Revolution in composite manufacturing

From June Issue of Compositi Magazine

Zund


Formed in 2007 in the UK, Velocity Composites manufacture advanced carbon fibre and process material kits for use in the production of aircraft. The company uses its process knowledge, industry accreditations and proprietary technology to reduce the amount of material and process waste created in the manufacture of advanced composite aerostructures. In turn, this reduces the aircraft manufacturers’ costs to allow its customers to meet the cost challenges and rate demand from the global OEMs: Airbus and Boeing.

The majority of the raw materials used by Velocity are supplied on rolls and are both expensive and temperature-sensitive with long lead times from single source providers. Having used equipment from other suppliers Velocity Composites purchased their first Zund Cutter in 2011 for their aerospace composites kit manufacturing department. Today, the company has a total of twelve Zund G3 Cutters across their Burnley and Fareham state-of-the-art production sites. 
 

Jon Bridges, CEO of Velocity Composites

We first spoke to Zund ten years ago and we were very impressed with the flexibility and endless digital opportunities the cutter offered. The Zund G3 proved to be very adaptable, and the versatile tools could process various materials with ease. We were also impressed with Zund’s approach to software flexibility as we have developed our own system to drive the machines, manage material efficiency and control the technical requirements of our products. This was an important factor to us as the digital machines allowed for our manufacturing cells to talk to our VRP system in real time and confirm process adherence, traceability and control”.

Due to the size of Velocity’s global customer and supplier base, the company has always worked towards being the advanced technology centre of excellence for material management and manufacturing.  They have heavily invested in IoT and have built proprietary software for the purpose of connecting and exchanging data with their Zund cutters and other systems over the internet.

 
Jon Bridges said

Real-time data is always more valuable than seeing data from past events. We need real-time awareness of:

  • how much material we are using
  • any material defects we have had to work around
  • material batch traceability
  • how often the cutters are stopped (including cause)
  • cutters’ production start time and end time

This information is fed through to our live dashboard system which is reviewed by production managers in real-time. The Zund Cutter is a very important junction to our manufacturing process as it both receives and creates valuable process data which we can use to control, report, and improve”.

In line with the global nature of its business Velocity Composites are entering the North American market equipped with two Zund G3 Cutters. The subsidiary in the USA is looking to expand the company’s manufacturing excellence by creating advanced “flexible” manufacturing sites equipped with Zund digital cutters. These highly adaptable sites can easily and quickly be constructed, in a matter of weeks to be based close to or on-site with customers. This scalable model has global reach and potential that Velocity Composites has identified as key to rolling out its technology and services alongside customers.

 

 

 

 

 


Leggi anche

An all-new Falcon jet was announced by the company Dassault Aviation. It will fly non-stop from New York to Shanghai, from Los Angeles to Sydney, from Hong Kong to New York, or from Paris to Santiago. Featuring a range of 7,500 nautical miles, the top speed will be Mach 0.925….

Leggi tutto…

Carbon ThreeSixty, Leonardo, and the National Composites Centre have joined forces for a new project co-funded by Innovate UK, the UK’s innovation agency, to develop a revolutionary all-composite helicopter wheel. The new NATEP project has the aim to design, develop and manufacture an ultra-low mass, robust, proof-of-concept carbon-fiber-reinforced plastic (CFRP) wheel for rotary-wing aircraft….

Leggi tutto…

Il corso di perfezionamento in “Ingegneria dei Materiali Compositi” organizzato dall’Università Politecnica delle Marche giunge alla terza edizione. Il corso, che avrà una durata di 120 ore e conferirà 12 CFU, si propone di fornire le nozioni necessarie per affrontare tutti gli aspetti inerenti il mondo dei compositi, partendo dalle fasi costituenti i compositi fino alla caratterizzazione del componente finito….

Leggi tutto…

Mikrosam has completed the installation of its latest custom-made prepreg tape slitting and tow-rewinding machine at the National Institute for Aviation Research (NIAR) at Wichita State University.

Leggi tutto…

GKN Aerospace is leading a new UK industry consortium called ASCEND to develop and accelerate composite material and process technologies for the next generation of energy-efficient aircraft and future mobility. The collaboration with other 13 partners will strengthen the UK’s position as a technology leader in future lightweight structures and help to reduce energy consumption and carbon emissions in the aerospace and automotive industry….

Leggi tutto…