Tl +44 (0) 1752 849998 fx +44 (0) 1752 849808 info@composite-integration.co.uk Company Overview

tl +44 (0) 1752 849998

fx +44 (0) 1752 849808

info@composite-integration.co.uk

www.composite-integration.co.uk

Company Overview

• Founded in 2002 by Richard Bland and Stephen Leonard-Williams.

• Over 40 years combined practical experience of ‘closed-mould’ processing.

• Offices and manufacturing facility in Saltash, Cornwall, UK

• Turnover £1.6 million• 15 employees• World wide distribution in more that

20 countries• Purpose built 9000ft² facility• ISO 9001 accredited• Our aim is to provide practical and

innovative manufacturing solutions supported by practical experience.

Our products include:

• Injection equipment for RTM processes

• Equipment for infusion processes

• Ancillary equipment• Vacuum equipment• Tooling• Data monitoring systems

Our products include:

• Injection equipment for RTM processes

• Equipment for infusion processes

• Ancillary equipment• Vacuum equipment• Tooling• Data monitoring systems

Our products include:

• Injection equipment for RTM processes

• Equipment for infusion processes

• Ancillary equipment• Vacuum equipment• Tooling• Data monitoring systems

Our products include:

• Injection equipment for RTM processes

• Equipment for infusion processes

• Ancillary equipment• Vacuum equipment• Tooling• Data monitoring systems

Our products include:

• Injection equipment for RTM processes

• Equipment for infusion processes

• Ancillary equipment• Vacuum equipment• Tooling• Data monitoring systems

Our products include:

• Injection equipment for RTM processes

• Equipment for infusion processes

• Ancillary equipment• Vacuum equipment• Tooling• Data monitoring systems

Our services include:

• Technical advice and consultancy• Training• Feasibility studies• Pattern and tooling design (full

3D in-house design)• Specialist equipment design• Prototype manufacturing• Project management

Our services include:

• Technical advice and consultancy• Training• Feasibility studies• Pattern and tooling design (full

3D in-house design)• Specialist equipment design• Prototype manufacturing• Project management

Our services include:

• Technical advice and consultancy• Training• Feasibility studies• Pattern and tooling design (full

3D in-house design)• Specialist equipment design• Prototype manufacturing• Project management

Our services include:

• Technical advice and consultancy• Training• Feasibility studies• Pattern and tooling design (full

3D in-house design)• Specialist equipment design• Prototype manufacturing• Project management

Our services include:

• Technical advice and consultancy• Training• Feasibility studies• Pattern and tooling design (full

3D in-house design)• Specialist equipment design• Prototype manufacturing• Project management

Our services include:

• Technical advice and consultancy• Training• Feasibility studies• Pattern and tooling design (full

3D in-house design)• Specialist equipment design• Prototype manufacturing• Project management

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

Our customers include:

• Our customers include:• General composite moulders• Marine manufacturers• Aerospace and military manufactures• Automotive manufacturers• Architectural manufactures• Universities• Research establishments

VRTM:

Advantages:• Relatively Low cost tooling• High quality laminates can be produced• Control of A and B surfaces• Control of thickness• Cycle times can be improved• Repeatability• Resolves environmental and H&S issues• Process can be de-skilled

Disadvantages:• Higher tooling costs (compared to ‘open

moulding’)• Tooling manufacture and design requires

knowledge and skill• Some investment in equipment is

necessary

Typical VRTM Production cell

Vacuum System Mould

Injection Machine

Injection Valve

Vacuum Catch Pot

The structure and operation of a typical VRTM mould

Lower (female) Mould

Air Ejector (to assist de-moulding)

The structure and operation of a typical VRTM mould

Fibre (and foam core) loaded

The structure and operation of a typical VRTM mould

Upper mould located against lower mould

Double vacuum seals

Catch-pot

Injection Valve

The structure and operation of a typical VRTM mould

Mould Closing

The structure and operation of a typical VRTM mould

Mould Closing

The structure and operation of a typical VRTM mould

Mould Closing

The structure and operation of a typical VRTM mould

Mould Closed and Vacuum connected

Maximum Vacuum connected to flange areaRegulated vacuum (50-

60%) connected to catch-pot

Injection valve connected to machine

The structure and operation of a typical VRTM mould

Resin injected at controlled pressure (via Injection Valve) into peripheral runner

The structure and operation of a typical VRTM mould

Resin flowing peripherally from runner

The structure and operation of a typical VRTM mould

The structure and operation of a typical VRTM mould

The structure and operation of a typical VRTM mould

The structure and operation of a typical VRTM mould

Final mould fill at catch-pot

The structure and operation of a typical VRTM mould

Vacuum maintained during resin cure

The structure and operation of a typical VRTM mould

Mould opened

(For a video of the VRTM mould manufacturing process and the operation of a VRTM mould see http://www.youtube.com/watch?v=f-vBw3HH7uI)

The link from RTM to Infusion:

Resin Infusion:

Advantages:• Low entry cost• Low cost tooling• Viable on large scale• High quality laminates can be produced• Helps to resolve environmental and H&S

issues

Disadvantages:• Skilled process• Only one fully controlled surface• Relatively slow (compared to RTM)• Relatively high consumable costs

(compared to RTM)• Relatively wasteful (compared to RTM)

Recognising the need for an alternative to the manual resin

mixing/handling process.......

The principal of using a machine to feed mixed resin directly into the infusion mould with pressure feed-back control (In Mould Pressure Sensor IMPS)

Resin inlet

Pressure feed-back

Example of using Ciject equipment to directly feed resin infusion process.(Dinghy project in collaboration with Falmouth Marine School)

Characterising the full-scale process using In-Mould Pressure Sensors (IMPS)

Large scale infusion using Ciject technology at Princess Yachts

Large scale infusion using Ciject technology at Princess Yachts

SCADA

(Supervisory Control and Data Acquisition)

• Remote monitoring

• Network enabled

• Real time and historical QA information/trending

Overview of Ciject machine range:

For details of the full range of Composite Integration Ltd range of products and services

please visit our website www.composite-integration.co.uk

Email: info@composite-integration.co.ukor call +44 (0)1752 849998

The lowest cost machine in the Ciject range with a simple electronic operator control system. The machine includes the accurate electronic pressure control.All the machines in the Ciject range include high quality purpose-designed pumps and the unique Ciject automatic mix-head.The ‘Zero Plus’ option allows additional control functions.

CIJECT™ Zero

The Ciject range of Injection equipment:

CIJECT™ One

A sophisticated machine with programmable functions and a extensive level of control options. The Ciject One features an unrivalled level of control with simplicity of operation.Designed for both RTM and infusion processes, the control system works accurately at negative pressures enabling the machine to also be used for directly delivering resin into vacuum infusion processes.

Available with a range of additional options including:• Flow monitoring, • Material level sensors • In-mould vacuum level checking.

The Ciject range of Injection equipment:

CIJECT™ Two

The most sophisticated machine in the range, the Ciject Two is based around a powerful touch-screen PLC enabling the addition of a wide range of options and control functions.Like the Ciject One, this machine is also suitable for directly delivering resin into vacuum infusion processes.

The Ciject two supports a wide range of additional options including;

• Material level sensors• Sophisticated Flow monitoring options• PLC controlled Motorised ratio adjustment • Radio frequency (RFID) mould recognition system• In-mould vacuum level checking• SCADA data monitoring

The Ciject range of Injection equipment:

CIJECT™ Four

A high output machine specifically designed for ‘Direct Injection’ into infusion processThe Ciject Four is based around a double pump system that can provide fluid output above 20kg/min plus a level of process security during the infusion (each pump/mix head can be shut-down and flushed if necessary during the infusion)

Multiple In-Mould Pressure Sensors (IMPS) can be connected to the machine to provide automatic control of the delivery rate and infusion pressure.The specification can be adapted and the control system can be configured to suit the particular parameters of the customer’s process.

The Ciject Four supports a wide range of functions including;• Material level sensing• Sophisticated Flow monitoring options• PLC controlled Motorised ratio adjustment 

• Process vacuum level checking• On-screen management of pre-infusion checks• SCADA data monitoring

The Ciject range of Injection equipment:

Ciject non-mixing ‘lab-scale’ equipment

Developed to answer the demand for simple yet flexible injection equipment for use in small-scale production, laboratories and research establishments.

This non-mixing equipment is based around the ‘pressure-pot’ principal and so has the flexibility to dispense most liquid resin systems.

The system can include:• Heated resin container• Heated outlet pipe-work• Evacuation of resin container to enable degassing of mixed resin• Digital weight monitoring of resin container• Accurate pressure control

The Ciject range of Injection equipment: