Aerospace engineers Dr Filip Stojcevski and Andreas Hendlmeier, along with organic chemist James Randall, combined their knowledge of carbon fibre manufacturing, electrochemistry and material interfaces to overcome the technical hurdles of using recycled carbon fibre to create a robust, affordable, high-performance surfboard.

The trio were inspired by their interactions with famous Torquay-based surfboard shaper Eiji Shiomoto.

While carbon fibre is an amazing material, more than 45,000 tonnes of it is thrown into landfill each year

The group is confident that the new recycled carbon fibre boards are stronger, lighter and more durable than conventional e-glass fibre-reinforced boards while costing around the same price.

Until now, carbon fibre surfboards have been too rigid and prone to delamination, due to micro-cracks in the carbon fibre interface. The new recycled boards use electrochemistry to improve the properties of surface-modified hydrophobic carbon fibres and recycled fibres to solve the problem.

Dr Stojcevski completed his Deakin PhD with Boeing R and T Aerospace, where he worked on improving surface treatments that make carbon fibre adhere to resin, while international student Andreas Hendlmeier is from Germany and has worked on optimising carbon fibre surface treatments.

The Australian surfboard industry account for almost a third of the global market, with 8.5 million surfboards in Australia alone. The new company is hoping to carve out a space for ourselves in this large potential market – and this venture isn’t just limited to surfboards; the technology could also be adapted for other sporting and marine applications.

The boards are available to pre-order from the JUC Surf website with prices ranging from $650 to $900 (AUD)

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We are delighted to be able to continue to build on the strong market position developed over many years by Summit Composites. We are looking forward to serving our highly valued customers and cementing a long-term sustainable presence in the Australian composites market.

Kevin Matthews, Scott Bader’s Group Chief Executive Officer

Members of the existing Summit Composites team have accepted new positions in Scott Bader Australia Pty Ltd

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The project is a $12.5 million investment by the consortium with support from the Federal Government in order to design, develop and manufacture flight-ready cryo tanks.

It brings industry and academia together to use advanced robotic filament winding using exotic materials suited to the extreme operating conditions of space. The new carbon fibre cryo tanks have the potential for up to 30 per cent weight saving and 25 per cent cost saving.

We are grateful to receive this funding, which will allow us to develop world-class composite materials and components for our orbital launch vehicles – making our rockets more efficient and reducing the cost of access to space

Gilmour Space, a Gold Coast-based rocket company, signed a strategic agreement with USQ in 2019 to collaborate on advanced rocket technology research.

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Bureau Veritas measured total oxidation times of sub-15 and sub-20 minutes over two separate production campaigns of 24K standard modulus (SM) carbon fibre, achieving fibre tow properties in excess of 270 GPa tensile modulus and 3,500 MPa tensile strength.

The BV audit was conducted on Carbon Nexus’s 100 metric ton (nameplate) pilot line which is currently producing samples for trials with LeMond’s target customers in several SM industrial markets. In addition to accurately measuring oxidation times and assuring process traceability, BV oversaw the fibre sampling, packaging and shipping of audit samples for extensive testing at the BV laboratories in Pessac, France. Composite tow tests of the LeMond fibre were completed according to ASTM D 4018-17 standards.

This is a significant milestone for our company. Having our technology independently verified by BV validates the revolutionary nature of our technology. My team and I are excited to bring our high-performance low-cost carbon fibre to the global market and look forward to expanding into new markets where the current high cost of carbon fibre has been a significant barrier to adoption Greg LeMond, Founder and Chairman of the Board of LeMond Carbon

LeMond and Deakin University are teamed to commercialise this innovative technology which enables reductions of 75% and 70% in Capex and energy consumption per kilo of output respectively. The rapid oxidation process enables LeMond to produce carbon fibre with the lowest embodied energy of any standard PAN-based carbon fibre available today.

Having proven the capability to successfully produce a competitive standard modulus carbon fibre, LeMond has launched a new capital raise to develop a 5,400-metric ton (nameplate) production facility in Oak Ridge, Tennessee. To date, parent LeMond Companies LLC has raised approximately USD 18.6M of seed capital from individual and institutional investors, including Deakin University.

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The system will be integrated into Swinburne’s Industry 4.0 Testlab for 3D printing of carbon fibre composites in 2020 and has the capacity to reduce costs and manufacturing time.

The collaborative robotic system, known as DrapeWatch, has been installed as part of a partnership between Swinburne; the University of Stuttgart; their industry on-campus research facility, ARENA2036; and German composite technology and engineering company CIKONI.

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To demonstrate how DrapeWatch can identify gaps, misalignments and other irregularities, Swinburne researchers are using a representative ‘double-dome’ geometry. This complex shape, made of two conjoined domes, is commonly used in engineering for moulding tests because the curvature can produce defects to test the system’s precision.

The robot is used to control a vision-sensing system that allows the outermost layer to be inspected, as well as an additional probe to study internal defects and send back data. The clever innovation from CIKONI is in the artificial intelligence algorithms that analyse this data.

Carbon fibre composite manufacturing can be a slow and expensive process. The early detection of defects using DrapeWatch will reduce unnecessary costs and waste. The collaborative robot is designed to work in partnership with human beings, eliminating the need for fencing or safety features as it stops when it senses close human movement.

Manufacturing process inspection is a pillar of Industry 4.0, because it gives you the ability to measure, monitor and inspect the process, collect that data and then use it to enhance process improvement and flexible manufacturing processes. Professor Bronwyn Fox

The Factory of the Future, which is a hub to connect manufacturing businesses to staff, students and the community, is connected with Swinburne’s Manufacturing Futures Research Institute. The institute’s director, Professor Bronwyn Fox, says the facility enables Australian manufacturers to have access to cutting edge technology that contributes to the fourth industrial revolution or Industry 4.0, which is the rapid advancement of digital technologies to enhance products and machines in the physical world.

Swinburne has a research partnership with the University of Stuttgart, which enables the institutions to combine their expertise in advanced manufacturing. This shared commitment to technological innovation and productivity has been ongoing since 2017 and has since contributed extensively to Swinburne’s promotion of Industry 4.0.

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The automotive industry is looking for lightweight solutions and the one-piece carbon composite technology is becoming a popular choice for global carmakers. Single piece carbon fibre composite wheels can offer up to 50% weight savings relative to conventional aluminium wheels and offer a sleek, attractive surface finish.

The collaboration with Carbon Revolution is targeted at providing various global OEM carbon wheel programs with the best solutions available and includes active support from Henkel via dual production capacities in the EU and locally in Australia. Konrad Brimo Hayek, Senior Business Development Manager for Automotive Components at Henkel

Carbon Revolution’s composite wheels are used on some of the world’s most prestigious sports cars. The significant reductions in unsprung rotational mass translates into immediate vehicle handling benefits, from better steering feel and traction to improved accelerating and braking response thanks to the composite wheels’ lower inertia. In terms of sustainability, technology can also enhance fuel or electrical power efficiency and help automotive manufacturers reduce the CO₂ emission balance of their fleets.

The post Henkel and Carbon Revolution confirm supply agreement appeared first on Composites Today.

The funding has been allocated to the Advanced Fibre Cluster Geelong and will support joint projects by businesses and researchers on carbon fibre, advanced fibre and composite manufacturing.

It’s hoped the new funding will raise the region’s technology leadership resulting in new products and processes making the region more globally competitive. Examples of project outcomes will include: reduction in energy consumption; new products for automotive and defence industries; other new industrial applications for carbon fibre; and improved carbon fibre recycling.

Federal Member for Corangamite, Sarah Henderson MP, said the $14 million Advanced Manufacturing Growth Centre is an incredibly important initiative for our region.

The Advanced Manufacturing Growth Centre sends a very strong signal to our nation that Geelong and Corangamite are at the forefront of advanced manufacturing.

Members of the Advanced Fibre Cluster include carbon fibre wheel manufacturer Carbon Revolution, CSIRO, Austeng and Quickstep. The cluster is supported by the Geelong Manufacturing Council. Geelong is also the location of the Advanced Manufacturing Growth Centre’s National Carbon Fibre Manufacturing Collaboration Hub, created with Deakin University and CSIRO Fibres of the Future Laboratory.

The Advanced Manufacturing Growth Centre is part of the Government’s $250 million Industry Growth Centres Initiative, an industry-led approach to driving innovation, productivity and competitiveness through investing in key industry sectors.

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To enable these modern gladiatorial scraps, the company has created the Lorica, a suit of armour made from carbon fibre, polycarbonate materials and elastomeric foam. These materials combine to create a suit that can stand up to a real beating, allowing the wearer to absorb the impact of a weapon and escape unscathed.

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Underneath the armour is a range of vibration sensors and accelerometers that detect where the fighter lands a hit on the opponent and measures the severity of the blow. The team also plans to include technology to monitor biometric data including heart-rates, oxygen saturation levels and body temperature, giving useful insights into the health of the combatants. This data will then be fed back from the suit to a special ringside computer that monitors the fighters and keeps score.

The company is going to start holding small-scale events in 2015 around Australia and will move to larger events from there. The suits will be made available to purchase but the company have not given any release dates or prices yet.

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DowAksa will work with Deakin’s carbon fibre research centre, Carbon Nexus, under a new agreement for collaborative research and development projects plus professional development and exchange opportunities to advance materials and manufacturing process technologies.

Professor den Hollander said the partnership between Deakin and DowAksa would initially include collaborative carbon fibre research projects focused on catalysing local demand for DowAksa carbon fibre, with eventual opportunities for adoption by industries globally.

Once the new Institute begins operations, the University hopes it will provide an extended platform for collaborative engagement and networking with business and academic leaders in the American market.

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Nuplex Composites, was established in 2011 through the merger of Fibreglass International, Nuplex Structural Resins (NSR) and Nupol Composites business units. The company produces and supplies polyester and vinyl ester resins, gelcoats and flowcoats for a wide range of market segments.

Gurit believes that this partnership serves to reinforce its commitment to the Australian market and that it will further enhance the service to its Australian customers, both technically and commercially.

Paul Goddard, Regional Director APAC and India at Gurit comments:

We are pleased to welcome Nuplex Composites as a new distributor for Gurit PVC products in the Australian market. The company brings a track record of delivering high quality products and growing a successful organisation in market segments that are relevant to Gurit.

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