Bristol Composites Institute Launch and ACCIS 10th Anniversary Conference

The Composites Age is Arriving

Prof Mike Hinton HVMC Core TeamR&T Partnerships15th November 2017

UK Composites Manufacturing - Some History (1971)

UK Composites Manufacturing - Some History (1971)

▪ Strategy published Nov 2009

▪ To develop an integrated and cross-sector composites industry

▪ In a global market forecast to grow to £75bn by 2015

▪ Driving composites growth using advanced manufacturing

▪ Achieved by delivering improved— Strengthening capability

— Increasing sustainability

— Building capacity

▪ With industry and stakeholder leadership

4Composites Leadership Forum

UK Manufacturing of Composites – Political & Market View- UK Strategy

▪ Initiated by UK Composites Strategy (Nov 2009)

▪ Delivered on time and on budget

▪ Has more members and engagement than forecast

▪ Working on projects of utmost importance to UK

▪ Initiated the Composites Leadership Forum – advising BEIS etc. on needs of the sector

▪ Capability enhancements supported by HVM Catapult

▪ Major capex expansion underway to support ATI funded programs

The National Composites Centre:

Set Up & Funded by

Composites Leadership Forum

Established as a result the 2009 UK Composites

Strategy to strengthen leadership in the sector.

The CLF is working to influence the Government

and other bodies to bring together support for

composites and ensure growth and industrial

success for the UK.

Strategy refresh delivered 2016.

www.compositesleadershipforum.com

Stakeholders:

BEIS, Innovate UK, EPSRC, KTN Ltd, DIT

(formerly UKTI).

Delivery Partners:

National Composites Centre, Composites UK,

CIMComp.

Industry Groups:

Aerospace Growth Partnership, Automotive

Council, Motorsport Industries Association,

Construction, Defence, Renewables UK, Marine

Industries Alliance, Railway Industry Association,

Materials Suppliers

6Composites Leadership Forum

UK Trade Body for Composites :-

Ceramic MatrixComposites

Metal MatrixComposites

Carbon FibreReinforced Products

2017: $22.6 Bn2020: $30 BnCAGR 10.5%

Glass FibreReinforcedProducts

2017: $47.0 Bn2020: $57 BnCAGR 6.6%

Global Composite Products

2017:$79.6 Bn

2020: $97 Bn

CAGR 7%

Natural Fibre Reinforced Products

2017: $4.2 Bn2020: $5.8 BnCAGR 11.68%

2017: $3.3 Bn2020: $4.3 BnCAGR 9.7%

Carbon Fibre

2017: $3.2 Bn2020: $4.3BnCAGR 10.8%

Glass Fibre

2017: $11.8 Bn2020: $14.23BnCAGR 6.4%

Aramid Fibre

2017: $3.5 Bn2020: $4.6BnCAGR 6.4%

CompositeResins (TS)

2017: $1.1 Bn2020: $1.3BnCAGR 6.4%

2017: $518 M2020: $619 MCAGR 6.1%

Polymer Matrix Composites

- Significant global growth prospects for composite products

UK Manufacturing of Composites – Political & Market View

Source: Markets & Markets data compiled by NCC

The UK Market Opportunity

Composites Leadership Forum : Source Data @2016 9

Potential growth from composite part production from £2.3bn in 2015 to £12.5bn in 2030.Focus on High Growth Markets: Aerospace, Automotive and Defence

The UK Market Opportunity

Composites Leadership Forum : Source Data @2016 10

Potential growth from composite part production from £2.3bn in 2015 to £12.5bn in 2030.Focus on High Growth Markets: Aerospace, Automotive and Defence

UK Manufacturing of Composites – Political & Market View- Aerospace

UK Manufacturing of Composites – Political & Market View- Aerospace

UK Manufacturing of Composites – Political & Market View- Aerospace

Sector Body :- AGP Planning Body :- ATI

▪ A350 and A400 in production (composite wings)▪ Bombardier C-series EIS in service 2016 (composite wing)▪ Increasing use of composites in engines (blades, cases, nacelles)▪ (Production rates of A320 increasing)

▪ Next generation of single-aisle coulduse composite wing and engines withhigh composite content

Challenges:▪ Production rates▪ Globally mobile/ high value manufacturing

UK Manufacturing of Composites – Political & Market View- Aerospace

▪ Government commitment to UK Automotive Sector— Advanced Propulsion Centre:

£1bn over 10 years

— Automotive Inward investment organisation

— Investment in Skills

UK Manufacturing of Composites – Political & Market View- Automotive

High composites growth forecast: due to 2020 and 2025 emission targets

Applications include:▪ Structures (body in white)▪ Wheels and brakes▪ Suspension and clutches▪ Interiors (seat frames, consoles)

Challenges:▪ Cost, rate and quality (surface finish, painting, joining)▪ Capital cost of new production facilities▪ UK supply chain?

UK Manufacturing of Composites – Political & Market View- Automotive

McLaren Composites Technology Centre

▪ 1st UK McLaren facility outside campus

▪ In-sourcing the development and manufacture of carbon fibre chassis

▪ Using advanced know-how and technology developed with HVM Catapult (AMRC)

▪ £50m combined investment

▪ 200 high level jobs

▪ Projected cost saving of £10m

▪ £100m GVA to UK economy by 2028

▪ Value of UK sourcing of a McLaren car to

grow by 8% (from current average of 50%)

▪ UK’s largest sector bycapital investment (£14b/pa)

▪ UK world leader in sub-seatechnologies

▪ Major opportunities in deepwater in Gulf of Mexico, WestAfrica (up to 30x deeper than North Sea)

Challenges:▪ Well depths up to 3000m▪ Well pressures increasing to >20k psi▪ Regulation/assurance (hence IUK mJumper project)

UK Manufacturing of Composites – Political & Market View- Oil & Gas

UK Manufacturing of Composites – Political & Market View- Oil & Gas

UK Manufacturing of Composites – Political & Market View- Renewables

Siemens Manufacturing Facility –Hull, UK

UK Manufacturing of Composites – Political & Market View- Renewables

▪ Current UK Gov’t Initiative :-

▪ Industrial Strategy Challenge Fund

- Faraday (Auto Batteries)- (Digital Manufacturing)- (Materials)

▪ Sector Deals- Construction- (Chemical Industry)- (Composites Manufacturing)

Composites Sector Deal - Initial Thought Process

Composites Leadership Forum 23

Delivering:• Aerospace and Automotive

Composites Roadmapping.• £XX APC, £XX IUK, £XX ATI

composite innovation projects.Ask:• Composite bridge demonstrator.

Link to Construction Sector Deal?

Industry Specific Work

Delivering:• HVM Catapult preforming Large

Scale Project • Scottish Lightweighting Centre.Ask:• National Composite Materials

Innovation Hub.• Materials extension to

CIMComp.• Composite related extension to

HVM Catapult Infrastructure.

Cross Sector Work

TechnologySustainability Skills/Workforce

Supply Chain Regulations & Standards

Delivering:• Composites Resource and

Efficiency Action Plan.• Climate Change Levy Scheme.

Ask:• Support for iComposites-style

collaborative research programme to address market failure.

Delivering:• Composite Trailblazer

Apprenticeship.• Composite Accredited Practitioner

Scheme.Ask:• HEFCE Catalyst fund proposal for

curriculum development.• Allow Apprenticeship levy to be

used on other forms of skills.

Delivering:• Industry database.

Ask:• Support for market & industry

data refresh, cross sector & supply chain analysis.

• Funding to support engagement and communication with industry.

Delivering:• Modernising Composite

Materials Regulations Paper.• Ongoing work challenging

materials based standards.Ask:• TBC

Part and Materials Value For UK

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4

6

8

10

12

14

2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030

Val

ue

/£b

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UK CompositeProducts

Material Value

Material Valuefrom UK withNCMCMaterial Valuefrom UKwithout NCMCNCMC work increases

UK produced materials, increasing UK GVA and

Automation and process optimisation will lead to material cost dominating composite product cost.Need to capture the material supply chain in the UK, increasing UK GVA and reducing imported goods.(example: without action, up to £3.4bn of carbon fibre may need to be imported by 2030)

NCMC - Indicative Academic Projects

Matrix Reinforcement Intermediates Sustainability

M1

Large sca le production of monomers from bio-

mass (as drop in replacements for selected

polymers)

R1

High performance discontinuous

compos ites I1

High-speed weaving of broadcloth

through machine development and

tow s izing

S1

More susta inable matrices and s izes

(thermosets and thermoplastics )

M2

Appl ication of multi -sca le model l ing techniques

to optimise performance through rational des ign

and formulation

R2

Structured s ize

I2

Variable width broadcloth weaving

S2

More susta inable reinforcements (fibres ,

fi lms , precursers )

M3

Development of lower temperature cure

process ing for thermoset compos ites R3

Next generation carbon fibres

I3

Nearnet 2D preforming

S3

New solvolys is processes for improved

fibre recovery - Current thermoset matrices

and carbon & glass fibre

M4

Developing new reactors to enable the rapid

sca le up of new monomers R4

Higher performance low-cost (glass )

fibres I4

Direct preforming with long

discontinuous tows into formable

preforms

S4

M5Tai loring exis ting matrix/reinforcement interface

regions to improve mechanica l performance R5High performance polymer tape

compos ites I53D weaving of broadcloth (2.5D

weaving) S5Improved pyrolys is processes for carbon

fibre recovery from legacy matrices

M6Development of rel iable sel f heal ing polymer

matricesR6

Next generation fibres to displace

conventional carbonI6

3D weaving of thick and complex

near-net preforms S6

Improved s izes for fibres

M7

Developing tough, high operating temperature

(350-400 C) matrices R7

In s i tu formation of reinforcing s tructures

I7

Novel cutting technologies , for

example laser based (with

AMRC/MTC)

S7

Compos ites with variable discontinuous

fibre properties

M8

Developing the next generation of

multi functional compos ites us ing new

nanomateria ls

R8

New des ign tools

I8

Yarns or tows from discontinuous

(recycled) fibres and hybrid fibres S8

QC methods and s tandards for recovered

fibres (NPL-led?)

M9Developing s tandards for routine use of

nanocompos ites across supply chainR9

Fibres as del ivery routes for addition

components (LINK TO MATRICES)I9

Novel cyl indrica l 3D preforms S9

Development of short fibre a l ignment

processes

M10

Reducing rel iance on VOCs by developing water-

borne technologies and moving towards ci rcular

process ing

R10

Hierarchica l s tructured fibre tows

I10

Just-in time prepregging of 3D

preforms S10

LCA methodologies

S11Process ing mixtures of recovered glass

and carbon fibre

Composites Leadership Forum 25

• Increasing demand for large components (aerospace, wind, construction…)

• Processes and costs that suit increased manufacturing rates (105/y not 102/y)

• Automated manufacture

• Reducing cost and time to market (design >certification>in-service)

• Growing the UK skills/expertise to compete with the world (supply chains)

UK Manufacturing of Composites – Political & Market View

- Big Challenges

• Increasing demand for large components (aerospace, wind, construction…)

• Processes and costs that suit increased manufacturing rates (105/y not 102/y)

• Automated manufacture

• Reducing cost and time to market (design >certification>in-service)

• Growing the UK skills/expertise to compete with the world (supply chains)

UK Manufacturing of Composites – Political & Market View

- Big Challenges

• Increasing demand for large components (aerospace, wind, construction…)

• Processes and costs that suit increased manufacturing rates (105/y not 102/y)

• Automated manufacture

• Reducing cost and time to market (design >certification>in-service)

• Growing the UK skills/expertise to compete with the world (supply chains)

UK Manufacturing of Composites – Political & Market View

- Big Challenges

There has never been a better time for Composites

Discussion and questions