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Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Machine Manufacturing CompanyPresents:
SME Smart Manufacturing Series: Thermoplastic Tape Formatting & Conversion Processes Enabling High Volume Manufacturing
Jim Martin
701 East D StreetTacoma, Washington, USAPh 253-383-2584Fax 253-572-9672www.globemachine.com
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Machine Manufacturing CompanyTacoma, Washington, USA
• Established in 1917
• 120,000 square foot manufacturing facility + 20,000 sf engineering and administrative offices
• Employs over 170 people in Tacoma, WA, USA
• 25% engineering and sales engineering staff
• An industrial machine and systems manufacturer with expertise in all aspects of process equipment and systems fulfillment, including Design, Engineering, Fabrication, Machining, Assembly, and Sourcing
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
100 Years of Globe History
Jesse Bamford purchased Tacoma Machine Works
c.1900
c.1950Presses
1917Calvin Bamford, Sr. assumes control and
renames company Globe Machine
1966Current owner, Calvin
Bamford, Jr. takes over company
1937Log Debarking Machine
Plywood Sawlines
c.1930
Plywood Glue Spreaders in Assembly at Globe
1958Door Making Machines
c.1920
Wood Doors Plywood Particleboard MDF
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
100 Years of Globe History
Globe delivers 14 OSB Finishing Lines over 2 years
1994 - 1995
1996Membrane Press
Technology
1997High Pressure Short
Cycle Press Technology
Globe diversifies into Pulp & Paper
2001
2007Ultra-high Pressure Press Technology
1989Globe develops high speed I-joist Manufacturing Lines
Globe develops non-autoclave rapid cure system
2009
Globe continues to innovate for the booming
Plywood industry
1960’s
OSB I-Joists Cabinet Doors Pulp & Paper Plastic Armor Composites
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
What does very high volume manufacturing look like in other Globe product lines?
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Finishing Lines for MDF and Particleboard
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Finishing Lines for OSB
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe I-Joist Manufacturing Systems
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Highly Specialized In-situ Thermoplastic Processing
• Very fast conversion of material; 40”/sec with continuous fiber tape has been proven, BUT…• Some of the most expensive input materials• Expensive individual process equipment without supporting equipment• Production rates unacceptable at moderate-to-high volume, generally restricted by
geometry, somewhat inflexible
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Machine Manufacturing Company
• Volume Thermoplastic Processing by Globe:– Multi-opening full-vacuum press for polymer ballistic armor
manufacturing
– Formatting of CFRT Tape to enable high-rate lamination and consolidation
– Modular workcell for UD Tape layup and compression molding of tailored blanks
– Process and business development relationships with BASF, TenCate, Barrday, Suprem, Celanese, Arkema, Web Industries and other thermoplastic polymer and composite material suppliers and formatters
– In-house technical staff with three decades of thermoplastic process engineering and execution success
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Ultra High PressurePresses for Composite Armor
• Light weight composite armor
• Up to 5,000 psi (12,000 ton)
• 5’ x 10’ and other custom sizes
• Full enclosed vacuum press
• Multi-daylight (10 opening shown)
• Heated and cooled platens
Press Rams at Assembly
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Ultra High PressurePresses for Composite Armor
• Light weight composite armor
• Up to 5,000 psi (12,000 ton)
• 5’ x 10’ and other custom sizes
• Full enclosed vacuum press
• Multi-daylight (10 opening shown)
• Heated and cooled platens
Fully Automated Press Loading and Unloading System
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Ultra High Pressure Presses for Composite Armor
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Globe Ultra High Pressure Presses for Composite Armor
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
CFRT Tape format & packaging optimized for application
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Automated Workcells for Thermoplastics
• Manufacturing - RELAY 2000 Motion Table for Four (4) Machines
• Capital Equipment – Consolidation Presses (Hot & Cold) and Thermoforming Presses
• Capital Equipment – RELAY System Robotics Automation, Materials Handling, and Controls
Motion Table Y-Axis
Motion Table A-Axis
Layup and Welder
Hot & Cold Consolidation Presses
Robotics Automation, Materials Handling, and Controls
Thermoforming Press
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Next Generation Tailored CFRT Tape 2D Blanks
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
The Need for Formatted CFRT Tape- Aerospace CCM
Where are the rolls of formatted tape? 90, 45, -45…
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Mid-presentation Summary
Conventional industry approach to automated thermoplastic composite lamination:
– Complex robotic (gantry) automation with multi-axis movement
– Robot has an end-of-arm tool that…
• Feeds
• Cuts
• Places
• and Tacks
• only one piece of a ply of thermoplastic prepreg at a time…
• as fast as it can with safety and quality
– HLU and formatting to feed some version of compression molding press
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Single Thickness Oriented CFRT Tape Rolls
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
What High Volume for Automotive Looks Like
In general, structural and semi-structural part examples are:• 0.2-0.5 lb parts
• 6-12 plies of 0°, 45°, -45°, 90°
• 6” x 10”; 8” x 24”
• Scrap range from 4%-20% acceptable (regrind all scrap)
• 10-30 seconds per fully consolidated 2D blank
• Single thickness, but details may be added during secondary process
• >2 million pounds of PA-6/GF tape processed/workcell/year
• New consolidation methodology required for this volume level
• Injection overmold part details- 2D blank may be pre-formed or in-mold formed
ELIUM® Resin
ELIUM® - Liquid Thermoplastic Resin
● Two-part reactive resin
● Low viscosity: 100-500cps
● Capable of RT cure
● Styrene Free
ELIUM® Composite Parts
● High modulus and toughness
● Thermoformable
● Recyclable
Designed for a wide range of applications
● Aesthetic parts
● Structural mechanical parts
Proprietary to Arkema
ELIUM®
Resin
Initiator
(ex. LUPEROX® AFR40)• Low pressure injection (RTM, Infusion)
• High MW fiber-reinforced parts.
• No tooling changes
ELIUM® Resin(100- 500 cPs)
Fiber
Glass / Carbon
or other
+ +
Thermoforming
When “cured” ELIUM® resin remains fully thermoplastic!
● Allows for post-forming
● Excellent aesthetics; clarity and surface finish
Forming conditions
● ~200°C and 15 - 20 bar applied pressure (~250 PSI)
● Degree of draw and applied pressure are dependent on thickness and reinforcement
type used in the part
Complex bends 90° bends
Care of Savoie Composite SolutionsCare of Savoie Composite Solutions
Proprietary to Arkema
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Systems Engineering For Thermoplastic Composite Processing
Rate improvement requires separation of critical process steps:
• Create modular workcells
• Rearrange modules for differing production runs
• Offline processes, tape formatting, creating ready stacks of plies, ply-packs, details and other material forms for rapid pick-and-place by other simple automation
Blanking Press
Preform Press
Precut Ply
UD Tape Infeeds
Precut Ply
Precision Thermoforming
& Overmold
Tacking or Consolidation
Advanced Composites Equipment Group
PROPRIETARY + CONFIDENTIAL + PATENTED :: 2016
RapidClave® Technology by
Company & Facilities+ Globe founded in 1917 in Tacoma, Washington, USA
+ Lightweight Labs founded in 2010
+ 140,000 square feet
+ Engineering offices
+ Manufacturing facilities
+ R&D lab
+ 100+ employees, including 25+ engineers
+ First-class products known world-wide
+ Demonstrated domestic and international
professionalism in both product offerings and business
approaches
An industrial machine manufacturer with expertise in all aspects of process equipment and systems fulfillment, including Design, Engineering, Fabrication, Machining, Assembly, and Sourcing.
Engineering & Development+ Product design
+ Systems design
+ Mechanical engineering
+ Electrical engineering
+ Hydraulic & pneumatic engineering
+ Controls engineering
+ PLC and HMI programming
+ Research and development
Manufacturing+ Fabrication
+ Machining
+ Assembly
+ UL panel shop
+ Industrial robot integration
+ In-house shop testing
+ Global materials sourcing
Systems & Processes+ Consistent system procedures and
management of all jobs of all types
and sizes
+ Enterprise resource planning
+ FEA, 2D, 3D modeling
+ Dedicated project management
+ Single point project contact
Clients
An engineering and technology company that develops materials and manufacturing processes for plastic composites including carbon fiber products.
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