • Porosity in Composite Materials - Part I
      • Pultrusion of Thermoplastic Composites
      • Simulation models for rapid liquid composite molding
      • CKN’s Approach to Developing Products with Composite Materials
      • Introduction to Sandwich Structures - Materials and Processing
      • Case Study: Optimizing a Press Moulding Process
      • Introduction to the welding of thermoplastic composites
      • Introduction to the processing of thermoplastic composites
      • Heat Transfer in Composites Processing
      • Effect of cure on mechanical properties of a composite (Part 2 of 2)
      • Effect of cure on mechanical properties of a composite (Part 1 of 2)
      • Fabric Forming: how it affects design and processing, and how simulation can address this
      • Fibre Architecture: Availability, pros and cons, and selection for my application
      • Strengthening the Canadian Advanced Manufacturing Innovation Ecosystem: What types of intellectual property matter, and to whom?
      • Understanding Polyester Resin Processing: The Effect of Ambient Temperature on the Final Part
      • Composites Process Simulation: A Review of the State of the Art for Product Development
      • Resin Behaviour During Processing: What are the key resin properties to consider when developing a manufacturing process?
      • The Composites Knowledge in Practice Centre – an open resource for composites manufacturing knowledge and best practices
      • Deconstructing composites ''processing'' - Why it seems so complex and how to think about it in a structured way
      • Parameters for Structural Analysis of Composites
      • Costing composite parts
      • Composite materials engineering webinar series
        • Composite materials engineering webinar session 1 - Introduction
        • Composite materials engineering webinar session 2 - Constituent Materials - Fiber
        • Composite materials engineering webinar session 3 - Constituent materials - Resin
        • Composite materials engineering webinar session 4 - Thermal management and resin cure
        • Composite materials engineering webinar session 5 - Manufacturing processes - Introduction
        • Composite materials engineering webinar session 6 - Manufacturing processes - Prepreg processing
        • Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding
        • Composite materials engineering webinar session 8 - Mechanics of composites - Part 1: Lamina level
        • Composite materials engineering webinar session 9 - Mechanics of composites - Part 2: Laminate level
        • Composite materials engineering webinar session 10 - Failure of composites
        • Composite materials engineering webinar session 11 - Defects
        • Composite materials engineering webinar session 12 - Testing
    • Diversity & Inclusion Coffee Breaks
      • D&I with Janice Barton
      • D&I featuring Kero Saleib
      • D&I featuring Rosemary Pham
      • D&I featuring Sampada Bodkhe
      • D&I featuring Isabelle Paris
      • D&I featuring Janic Lauzon
      • D&I featuring Anoush Poursartip
      • D&I featuring Courtney Mandock

Case Studies - A7

From CKN Knowledge in Practice Centre
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 Welcome to the Case Studies volume. This volume contains a collection of case studies covering industrial projects performed by the Composites Research Network (CRN) and its academic and industry partners. By clicking the links below, you can access chronicles of development, optimization and troubleshooting industrial projects.


Want to learn more about the Case Studies volume? Find more explanation at Level II.



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Development
Optimization
Troubleshooting
Read more

Do you want to learn from previous development projects? This section of the KPC provides real-world situations where practitioners had to develop a process, all the way through to building a factory. The development case studies illustrate the complexity of developing a factory layout and defining the processing steps and selecting materials, shape, tooling, and equipment combinations that are compatible. Click here to access the full list of of development case studies.

Do you want to learn from previous optimization projects? This section of the KPC provides real-world situations where practitioners had to optimize a process and/or a factory. The optimization case studies illustrate the complexity of optimizing a manufacturing system defined by a wide range of parameters with intrinsic variability. They show how different tools and methods can be used to make a manufacturing system more robust and efficient. Click here to access the full list of optimization case studies.

Do you want to learn from previous troubleshooting projects? This section of the KPC provides real-world situations where practitioners had to troubleshoot a process and/or factory. The troubleshooting case studies reveal the numerous defects and sources of variability and unreliability inherent to composite manufacturing. Click here to access the full list of troubleshooting case studies.

How to Use this Volume[edit | edit source]

Volume Framework

This volume provide users with three different types of case studies: development, optimization and troubleshooting case studies. The case studies describe industrial projects as actually performed. As they are faithful chronicles of industrial projects, often the guidelines provided in the Practice volume might not have been followed. This is highlighted as best possible. Also, the case studies might differ from the practice described in the Practice volume as best practice evolves over time. This is also pointed out where possible. However, exhaustive mapping of any difference is outside the scope.

Volume Features[edit | edit source]

Where appropriate, this volume includes link to relevant Practice pages and also to Foundational Knowledge, Systems Knowledge, Systems Catalogue, and Practice pages for further reading.

Content[edit | edit source]

Listed below are the case studies covered in this volume.

Development case studies[edit | edit source]

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 A collection of development case studies can be found here. The content largely covers development projects performed by the Composites Research Network (CRN).


See the shortlist below to explore the development case studies.


Optimization case studies[edit | edit source]

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 A collection of optimization case studies can be found here. The content largely covers optimization projects performed by the Composites Research Network (CRN).


See the shortlist below to explore the optimization case studies.


Troubleshooting case studies[edit | edit source]

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 A collection of troubleshooting case studies can be found here. The content largely covers troubleshooting projects performed by the Composites Research Network (CRN).


See the shortlist below to explore the troubleshooting case studies.



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About Help

Engineered materials (designed to have specific properties) made from two or more constituent materials with different physical or chemical properties. The constituents remain separate and distinct on a macroscopic level within the finished structure.

Any manufacturing and/or decision making activity that occurs during any stage of the development design cycle (e.g. conceptual design to production).

In the context of Knowledge in Practice, practice refers to the systematic use of science based knowledge to reduce composites manufacturing risk, cost, and development time.

Retrieved from "https://compositeskn.org/KPC/index.php?title=A7&oldid=4841"
CKN KPC logo

Welcome

Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:

Understanding Composites Processing

The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:

The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.

The relationship between material, shape, tooling & consumables and equipment during a process step


Interrelationship of Function, Shape, Material & Process

Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:

The relationship between function, material, shape and process


Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.

The relationship between function, material, shape and process consisting of Equipment and Tooling and consumables


Workflows

The KPC's Practice and Case Study volumes consist of three types of workflows:

  • Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
  • Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
  • Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.
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