Introduction to Composites
9:00 AM-12:00 PM
Associate Technical Fellow
Boeing Commercial Airplanes
David C. (Dave) Dickson is an Associate Technical Fellow of the Boeing Company, located in Seattle, WA. Dave’s current responsibilities include investigation and implementation of new and existing tooling technologies that help reduce overall production and tooling costs.
Dave has been a Boeing employee for more than 35 years. He has had assignments as a Tool Engineer and in Tooling Management, in both Boeing Commercial Airplanes and Military programs, including 787, B-2, F-22 and other Programs. He has also been an Integrated Product Team Leader on a Military Airplanes program and in Commercial Product Development. Dave spent several years on 787, from the beginning of the program through late 2010, he was Tooling Technical Leader. He is a Boeing Designated Expert in Tooling for Composites.
Dave has a BS in Mechanical Engineering Technology from Arizona State University in Tempe and a Graduate Certificate in Project Management from City University of Seattle. He is an industry-recognized expert in and has served as an Instructor for “Tooling for Composites” for several years for joint Boeing / University of Washington extension program and for the FAA AMTAS Center of Excellence.
Dave is a member of SME and is Co-Chair of its Composites Fabrication Technical Group, a member of Society for the Advancement of Material and Process Engineering (SAMPE) and is currently the manager of its LinkedIn Tooling Technical Community. Dave has spoken at many technical conferences, serving on several Tooling Panels & often as Tooling Session Chair. He was Chair of the advisory committee for the 2008 SME Tooling for Composites conference, also for the SME Composites Manufacturing 2013 conference and a member of the advisory committees for several other SME composite conferences. He was also named the Recipient of 2010 Judge “Jud” Hall Composites Manufacturing Award by SME; the award honors outstanding contributions to the advancement of composites manufacturing and tooling.
This workshop is intended as an introduction to materials and processes related to the production of parts made of composite materials. The workshop will have an emphasis on parts for aerospace applications, but will briefly cover some non-aerospace applications as well. The workshop will walk the audience through the major materials utilized – how they are made and used, primarily focusing on carbon fiber-based materials. We will cover the processes for fabrication of parts. Key parts of this presentation include:
- Basic concepts related to composites
- Materials used – production, consumables and tooling
- Looks at various types of typical Tooling & Equipment used, including automated layup
- Various fabrication processes, including autoclave-based, Out-of-Autoclave-based, or stand-alone cures
- Processes for thermoset resin systems
- Processes for thermoplastic resin systems
- Ply Prep, Layup, Bagging, Cure, Trim, NDI and a brief look at Assembly
- How all this goes together to make parts
- Understand the types of composite materials used in composites processing.
- Understand the differences between prepreg processing, infusion processes and thermoplastic processes.
- Understand the consumable materials used in the various methods of composites processing.
- Understand the various layup, cure and trim methods used and the types of equipment used.
- Understand the typical sequence of operations for making various types of composite parts.
Tooling for Composites Manufacturing
9:00 AM-12:00 PM
Louis C. Dorworth
Abaris Training Resources, Inc.
Louis C (Lou) Dorworth has been involved with the advanced composites industry since 1978. He has been associated with Abaris since its inception in 1983 and has been employed by Abaris Training Resources, Inc. since 1989, where he currently manages the Direct Services Division.
Lou is a composite materials and process specialist, with experience in research and development (R&D), material and process (M&P) engineering, manufacturing engineering, tool engineering/design, and tool fabrication.
Lou has been a senior member of SME since 1997, where he is currently the chair of the Plastics, Composites, and Coatings Community (PCC) and has been a professional member of the Society for the Advancement of Material & Process Engineering (SAMPE) since 1982.
Lou is a well-published author and conference presenter and is a co-author of the popular textbook titled “Essentials of Advanced Composite Fabrication & Repair,” published by Aviation Supplies & Academics, Inc. (ASA). ISBN 978-1-56027-752-1.
An overview of industry recognized tooling practices, this workshop will explore materials, processes, unique molding systems, and fundamental design ideas for producing quality molds, mandrels, and fixtures used to manufacture composite components and structures. During the course of the seminar, we will investigate both legacy and modern tooling systems and applications. This session is designed to be audience-interactive, allowing attendees to ask questions and discuss ideas during the course of the presentation.
Students Will Learn About:
- Common Types of Tools and Functions
- Tooling Materials and Properties
- Tool Design Standards & Fabrication Methods
Benefits of Attending:
- Knowledge of the latest in tooling trends and material options.
- Interaction with the presenter and other audience members about specific tooling challenges.
- Networking opportunities with other like-minded attendees.
- Overview of Tool Types & Function
- Tools necessary to tool fabrication (digital and physical models and patterns)
- Tools necessary for component manufacturing (molds/jigs/fixtures)
- Tooling Materials
- Model materials
- Conventional block materials
- Carbon foam block
- CFRP laminate, and HexTool™ forms
- Invar-faced CFRP laminates
- Epoxy, BMI, and Benzoxazine matrices
- Nano-silica filled prepreg
- Fluoroelastomers- cauls
- Silicone bags and mandrels
- Latex inflatable bladders
- Model materials
- Chemically bonded ceramics
- Freeze-cast ceramics
- Wash-out ceramics
- Monolithic graphite
- Tool Design Criteria
- Based on component material and process selection
- Metal Vs Composite tools
- Thermal profiles
- Substructure design
- Tool laminate design standards
- Tool Fabrication Methods and Techniques
- From machined master models
- Directly machined from CAD/CAM files
- 3D printing/laser sintering
FUNDAMENTALS OF ADDITIVE MANUFACTURING FOR AEROSPACE
1:00 PM-4:00 PM
Additive Manufacturing Principal Investigator
Lockheed Martin Missiles and Fire Control
Thomas Hiromoto is an Additive Manufacturing (AM) research principle investigator at Lockheed Martin Missiles and Fire Control, located in Dallas, TX. Mr. Hiromoto has worked in the Aerospace/Defense industry since 2002 with mechanical design experience in missiles, sensor platforms, intelligent microgrids, and military ground vehicles. His current responsibilities are focused on AM and other advanced manufacturing technologies.
Mr. Hiromoto has also been involved in two America Makes, National Additive Manufacturing Innovation Institute (NAMII) projects related to the design and fabrication of multi-functional AM structures (combination of mechanical and electrical systems) and design-for-AM strategies.
This workshop will begin with background information on Additive Manufacturing (AM) including its benefits and challenges, the different polymer and metal AM processes including discussion of the characteristics of the equipment, the materials available for each process, and historical applications. Next will be a review of current applications for AM in the aerospace industry. The workshop will then move to a discussion of emerging applications in aerospace ranging from smaller complex structures to large primary metallic structures. The workshop will conclude with a view of future needs for high-performance aerospace applications including: closed-loop process control, standards/specifications for feedstock materials and AM processes, requirements for the digital thread and supply chain, and finally improved non-destructive testing techniques.
ASSEMBLY & JOINING OF COMPOSITE MATERIALS
1:00 PM-4:00 PM
George N. Bullen, CPIM
President & CEO
Smart Blades, Inc.
George N. Bullen is an internationally recognized expert and consultant to industry for the manufacture of fixed and rotary wing air vehicles, rockets, missiles, and space vehicles. His expertise includes inhabited and uninhabited aerial vehicles, space vehicle design and manufacture, laser weapon system design and manufacture, and lean processes and applications. He has been awarded 16 US and international patents for technology innovations related to manufacturing, mechanization, robotics, robotics control software, and nuclear testing/quality devices, which are the basis for all current automated systems for the assembly of airframes in the United States and Europe.
A Fellow of the Society of Manufacturing Engineers (FSME) and certified in production and inventory control management (CPIM), George Bullen has an MBA from Loyola Marymount University and a BSMG degree from Pepperdine University. He maintains membership on the academic boards of major universities and is a member of the steering committees of professional societies. George is founder of the International Aerospace Automation Consortium and cofounder of the international Economics of Composites Symposium. He is widely published in magazines, conference proceedings, and peer-review journals. In 2014, he received SAE International’s Forest McFarland Award, and in 2000 the American Institute of Aeronautics and Astronautics (AIAA) Design Engineering Award for significant advances in aerospace engineering.
Mr. Bullen retired as principal engineer and Technical Fellow from Northrop Grumman Corporation at the end of 2010.
This workshop will address the challenges related to the assembly of composite structure and cover a broad spectrum of factors across a range of disciplines – design, manufacturing, quality and logistics. Within these disciplines, there are many elements that affect the cost and the time required to assemble composite parts and components into subassemblies and assemblies. In this workshop these factors will be addressed and their impact on fabrication and assembly cost and schedule discussed in more detail. The context of the workshop is focused on aircraft structure, but many of the principles and ideas apply to structures in marine, transportation, energy and other industrial sectors.
The workshop discussion will revolve around three basic topics:
- Weight savings
- Part count reduction
- Design for manufacturing and assembly (DFMA)
There is a great deal of interrelationship between these topics and the usual set of trade-offs and compromises that are needed to develop the right balance to meet economic and performance objectives. Weight optimization often leads to increased design complexity and more difficult manufacturing. Part count reduction can provide weight savings and assembly savings, but increased detailed part manufacturing complexity. The trade-offs require a systems level perspective to achieve the best overall approach. The argument will be made that it all falls under the umbrella of DFMA.