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Winners of 2017 ICERP-JEC Innovation Awards

News International-French

11 Jan 2017

ICERP is one of the most important events of the Indian composites industry organized by FRP Institute once in two years and it is one of the biggest events on composites in India and Asia.To encourage the innovations carried in the field of composites in India an innovation award programme was initiated in 2008 by FRP Institute and JEC group.

2017 ICERP-JEC Innovation Awards

The Innovation Award Program encourages the Indian composite professionals and companies to focus their application of information, imagination, skill and initiative through which new ideas and processes are generated and converted into useful composite products or processes. This Innovation Award Programme gives the Indian composites professionals and companies great scope to create value to their customers and also brings recognition, not only in India but also internationally.

FRP Institute (India) and JEC Group (France) decided to further widen the scope of the program with special emphasis on India. This program has been created to achieve the following:

  • Discover, promote, and reward the most innovative composite products and solutions made in India,
  • Encourage and enhance the visibility of Indian composites companies and their partners involved in innovative composites developments
  • Contribute to composite industry advancement.

BIOCOMPOSITES: Jute/coir biodegradable pultruded “green composite” - Hindoostan Composite Solutions part of Hindoostan Mills

Jute/coir biodegradable pultruded “green composite” - Hindoostan Composite
Hindoostan Mills has developed a new composite product using natural fibers like jute and coir. The development of natural fibers composites is emerging as long term sustainable growth. The recycling properties, bio-degradability and natural availability are advantageous for being environment friendly nature.

Based on high performance requirements, two types of prepregs were designed for defense
1. Jute Pultruded Composite: This is specially developed composite in continuous Unidirectional fibers/epoxy composite form as well as balanced, woven fabric/epoxy composite form.
2. Coir Pultruded Composite: This is specially developed composite in continuous Uni directional fibers/epoxy composite form. 

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INTERMEDIATE PRODUCTS: High performance prepregs based on quartz reinforcements and solventless cyanate ester matrix resins and cyanate ester base resin film adhesive  - Hindoostan Composite Solutions part of Hindoostan Mills

Indigenous development of high performance prepregs base on quartz reinforcements and in-house formulated solventless cyanate ester matrix resins and cyanate ester base resin film adhesive  - Hindoostan Composite Solutions part of Hindoostan Mills Ltd.
Hindoostan Composite Solutions has developed cyanate ester formulations and processing of the solvent less formulated resin with quartz fabric for prepreg, also in the form of adhesive film to manufacture indigenous composite parts. The materials offered to Aeronautical Development Establishment (ADE) for testing and composite part fabrication. Hindoostan Innovation Centre has developed a technology known to very few companies in the world and often their products are not available in India due to end use licensing denials by respective Governments of foreign establishments. This innovation helps country to have strategic material for aerospace and defense application. 

ADE evaluated thermal, mechanical and electrical characterization of cyanate ester resin film as well as cyanate ester/ quarts prepregs developed by Hindoostan Mills. ADE has intention to indigenize strategic aerospace grade composite intermediates using their composite development and characterization expertise. 

A prepreg is a fiber reinforcement that is pre-impregnated with a resin matrix Hindoostan Mills has developed an advanced cyanate ester/quartz prepreg and cyanate ester resin adhesive film for defense. The development includes identification of process parameters and their resultant parameters such as cure cycle, b-staging, resin flow during cure, tackiness, material properties and storage life.

Based on the performance requirements and application two products were designed for ADE:

1. Hinpreg HQS286-CEA0020-38 : 
A high performance cyanate ester prepreg with quartz fabric of balanced woven quartz fabric of 290 gm per sqm areal weight and 28% of wt of resin matrix. It is an advanced cyanate-ester prepreg developed to enable economic manufacturing of various high performance composite applications. It has a versatile curing cycle, from 100°C to as high as 180°C It is been specially formulated to achieve excellent through-cure and mechanical performance. 

2. Hinfilm TCEGF 200160 : 
It a specially designed advanced Cyanate Ester resin system film adhesive developed for bonding high performance composite materials, the substrates like honeycomb, foams, metals, and ceramic are can be bonded with excellent adhesion. It is been specially formulated to achieve goodthrough-cure, and enhanced for adhesive bonding applications. It has high fracture toughness and high shear strength. The material can preferred to produce a wide range of composites from small components to large structures of excellent quality and performance.

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EQUIPMENT: Pultrusion machine with 4 grippers - Ashirvad Industries​

Pultrusion machine with 4 grippers - Ashirvad Industries

Machine characteristics:

  • 10, 12 & 16 ton pulling capacity
  • 4 individual gripper in each reciprocating hydraulic pullers, with extended puller width to 1200 & 1400MM
  • allows using machine for 4 different profiles, with different width, height and configuration, with same machine installation space, power requirement and men power engagement
  • selective operation [on/off] for all 4 grippers during production by easy action at operating panel buttons
  • single operator will able to handle all profiles under pulling process
  • reduced installation space, power demand, men power engagement and initial project cost by avoiding investment in multiple machines
  • flexibility if producing different size of profiles at very low auxiliary requirement, and minimum product change over time during production, saves downtime cost as well as increase productivity.

If a beginner customer have this machine, he can capture and handle orders of different profile size without clamping adjustments complexity. There is no need to stop entire production of other profiles, if any one profile required to be changed or attained due to any production interruption, resulting increased ultimate productivity. Benefit of single larger profile is also covered, by simultaneous actuation of all 4 gripers in case of requirement.

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MEDICAL: Carbon fiber sheets, plate and components with high radio transparency - Adorn Engineers

 Carbon fiber sheets, plate and components with high radio transparency - Adorn Engineers
Manufacturing carbon fiber sheets and various carbon composite custom parts. The company standard product range are made from carbon fiber (3k to 48K) with high performance resin system to meet customer’s demand.  

In medical field by using carbon fiber plate / sheet / components it gives accurate result and treatment due to its radiology higher transparency, as well as its very easy to operate. 
Adorn Engineer developed carbon fiber sheet within 2 year and now they are manufacturing and supplying their products across India since 1 year with exponential growth.

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MARINE: Hull & deck single shot resin infusion process with stiffeners - Diab and Aquarius Shipyard

Hull & deck single shot resin infusion process with stiffeners - Diab and Aquarius Shipyard
The companies developed a single shot infusion process with stiffeners for the first boat completely infused in India. 
Benefits of this process are:
  • all type of boats is infused using core infusion process
  • customer is getting a lot of government orders by using core infusion process
  • production of larger components
  • ultra-low VOC emissions
  • faster mold cycle times
  • high fiber fractions
  • weight savings
  • consistent & repeatable components
  • good skin/core bonding

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AEROSPACE: Reflector antennas made with aluminum lined carbon fiber composite for satellite applications - Space Applications Centre ISRO

 Reflector antennas made with aluminum lined carbon fiber composite for satellite applications - Space Applications Centre ISRO
Space Applications Centre is responsible for the delivery of various payloads that fit in to the satellites. In order to have better structural efficiency, CFRP as a structure material usage is envisaged for the payloads hardware. 

Spacecraft programme of ISRO is based on a 3 axis body stabilized geostationary satellite based on ISRO’s I-3K structure which will provide communication services. GSAT-19 spacecraft will be located at 48⁰E. For the transmission and reception of Ku-band uplink and downlink signals, two numbers of high gain transmit/receive deployable reflector antennas of 2.0m diameter, shall be used with four feeds per reflector. Each reflector shall cater to four beams. 

Considering the advantages of high specific strength, high specific stiffness & low CTE carbon fibers and advancements in fabrication technology for realization of thinner metallic liners, a development programme has been undertaken by the Mechanical Engineering Systems Area (MESA) of Space Applications Centre to realize state-of-the-art Aluminum Lined Carbon Fiber Reinforcement Plastic (CFRP) feeds as well as CFRP chopped fibers filters for Satellite applications. The design approach and qualification aspects are described in this paper. 

The use of composite materials in this application allows weight savings by at least 30 percent and increases in-mission life.

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A micro turbine for use near residential areas - Moldex Composites
This project was developed for Anakata of Oxford, UK. Their objective for this product was to develop a micro turbine for use near residential areas. The blade design concentrating therefore on noise reduction as well as improved efficiencies for a wind turbine system of this size.

Process: hand laminated carbon and glass fibre epoxy / prepreg. A mix of unidirectional carbon, lightweight carbon fabric (120 gsm) standard carbon fabric (200 gsm) and mid weight glass fabric. Made in two halves and bonded together in a jig.

Anakata developed the blade profile in CAD and some use of CFD (Computational Fluid Dynamics). Initial prototypes for testing at their in-house wind tunnel facility made from 3D printed and resin models. Not really representative but helped to indicate development was in the right direction. The blade has a curved end for improved efficiency and noise reduction and very fine trailing edge details. The trailing edge being “wavy” and only 0.5mm thickness. On the outboard leading edge is a very fine detail, a raised zig zag, whose purpose is to “trip” the air again for efficiency and noise reduction. 

Production has now reached into 3 figures and are installed in many sites. Particularly in South Korea from where the enquiry had come from to Anakata.

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INDUSTRIAL: A composite material made by selective prepregging & compressed molding process for cryogenic applications - Permali Wallace

A composite material made by selective prepregging & compressed molding process for cryogenic applications - Permali Wallace
Permaglass PG-22 CPG grade composite material has been produced for cryogenic applications by selective prepregging & compressed molding process. The raw materials used are suitable for the said application at a temperature gradient of -196°C to +155°C. The special features of this product are that the composite is easily machine able to the desired composite design from small to large parts used for critical applications by few customers. The material is having high mechanical strength with combination of electrical Insulation properties. The product is additionally fire retardant having low thermal insulation & low conductivity. 

It is a light weight material capable of replacing a very heavy part providing for both the thermal insulation as well as mechanical requirements as well as catering to high operating range thus can cover applications both for low temperatures applications as well as in high temperature. 

The company currently supplied parts made of the same material to a German customer in 2 pcs. with each part weighing approximately 420 Kgs. – total weight of almost 840 Kgs. The same part in any other material would have weighed much more. 

The laminates for these have already been developed and have been accepted by the customer. The sheets can be made in varying thickness and customized to specific design of the customer. 

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DEFENSE: A sonar dome made with glass fiber composite by VARTM process - Kineco

A sonar dome made with glass fiber composite by VARTM process - Kineco
India’s first indigenous developed bow mounted sonar dome flagged off by defence minister during DefExpo 2016 at Goa.

Manufacturing of sonar dome involves state of art technology for realization. The first challenge was manufacturing precise and accurate FRP tooling suitable for the process of VARTM. The sonar dome has been developed using high end glass reinforcements & resin systems by VARTM process, assisted by advanced process control technology. State of art equipments specially designed for manufacturing large and complicated composite parts have been used to produce sonar dome of 10.5 meters length, 3.5 meters height, and 3.0 meters width as a single component without any joinery.

Design & analysis, involves critical acoustic and structural 2017 considerations to meet the acoustic transparency and very high rough sea state conditions and hydrodynamic forces.

Sonar dome has been proven for its structural strength by FE analysis and tested to full size for acoustic transparency for the first time in India. The Sonar dome is finally supplied with drilled flanges suitable for mounting to ship hull along with specially engineered installation fixtures.

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E-MOBILITY: An electric trycycle with whole body in composites - Triovision

Indian Market has seen tremendous growth in renewable energy over the past few years as everyone is trying to move into green energy but not much focus was considered in the automotive segment. Electric vehicles are becoming popular these days because of the advantages in fuel costs and increase in pollution especially in city traffic where the vehicle stopped continuously. To address these, a tricycle electric vehicle car is designed and the body is made in composites with the advantages of light weight, class A finish, weather resistance, fire and smoke retardancy and better strength. It is one of the first electric vehicle tricycle to be soon introduced into Indian Market made out of composites. 

The car is a 3 seater vehicle which comes under L2E segment. It is fully automatic and totally enclosed to cater to the city pollution and traffic issues. The body is in composites to be produced in Resin Transfer Molding. The car can reach upto a peak speed of 45 kmph. The car also can maneuver easily and can be parked at ease. One charge of 2.5 hours can get a ride upto 120 km. It has also got some unique features which are to be revealed on the launch date. 

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