capability presentation 2010

Capability Presentation

Composite Components - 2010

Index1.Relative experience2.Past and current works3.Relative projects4.Conclusion

1990

First exposure to composites building and racing the 'unrestricted' sailing class International Moth. Four boats were built of which 2 won state championships

1998

Employed with Eagle Aircraft as a composite laminator building aircraft components, primarily responsible for the control surfaces (rudder, flaps, ailerons). Temporary placement in Malaysia training staff on correct procedure to manufacture control surfaces of the Eagle 150 when the moulds were transferred to Eagle Aircrafts‘ parent company CRTM in Melaka.

1999

Upon return to Australia, a request to transfer to composite assembly was successful and Glen worked in 'bay 1' responsible for the wing(s) to fuselage fitment and bonding.

2000

Working with a colleague on Perth's only V8 Supercar team - CAT Racing. Co-development of a resin infusion system which was a first for Perth and likely Australia as this technology was in its infancy in the US only.

Composite Experience – Glen Oldfield, Manager

2000

Design Acumen, designers of the first ‘flat bed in the sky' for British Airways, were shortlisted down to the final 2 companies working on the interior of the A380 'super jumbo' work done here was primarily model-making from detailed drawings. The full scale models were made from metal, alloys, wood, composites or high / medium density tooling boards machined and / or hand finished to close tolerances

2001

McLaren Composites - P7 project , Employed to work jointly between the R & D department; for resin infusion / RTM component construction and the clean room to manufacture first article components from pre-preg, or SP Sprint materials. The P7 project would later be known as the McLaren Mercedes SLR.

McLaren Composites manufactured components for the McLaren Formula 1 racing team as well as being involved in composite component manufacture of the Beagle Mars Land Rover.


2002

DPS Composites – construction of tooling and the main chassis components for the Jordan F1 team, DPS was also contracted to manufacture smaller components for McLaren F1 team, British touring car driver safety cells and 2 Cadillac LeMans chassis.

2003 to present

Composite Design was founded to design and manufacture ‘high end’ composite furniture for corporate and commercial clients. We had good results immediately with awards for our Linea range in the first year and an Australian Design Award for the ‘Lux’ table in 2006. Composite Design continues to manufacture furniture products with retailers Australia wide.

Composite Components was created to specialise in advanced composite products and research and development into composite structures for all industries.

The first major project was manufacture of tooling for the ‘S-Core’ surfboard project (based in Perth) for French Snowboard and clothing manufacturer Salomon. The tooling contract evolved into an extensive R&D phase lasting 3 years, where upon production was established in Thailand and Romania.

Composite Components now concentrate on diversity, with clients in fields ranging from Medical, Defense, Automotive, Sporting goods and R&D projects for industry.


ArchitecturalFire, smoke and toxicity-rated building cladding for the Perth underground train station and custom made lighting designed by renowned Australian designer Paul Morris from Join for a hotel lobby

Past and current works

MedicalProsthetics (legs and upper thigh socket), custom fitted feet orthosis (or orthotics) and custom fitted seats for wheel chairs


Unmanned Air Vehicles• Hoverpod - CAV (compact air vehicle)

• Phoenix - Jet turbine powered target drone*

• Cybird 5 - High speed jet powered drone*

• Cybereye 2 - MALE surveillance drone*

*autonomous, contains a pre-programmed autopilot on board


Production componentsComposite design furniture – manufacture and support for the Lux table (recipient of an Australian Design Award, 2006) and Linea range of occasional tables. The tables are sold Australia wide through commercial and corporate based retailers.


Production componentsOKA Truck headlight surrounds – contacted to replace the traditional surrounds with a ‘new look’, we identified a rapid composite manufacturing process and proceeded to generate CAD models and master patters before sourcing a local manufacturer to manufacture the components for OKA.

We also have been involved in components for a V8 dirt drag bike and ‘nitro Harley’ racing team


Production componentsVacuum chambers for pressure sensing, racing jet ski ride plate, vacuum forming moulding and sailing yacht rudder foils


Production componentsManufacture of light weight structural composite turret and camera housings and associated CNC machined carbon fibre flat plate for ‘UAV dedicated’ HD video cameras.

Carbon fibre road bicycle frame repairs – we currently service every bike store in Perth requiring carbon fibre frame repairs and have done so for 2 years now.

Carbon fibre reinforcement of cricket bats – a local manufacturer used carbon fibre to reinforce their cricket bats, unfortunately due to recent ICC laws the reinforced bats have been ruled illegal.


Research & DevelopmentSalomon 's-core' project – a point of difference for the surfing industry, a ‘hollow’ board with 3 foam ribs for stiffness and an epoxy resin and glass / carbon fibre construction. The boards received excellent feedback and were even ridden by multiple world champion Kelly Slater (pictured).

Starboard Windsurfing (the largest windsurfing company in the world) also conducted R&D based on the s-core technology, Starboard saw potential in the hollow board construction and a 100 board pre-production was subsequently initiated.


Research & Development‘Bladerider’ hydrofoil computer analysis development - for high performance sailing and subsequent input into structural design and product development.

Composite Components have been involved in Bladerider’s development since the creation of the company in 2005.


CNC Machining / Model makingWe have undertaken all manner of machining jobs including 2 x 1:100 scale models of a 100m luxury motor yacht, water purifying components, a scale swimming pool and signage for local companies without CAD/CAM access


Non Fragmenting explosive boxesInitial prototypes were created and a series of materials selected for a segmented box to transport detonators and small charges to blast sites for mining operations, the key benefits indentified:•Interlaminar Faraday cage to block external electric fields and electromagnetic radiation eg: radio signals•Box construction ensured no life threatening fragments were thrown in the case of an explosion•Lightweight construction to meet OH&S standards for single person lifting and carrying

Relative works

Custom fitted composite seatingProduction for the Cerebral Palsy Association of a seating system that uses 3D scans of patients backs to generate a CAD model which is used to CNC machine a ‘sacrificial’ mould (with offset tolerances for padding) the mould is used to create the advanced composite seat using a proprietary resin infusion method. The seats were tested by Curtin University against a variety of traditional materials, only the composite seats reached the required CPA criteria.

Relative works

UAV aircraftCybertechnologies - Cybereye 2 (MALE) and Cybird 5 high speed droneAir Affairs – Phoenix target drone

Relative works

UAV aircraft

Relative works

Unmanned Air VehiclesHoverpod and Mupod (scale version) project components.

The hoverpod is designed as a one man personal flying device or a CAV – compact air vehicle.

Relative works

Architectural componentsConstruction of the cladding system for the two information 'pods' for the Perth Underground station. As the cladding was being installed in an underground environment it meant conforming to strict FST (fire, smoke, toxicity) regulations.

We structurally designed the cladding to meet the regulations and ‘lifecycle challenges’ that public transport buildings can be subjected to.

Relative works

Sub-sea buoyancyRecently we have completed large sub sea buoyancy units for a heavy work class deep sea ROV capable of over 1000m sea depth. The main block component weighed just under 800kg after CNC machining.

In conjunction with the client we undertook pressure testing(to failure at just over +100 bar) to evaluate the SAN based foam material, the bondline between sheets and the shear strength of the secondary bonded threaded inserts.

Relative works

Composite Components are a small operation with large experience. We continue to service companies large and small across a range of fields all over Australia.

We are responsive due to our size and have the ability to source materials from all over the world and the expertise to deliver effective solutions for our clients.

Conclusion

composite componentsengineered composite solutions

9a Morse Road Bibra Lake, Perth WA 6163www.compositecomponents.com.au

capability presentation 2010

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