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Winners of 2019 ICERP-JEC Innovation Awards

News International-French

11 Jan 2019

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.

Winners of 2019 ICERP-JEC Innovation Awards

Winners of 2019 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.
     

RAW MATERIAL: Development of Hotmelt Epoxy/Carbon prepreg curable at 175 C
 

Development of Hotmelt Epoxy/Carbon prepreg curable at 175 C – A step forward for availability of Indigenous Aerospace prepreg
BHOR has developed and established commercial hotmelt epoxy/ cyanate ester/ benzoxazine resin prepreg technology where carbon, aramid and glass fiber unidirectional spread tows or woven fabrics can be impregnated. The commercial prepreg need resin formulations where 100-130 Tg is sufficient for most of the applications whereas aerospace industry demand high Tg and high temperature curable systems.
 

This innovation outlines properties of hotmelt epoxy formulations, where the prepreg can be cured at 175 C and a Tg in the range of 165 to 190 C can be achieved.


More information: www.bhor.com

 

AERONAUTICS: Integration of conductive current carrying elements into structural composite parts of the aircraft for power transmission.

Integration of conductive current carrying elements into structural composite parts of the aircraft for power transmission.

The composite innovation involves integrating conductive current carrying elements (alternating and direct current) into structural composite parts of the aircraft for power transmission. It involves Structure – System integration, where the part performs the multifunctional role of load bearing structure and electrics, enabling multi-ATA integration.
 
The innovation is a novel method of integrating / embedding laser cut electrical grade Cu circuits that undergo specific surface treatment to increase adhesion. These Cu circuits are then placed into the Carbon Fiber Reinforced Plastic (CFRP) mould as a part of the composite layup. The entire setup is bagged under vacuum and co-cured in the autoclave to form the final part with integrated electrics.

More information: www.airbus.com - www.tamlindia.com - www.india.ul.com


AUTOMOTIVE - Intake plenum chamber for V6 engine

Moldex has develop a new tooling design and manufacture along with the calculation of laminates. In addition the project was run on a very tight schedule, the component went from CAD to prototype in just 4 weeks.

Intake plenum chamber for V6 engine
With this innovation, existing aluminum Intake plenum chambers can be replaced with the carbon fibre plenums.
Key advantages are:
> Composites tooling costs significantly less than that for the casting.
> 50% mass reduction over the aluminium
> no limit wall thickness (where the casting has a minimum all over thickness)


More information: www.moldexcomposites.com
 

UNMANNED AERIAL VEHICLE - Propeller blade

UAV Propeller blade
The base profile for the blade was supplied to Moldex Composites and then they completed the detailed design of the assembly. The aluminium insert and the composite blade were analysed using finite element techniques and the specific materials and lay-ups chosen.

The keys benefits of this innovation are:
> Composites blade was made in single curing, reducing the manufacturing time.
> Foam core material was used, which helps in mass reduction.

More information: www.moldexcomposites.com
 

WIND ENERGY - Single stage infusion process for multiple cross rib stiffeners on nacelle top cover

Single stage infusion process for multiple cross rib stiffeners on nacelle top cover
Problem Statement: Optimized nacelle top cover design has multiple cross ribs, it has to be either bonded or laminated after nacelle shell moulding as standard post moulding operation, which increased production time by 8 hours.
Solution: A strategic decision made to infuse cross ribs in single stage moulding process with specific resin viscosity, multiple bent runner, controlled resin flow rate, followed by pre & post curing.


Key Benefit:
> Process Time Reduction by 8 hours
> 32 man-hours saved
> Manual error reduced by 80%

More information: www.suzlon.com
 

3D PRINTING - 3D Printing Continuous Fiber Reinforced parts

3D Printing Continuous Fiber Reinforced parts
Fabheads innovation provides innovative new methods of fabricating fibre reinforced composite parts via their automated and hybrid solutions.
> Compared to typical 3D printed parts, the parts made using Fabheads’ machines by way of selective continuous fibre reinforcement are much stronger and are less brittle.
> The machine can be used to replace common fabrication process of typical fibre reinforced composite parts too. It allows to make parts without any use of mold, thereby reducing costs and time greatly. Even sandwich structures, with traditionally take multiple steps to fabricate, can be created in one shot using the new process.

The essence of the offering here is being able to make composite parts in a fast and inexpensive manner even without the need of a mold, thereby enabling rapid fabrication of fiber reinforced composite parts.
 

More information: www.fabheads.in
 


CONSTRUCTION - Expanded Poly-Styrene for FRP sandwich application

Expanded Poly-Styrene for FRP sandwich application

There are situations when a FRP sandwich structure using PU foam is not viable due to its high cost. However, the use of Expanded Poly-styrene is not possible when styrene is used as the monomer in Unsaturated polyester resin. EPS would normally dissolve in styrene.

The resin developed is styrene free and can be used for FRP fabrication. With the development of this resin C’POL-8531 it is now possible to manufacture sandwiched FRP panel using Expanded Poly-styrene. These would find ready application insulation panels for Building and Construction, marine application and any other application where styrene cannot be used.

It is a special resin that could find application in niche areas of construction and building, marine, enabling the use of FRP sandwich panel using EPS.


More information: www.crestcomposites.com
 

 

ELECTRIC VEHICLE - 3-Wheel electric Auto with charging station

 

Innovative 3-Wheel Electric Auto with Charging Station
The future of transportation is all set to be green, which means there are various possibilities to look in for alternatives than the traditional gasoline vehicles. There is also challenge to make it light weight with improved strength to have better efficiency at the same time can be able to mass produce considering the demand aspect. The current industrial trend is electric vehicles in full scale development but at the same time proper infrastructure to charge the vehicles is of prime importance. TrioVision Composite Technologies along with its partner companies TrioBotics Automation Solutions Pvt. Ltd. and Windstrip LLC have come forward with an excellent solution by using advanced composites to  manufacture a 3 wheel electric vehicle and a vertical axis wind mill for a charging station.

 

Usage of composites is growing rapidly where many segments are trying to change their way of thinking to utilize the key benefits composite material can offer. Use of composites in both the projects of Electric Auto and Windstrip for VAWM has tremendously benefitted the end product. TrioVision is working on its next project which is developing a 4 wheeler car with modern design approach but yet affordable. The Auto and Charging Stations shall go in production from March 2019 whereas the composite car prototype should be ready by May 2019.

 

More information: www.triovision.in