Flagship center console boat model, H:CRAFT H44Z.
Photo Credit: Hayaari Marine

The resin infusion process.

Resin-infused center console boat configuration proves higher performance, speed, quality

Hayaari Marine employs a revised infusion setup using semi-permeable membranes to eliminate porosity and improve laminate consolidation, reducing about 450 kilograms of resin per boat, and offering 20% weight savings.

Motorboat builder Hayaari Marine (Abu Dhabi, United Arab Emirates) has recently launched a fully resin infused version of its flagship center console boat model, the H:CRAFT H44Z, with weight savings of more than 20% enabling a top speed in excess of 90 miles per hour.

Hayaari Marine says it has seen major benefits with the switch to infusion, saving approximately 450 kilograms (~992 pounds) of resin per boat and reducing the overall hull weight by more than 20%. The investment in infusion technology has also increased the laminate quality and consistency, as well as provided for cleaner, safer shop floor conditions with reduced volatile organic compound (VOC) emissions.

Working with a novel, in-house designed, glass-topped infusion test table, Hayaari’s engineering and production team evaluated flow speed and resin consumption for multiple laminate and consumable configurations. The optimum combination selected for series production uses Scott Bader’s (Wellingborough, U.K.) Lloyds-approved Crystic VE679-03PA infusion resin and Crystic gelcoat, glass fiber stitched multiaxial fabrics, PVC foam cores and what is said to be the latest in vacuum consumable technology.

Taking inspiration from the aerospace sector, Hayaari Marine also uses semi-permeable membranes to enhance the infusion process. By allowing air to pass, yet blocking the passage of resin, the semi-permeable membranes maintain the vacuum after the infusion is complete, eliminating porosity and improving the consolidation of the laminate.

Hayaari’s revised infusion setup requires only seven resin inlet points for the 44-foot hull, reducing the risk of air leaks and simplifying the resin management throughout the infusion. As well as the hull, Hayaari also uses the resin infusion process to manufacture the H44Z floor, cap deck, console, seats and roof.

According to Hayaari, the standard H44Z E-glass and infused vinyl ester construction delivers optimized performance. Further upgrades are also available, with Hayaari offering a carbon fiber and epoxy version of the H44Z for owners looking for the ultimate lightweight and high-performance center console boat.

“At Hayaari Marine, we have always focused on the highest quality raw materials,” comments Wassim El Zein, owner, Hayaari Marine. “With the H44Z switch to infusion, we created our own in-house testing tools to really understand how these materials interact with the vacuum consumables. The results speak for themselves. Exceptional laminate quality, a 20% weight reduction of unnecessary resin, and a 90-plus mile per hour top speed.”

#composites #ResinInfused #HayaariMarine

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Dear friends!

The main event in the composite industry, the Composite-Expo 2022 exhibition, will be held from March 29 to 31 in Pavilion 1 of the Expocentre Fairgrounds.

The entrance to the territory of the Expocentre Fairgrounds is carried out from three entrances: South, North and West.

Exhibition opening hours:
March 29 and 30 - from 10.00 to 18.00
March 31 - from 10.00 to 16.00

As part of the business program, on March 30, the 3nd R&D Conference «Practical use of composite materials in different industries» will be held.

• catalog of exhibitors

• conference program

• get an invitation

• venue

See you at the exhibition!

#composites #CompositeExpo2022 #CompositeExpoExhibition

Dear participants and visitors!

Behind three active days of the Composite-Expo 2022 exhibition.

We will post the final information on the event (press release, photos, feedback from participants, statistics, etc.) on the official website in the near future.

We are grateful to our regular exhibitors, as well as companies that took part in the event for the first time for making a decision about full-time participation in the exhibition in this difficult period, and visitors for their active interest in the event and the business program within its framework!

We hope that in 2023 nothing will prevent the exhibition from being held in full, with the full participation of our foreign exhibitors!

The 15th International Exhibition Composite-Expo will be held from March 28 to 30, 2023.

Advance booking of stands is already open!

The official website contain report on the Composite-Expo 2022 exhibition held from March 29 to March 31 in pavilion 1 of the Expocentre Fairgrounds.

Results of the Composite-Expo 2022 exhibition:

• reporting press release: list of exhibitors, statistics, reviews

• photos

• video interviews of exhibitors

In 2022, the exhibition was attended by 90 companies from 7 countries (Germany, Italy, China, the Republic of Belarus, Russia, Turkey, and France).

About 5400 people visited the shows (Composite-Expo and Polyurethanex) and 90% of them were specialists in different fields of industry.

In 2023, exhibitions will be held in pavilion 1 of the Expocentre Fairgrounds from 28 to 30 March.

Booth reservations for 2023 are already open!

RATH prepares for production of advanced oxide ceramic fiber for CMC

New facility in Germany is part of regional supply chain and vision to lead green energy transition using (CMC), supported by German government and Composites United’s Ceramic Composites network.

RATH advances as new source for oxide fiber in CMC materials. Michael Roth, German state parliament candidate, can be seen holding a spool of oxide fiber at RATH site in Mönchengladbach, Germany. From left to right: Denny Schüppel (Composites United), Dr. Peter Mechich (DLR), state parliament candidate Michael Roth and from RATH: Christopher Kluthe, Dr. Philipp Franja and Cedric Dreyszas.

For more than 125 years, the RATH Group (Vienna, Austria) has combined materials expertise, application know-how and personal consulting to provide high-temperature materials for unique applications. It is now breaking ground for a new facility in Mönchengladbach, Germany where RATH is developing a high-end oxide ceramic fiber, a key component for the production of fiber-reinforced ceramics known as ceramic matrix composites (CMC).

This market has been dominated by only one American fiber manufacturer. RATH seeks to change that, because broad use of these high-tech materials promises to make the green energy transition more efficient and ecological. “Wherever lightweight design meets high temperatures, we need CMC materials,” Christopher Kluthe says, responsible for ceramic continuous fibers in the Rath Group. “Fiber composite ceramics are based on the broad market availability of oxide ceramic fibers. Only in this way will these technologies be able to make their contribution to the energy transition.”

On May 3, key representatives from industry and research met with German state parliament candidate Michael Roth at RATH GmbH in Mönchengladbach to jointly discuss new technologies for the energy transition. In addition to Kluthe, this meeting was attended by Dr. Philipp Frania, plant manager for RATH; Dr. Peter Mechnich, co-department head at the DLR Institute for Materials Research in Cologne, Germany and Denny Schüppel, managing director of Ceramic Composites, said to be the world’s largest specialist network for ceramic composites, which has been formed within the German composites association, Composites United e. V. (Berlin).

Participants in the May meeting at Mönchengladbach learned about the new material to be produced there and the new possibilities it offers. “Technologically disruptive leap innovations are what the country needs to retain industrial jobs and drive green energy supply,” German parliament candidate Roth said. “It's great that small- and medium-sized businesses in my home country can contribute to this. I am happy to support RATH in this effort.”

With the closely meshed network of research and industry, the North Rhine-Westphalia (NRW) region where RATH Mönchengladbach is located, can become Evoa pioneer in the energy transition. Strong partners from research, such as the German Aerospace Center (DLR) and the Jülich Research Center (Jülich, Germany) — which is a member of the Helmholtz Association of German Research Centers, one of the largest interdisciplinary research centers in Europe — are reported to be just as active as small and large companies. From component manufacturers, such as WPX fiber ceramics (Bonn, Germany), to quality assurance at Diondo (Hattingen), to users such as Ford (Cologne), Linde (Lindlar) and Evonik (Essen), the partners in the NRW region represent the entire value network and are positioning themselves as pioneers of the energy transition.

#composites #ceramicmatrixcomposites #RATH

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Starlab, the planned LEO space station designed by Nanoracks for commercial space activities. Photo Credit: Nanoracks Space Outpost Europe

Anisoprint signs MOU for space-based continuous fiber 3D printing

Continuous fiber co-extrusion (CFC) technology capacities in orbit and for the deployment of additive manufacturing have been demonstrated and validated.

Anisoprint (Esch-sur-Alzette, Luxembourg), a continuous fiber 3D printing solution provider, has signed a memorandum of understanding (MOU) with Nanoracks Space Outpost Europe (Houston, Texas, U.S.), a private in-space services company involved in the commercial utilization of the International Space Station (ISS), to strengthen its position as a space technology developer and become a part of the low-Earth orbit (LEO) and lunar economy.

Since Anisoprint was selected for pre-incubation in ESRIC’s Startup Support Program to adjust continuous fiber 3D printing technology for microgravity conditions, the team says it has made great strides toward expanding the resources network. The MOU is said to further secure demonstration and validation of continuous fiber co-extrusion (CFC) technology capacities in orbit and for the deployment of 3D printing manufacturing.

“We are excited to join forces with such an experienced and well-respected in source industry partner. Adjusting CFC technology for microgravity is the first step, the next is to deploy the technology in orbit together with Nanoracks Space Outpost Europe,” Dmitrii Prokopiuk, Anisoprint head of space development, notes. In his presentation at Space Resources Week 2022, Prokopiuk discussed the role of CFC 3D printing for space resources use.

Anisoprint says in space, there is a large demand for on-site production of parts and components. On-site manufacturing minimizes delivery cost and shape limitations, and also reduces the number of delivery missions. Therefore, the company feels its patented CFC technology — which creates zero waste, thus minimizing the amount of space debris and is fully automated manufacturing — is ideal for these kinds of applications.
“With our plans to develop orbit stations and other space facilities to serve the market needs at the best, the role of these innovative in-orbit manufacturing machines are getting more and more crucial,” Veronica La Regina, director business development at Nanoracks Europe, adds. “We are looking forward to experiencing the CFC 3D printing capabilities in our portfolio.”

#composites #Anisoprint #SpaceBasedContinuousFiber #3Dprinting

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Photo Credit: Toray Composite Materials America Inc.

Toray and Bell collaborate on new NCAMP design allowable dataset for 3960 prepreg system

Allowable design dataset establishes conformity requirements and process specifications for traditional hand layup and AFP of the 3960 prepreg system in aerospace applications.

Toray Composite Materials America Inc. (TCMA, Tacoma, Wash., U.S.), a manufacturer of advanced carbon fiber and composite prepreg materials, has entered into a collaborative arrangement with Bell Textron Inc. (Fort Worth, Texas, U.S.) to support a new National Center for Advanced Materials Performance (NCAMP) design allowable dataset for Toray’s 3960 prepreg material system. This prepreg system uses Toray’s T1100 intermediate modulus plus (IM+) fibers, providing high toughness and exceptional tensile performance ideal for aerospace applications.

In 2016, Toray and Bell began efforts to refine the performance of the 3960 prepreg material to meet Bell’s design requirements for high-performance and low-risk airframe solutions for efforts such as the U.S. Army’s Future Vertical Lift (FVL) programs. In 2019, Toray says it began producing allowable design data for this material with guidance from the National Institute for Aviation Research’s (NIAR, Wichita, Kan., U.S.) NCAMP engineering team. This comprehensive plan establishes conformity requirements and process specifications for traditional hand layup and automated fiber placement (AFP) manufacturing processes for the 3960 prepreg system. Toray notes that the data will serve as a foundation for certification, enabling aerospace companies to achieve airworthiness approvals and bring products to market faster and at a lower cost.

“Toray’s T1100/3960 composite material offers the right balance of characteristics that enable Bell engineers to design the most efficient and reliable structures that meet our customer’s mission requirements including speed, range and agility,” according to Bell’s Vince D’Arienzo, technical fellow. “We, together with our partners, continue to optimize airframe performance attributes by building full-scale risk reduction and validation articles with Toray’s 3960 prepreg system.”

Jeff Cross, Toray director of business development adds that the company remains “committed to providing a full range of products with publicly available design data for the design and certification of aerospace and defense applications.”

#composites #Toray #prepreg #dataset

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