WEIR MINERALS AND THE CHALLENGES OF COMPOSITES IN THE AUSTRALIAN MINING INDUSTRY

Presented by David Busby-Wright, Senior Designer, Australian Engineering, Weir Minerals

Weir Minerals is one of the world’s leading engineering businesses providing innovative solutions for the mining industry. It has a number of manufacturing bases in Australia, the largest of which is located in Sydney, and is an OEM for industrial equipment. Weir is responsible for some 20 brand names of equipment and has around 20 engineering departments, of which four are based in Australia.

David will give an introduction to the Weir Group before discussing the use of fibre reinforced composites in their product portfolio. There will also be a focus on some of the supply chain challenges within the Australian domestic market.

David has had a diverse career spanning a number of industries including Formula one, defence and the mining industry.

COMPOSITE ENGINEERING AND OPTIMISATION – PUSHING THE BOUNDARIES OF UNLIMITED 2.0

Presented by James Ledingham, Gurit Design Engineer – GURIT Pty Ltd

Western Sydney University approached Gurit in 2017 for help in designing “Unlimited 2.0”, their single-seat solar vehicle, for entry into the 2017 Bridgestone World Solar Challenge – the nine day 2,800 kilometre race that ran across four states, from Nebraska to Oregon.

Going on to be the first international and first Australia solar car to win the 2018 American Solar Challenge, James will outline how the Gurit team used design and simulation software along with their expertise in composite engineering and materials to optimise the vehicle’s chassis and roll hoop. Ultimately the chassis weighed close to half that of the previous generation car; it was light, efficient, safe, regulatory-compliant, aerodynamic and capable of handling the racing conditions without a single composite failure.

With more than 30 years of experience in supplying engineering services and materials for the analysis and manufacture of composite structures, Gurit Composite Engineering are uniquely positioned to deliver composite solutions.

CRACKING THE CARBON CODE FOR AUSTRALIAN MANUFACTURERS

Presented by Drs Jasjeet Kaur, Research Scientist and Shaun Smith, Research Group Leader | Fibre Innovation & Composites, Manufacturing, CSIRO

Drs Jasjeet and Shaun will outline how CSIRO is investing its own money to change the carbon fibre paradigm – a market which has been dominated by a few major carbon fibre manufacturers and which has traditionally been cost prohibitive for smaller or innovative composite companies.

They will outline how the CSIRO research team has re-invented the conventional production model whereby the raw material, polyacrylonitrile (PAN) fibre, accounts for ~50% of the carbon fibre production cost, while determining ~80% of the final properties by using Reverse Addition Fragmentation Chain Transfer (RAFT) polymerisation technology. All of which leads to better quality PAN fibres with higher strength and stiffness than comparable grades currently available. This superior performance can allow composite manufacturers to use less carbon fibres in their components,  thereby improving processing, weight and cost in their final products.

STARTING-UP AND COMMERCIALISING TECHNOLOGY FOR A LIGHTER, HIGHER-PERFORMING BALLISTIC HELMET

Presented by Tristan Alexander, the CEO of the Smart Think

Through the Smart Think, one of Australia’s most promising start-ups, forming technology that was developed through the Defence Materials Technology Centre (DMTC) has been commercialised to producelighter, safer and higher-performing ballistic helmets for the global defence market. Tristan will outline the development path for the game changing”Double Diaphragm Deep Drawing” (D4)technology that converts a 2-dimensional stack of composite material into a curved 3-dimensional object in a single step, thereby removing the need for the traditional splicing of materialsand ultimately reducing the weight of the helmet. His presentation will also include an account of the task faced by his fledgling company to commercialise technology through enabling partnerships and traditional supply chains.

NAVIGATING THE WATERS OF AUSTRALIAN PROCUREMENT PRACTICES

Presented by Tony Caristo, Managing Director RPC Technologies

For the past few years, the word “collaboration” has become a term, now indispensable in the lexicon of government and academic messaging as a prerequisite to technical step change and supplying large projects. Whilst shared knowledge, value creation and successful global partnerships are formed from an alignment of commercial interests and mutual goals, the journey is not for the faint hearted. Tony will share his views on the opportunities for supplying large contracts through collaboration and partnerships as well as the key areas where assistance from government and procurement agencies could exponentially advance Australian industry.

MATERIAL CHOICES FOR PURPOSE BUILT SUBSEA SOLUTIONS

Presented by David Inggall, Founder of DIDesign. DIDesign is a pioneer of a new generation of subsea inspection and intervention remotely operated underwater vehicles (ROV)

David’s made to measure mini workhorses are an effective cost reduction strategy and also a safety solution for his oil and gas clients. David will outline how this new exciting horizon is using composites and also carbon fibre-reinforced 3D components.

THE OMNI TANKER JOURNEY

Presented by Dr Daniel Rodgers, Managing Director and Dr Luke Djukic, Chief Technical Officer for Omni Tanker

Manufactured using carbon fibre composites with a seamless interior of polyethylene thermoplastic, the lightweight tanker has a high degree of chemical resistance suitable for a wide range of liquid cargoes. The interior has food grade compatibility and is also approved for the transport of Dangerous Goods including Class 8 corrosive liquids. Daniel and Luke will outline the challenging journey to commercialise a product designed, engineered and made in NSW for selling to offshore markets.

COMMERCIALISING THE AWARD WINNING OCIUS BLUEBOTTLE – THE UNIQUE UNMANNED SURFACE VESSEL DEVELOPED FOR WIDE AREA OCEAN SURVEILLANCE

Presented by Alan Steber, General Manager for Steber International and Robert Dane, Founder of Ocius

The highly innovative Bluebottle unmanned surface vessel project is a collaboration between Ocius Technology and Steber International with the drones featuring rigid FRP opening sails and hybrid marine power technology. This joint presentation will profile how collaboration can bring a unique product to market.

BUILDING SUSTAINABLE INFRASTRUCTURE IN A CORROSIVE ENVIRONMENT WITH COMPOSITE TECHNOLOGIES

Presented by Mr Michael Kemp, General Manager – Engineering, Wagners CFT Manufacturing Pty Ltd

Michael will present on Wagner’s recent completion of rebuilding the wharf at Pinkenba. A project that included engineering, manufacturing and installing a whole deck made from FRP deck units, topped with concrete reinforced with FRP rebar.

COMPOSITES VESSELS SOLVING STORAGE SOLUTION IN THE CORROSIVE ENVIRONMENTS OF CHEMICAL AND MINING PLANTS

Presented by Dr Lucy Cranitch, Materials Scientist and Director of PATH

Lucy will present on a number of projects including the materials selection for a hot acid process tank made from composites and lined with PVDF, the installation of a large diameter pressure pipeline delivering irrigation water and the repair of a gas cooling tower.

FROM IDEA TO REALITY – DESIGNING AND BUILDING A UNIQUE MANNED VTOL AIRCRAFT

Presented by Rodney Thomson, Engineering Manager, ACS Australia

How do you go about designing an aircraft like no other? Using a combination of existing customer designs and completely novel ideas, the team at ACS Australia developed an innovative concept for the key structural components of a single person vertical take-off and landing aircraft for Martin Jetpack. Rodney will describe the approaches used to design the carbon fibre composite airframe, landing gear and ducts to meet the challenging requirements, including mass, operational and crashworthiness. Lessons learnt during the design, manufacture, assembly, integration and testing phases of the project will be shared.

COST EFFECTIVE REPAIR OF COMPOSITE COMPONENTS

Presented by David Dr Rik Heslehurst, PhD, CPEng, FIEAust, FRAeS, FSAMPE, Composites Australia (Hon), XTEK Ltd., Canberra, ACT

Dr Rik will outline how a mid-sized company based in Canberra has changed the paradigm of the lengthy and costly solution of sending damaged composite components back to offshore OEM’s for repair or replacement. He will demonstrate how the company built a practical repair facility for small air vehicles with a cost-effective budget that in a short period is saving the Australian Government approx. $500,000 p.a.- with further savings on the horizon. His presentation will show not only how costs have reduced also how repair times were improved from 15-20 weeks to less than 2 weeks. He will also discuss the business model and highlight the importance of recruiting the right people by effectively using the Composites Australia family network.

PARTNERING WITH AN ARC CENTRE FOR COST EFFECTIVE INDUSTRIAL PROBLEM SOLVING BY INVESTIGATION

Presented by Donavan Marney, Centre Manager, ARC Training Centre for the Chemical Industries, University of NSW

Ever had industrial/production challenge that you know will be costly and time consuming to analyse, investigate and solve? Or a strategic development project that requires time to explore for lift-off? Donavan will outline how the UNSW Australian Research Council Centre is redefining the relationship between Universities and industry by releasing graduates for 12-24 months into industry at a cost-effective rate. These graduates will participate in additional training around Lab, Business and OHS&E to suit the placement. He will outline how projects are supported by an academic but led and directed by participating companies that now have more control of the developed IP and full access to university laboratory, analytical and characterisation infrastructure.

AUDACIOUSLY RETHINKING FUNCTIONAL USES FOR CARBON FIBRE

Presented by David Geoff Germon, Founder and Chief Industrial Designer for Talon Technology

Geoff will discuss how the use of new materials and processes in the manufacture of traditional products will open up opportunities for aesthetically elegant, innovative products with greater functionality. Particularly, he will discuss the logic behind his two recent additions to his considerable portfolio of multi-award winning products – a carbon fibre tap and eyewear frames – both of which are consumer products with the promise of considerable production volumes.

LIVE DEMONSTRATION: ALAN HARPER COMPOSITES LTD – REUSABLE VACUUM MEMBRANE TECHNOLOGY

Presented by Blaise Visconti, Applications Specialist, Alan Harper Composites together
with Martin Nikolas, Managing Director of Marky Industries

Composite infusion and prepreg moulding single-use plastic has now been superseded by reusable vacuum membrane technology. The Alan Harper system uses resin morphing runners – which leave no trace and need no peel ply – combined with moulded in-flow mesh. Put simply, the reusable membrane system cuts down on wastage, time and costs. Delegates will have a unique opportunity to see for themselves how they can create production efficiencies, save money and save the planet.

PRODUCT PITCH: AWARD WINNING GURIT® AMPREG™ 3X RANGE, SAFEGUARDING WORKERS’ HEALTH AND SAFETY

Presented by Gerard Laffan, Gurit

Gurit has launched Ampreg™ 3X Series, a new range of wet laminating systems for the manufacture of large composite structures in the marine, wind and construction industries. The award winning Ampreg™ 3X Series laminating system has been reformulated to prioritise user health and safety through careful selection of base chemicals. The new low toxicity resin matrix is CMR, SVHC and AEP free* and the hardeners are classified as environmentally non-hazardous.

Ampreg™ 30 is also available with LRT (Light Reflective Technology) as standard. This addition to the resin matrix causes the resin or mixed system to fluoresce under UV light without changing the mixing properties of the laminating system of cured resin performance. LRT enables easy inspection of surfaces, equipment, clothing and skin. Resin contamination can be easily detected, ensuring minimum exposure for workers and helping to avoid transfer of resin outside the workshop.

PRODUCT PITCH: POTTERS Q-CEL HOLLOW GLASS MICROSPHERES

Presented by Dr Max Dehghan, Technical Rep at Potters Asia Pacific

Potters is the world leading manufacturer of Hollow Glass Microspheres as fillers for polymers and composite materials. The main features of Potters Hollow Microspheres, “Q-cel”, include extremely light weight, miniature size, ball bearing effect, high thermal stability and chemical resistance, environmentally friendly and recyclable.

Potters Q-cel is incorporated in thermosetting resins and composite materials to produce lightweight FRP parts, improve processability (sanding, cutting, drilling) of the cured product, and to improve weatherability, UV resistance and thermal and noise insulation properties of FRP products, paints and coatings.

PRODUCT PITCH: ADHESIVES IN THE RESIN TRANSFER MOULDING (RTM) PROCESS

Presented by Matthew Spandow, Director at Quin Global Asia Pacific

Quin Global is an Australian family owned adhesive manufacturer located in Canberra and is the sole manufacturer of canister adhesives in the Asia Pacific. Research and development are at the forefront of their business with laboratory teams dedicated to adhesive innovation.

Recently Quin Global entered the composite industry with an adhesive range. In this demonstration Matthew will discuss the effects adhesive have on the RTM process and the best adhesive practice for epoxy resins.

PRODUCT PITCH: BEST PRACTICES & CASE STUDIES IN ACCURATELY SIMULATING THE PERFORMANCE AND MANUFACTURABILITY OF COMPOSITE STRUCTURES

Presented by Das Supratik, Engineering Solution Manager, LEAP Australia

Whilst composite structures do pose modelling and manufacturing challenges due the nature of the materials, with the right simulation tools you can accurately account for important material properties of the composite and confidently predict product structural performance & reliability, analyse potential failure mechanisms & optimise your construction techniques – all prior to any physical prototypes being built. This session will introduce best practice modelling techniques using ANSYS Composite PrePost, plus discuss interesting case studies from different industries.

PRODUCT PITCH: CLOSED MOULDING REUSABLE VACUUM MEMBRANE

Presented by Blaise Visconti, Applications Specialist,  with Marky Industries

Composite infusion and prepreg moulding single-use plastic has now been superseded by reusable vacuum membrane technology. The Alan Harper system uses resin morphing runners – which leave no trace and need no peel ply – combined with moulded in-flow mesh. Put simply, the reusable membrane system cuts down on wastage, time and costs.

Delegates will have a unique opportunity to see for themselves how they can create production efficiencies, save money and save the planet.

PRODUCT PITCH: AUSTRALIAN MADE AUTOMATIC CNC CUTTING MACHINES FOR THE COMPOSITES AND TECHNICAL TEXTILES INDUSTRIES

Presented by Wayne Walker, Business Development Manager North America, Pathfinder

Pathfinder is Australian designer, manufacturer and exporter of advanced CNC Cutting Room Technologies, with conveyorised cutting machines that enable the flexibility to cut; Single Ply, Low Ply and High Ply materials at speeds and accuracy unmatched by many.

Solutions include; PathWorks CAD and Nesting software to optimise material yields, Photo Digitising, Easy Loader & Easy Feeder material feeding solutions designed for efficient materials handling with minimal labour input.

PRODUCT PITCH: ADHESIVES FOR THE COMPOSITE INDUSTRY

Presented by Jason Dickens, National Sales Manager, 3M Industrial Adhesives and Tapes Division

3M designs, manufactures and markets a broad range of structural adhesives, contact adhesives and adhesive tapes.

Recently they launched several new products for the composites industry. Jason Dickens from 3M will discuss the new products in the light of prevalent challenges in manufacturing assembly and RTM process within the composites industry.

PRODUCT PITCH: HOW WILL GRAPHENE MATERIALS HELP YOUR BUSINESS?

Presented by Neil Armstrong, Applications Engineer, First Graphene Ltd

Graphene additives have promised improved performance and reduced cost in composite systems. Until now, adoption has been slow due to poorly performing materials and the need for difficult mixing strategies. This is changing and the change is being led by an innovative material company, First Graphene Ltd. based here in Australia. Please join us to hear some real world examples of graphene adoption in the rubber and composites industry.