Globe Machine Manufacturing Companysmartmanufacturingseries.com/wp-content/uploads/2017/04/Martin.pdf · Globe Machine Manufacturing ... + Engineering offices + Manufacturing

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




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




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




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




What does very high volume manufacturing look like in other Globe product lines?




Globe Finishing Lines for MDF and Particleboard




Globe Finishing Lines for OSB




Globe I-Joist Manufacturing Systems




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




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




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




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




Globe Ultra High Pressure Presses for Composite Armor




Globe Ultra High Pressure Presses for Composite Armor




CFRT Tape format & packaging optimized for application




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




Next Generation Tailored CFRT Tape 2D Blanks




The Need for Formatted CFRT Tape- Aerospace CCM

Where are the rolls of formatted tape? 90, 45, -45…




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




Single Thickness Oriented CFRT Tape Rolls




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




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




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.

Documents

Globe Machine Manufacturing Companysmartmanufacturingseries.com/wp-content/uploads/2017/04/Martin.pdf · Globe Machine Manufacturing ... + Engineering offices + Manufacturing