Gurit (Bristol, R.I.) featured core materials for the marine and wind markets at its booth. Trademarked Corecell, PVCell, G-Foam, G-PET and Balsaflex, all with a distinct range of properties and attributes, are available in sheet form or as tailored pieces in kit format, which the company terms “B3 SmartPac.” B3 SmartPac is a construction solution developed by Gurit that contains all of the reinforcement and core materials required for a job, precut to exact shape and size to fit the mold, and clearly labeled for alignment and location, to ensure reduced waste and better quality for the boatbuilder.
HK Research (Hickory, N.C.) introduced a new polymer called Revolution, a gel coat-like material that offers 6 percent elongation and excellent water and UV resistance. To demonstrate the polymer’s flexibility, HK Research mounted two laminates in its booth, one using the Revolution polymer and one using traditional gel coat. Both were mounted under bending stress; traditional gel coat showed cracking under load (top photo), while Revolution showed no cracking under the same load (inset). Company tests reportedly showed that Revolution, when it does crack, self-limits crack propagation and minimizes damage.
Hennecke (Lawrence, Pa.), a supplier of production equipment for polyurethane core technologies, announced the establishment of a new customer test center at its German headquarters for high-volume, high-pressure resin transfer molding (HP-RTM). With a focus on reducing part cure time, HP-RTM combines fast injection of polyurethane components into the mold, accelerated reaction and extremely short curing times, says the company. The process’s high pressure metering equipment assures reproducible results and homogeneous injection pressure, regardless of raw material and filler content, says the company.
Huber Engineered Materials (Atlanta, Ga.) has developed Micral AM550 alumina trihydrate (ATH), a finely ground flame retardant and smoke suppressant with a median particle size of about 5.5 microns. Features of the ATH include viscosity stability, controlled thickening, fast dispersion, good mechanical properties and good process flow in glass fiber composites.
Interplastic Corp. (St. Paul, Minn.) displayed, among many other products, its trademarked Integrity high-performance gel coat, one of the company’s CoREZYN thermosets. The product, which is MACT-compliant, exhibits good resistance to sagging during application, outstanding weathering characteristics and good color stability, ease of spray-up, blister and crack resistance and low porosity. A wide range of colors are available, or custom colors can be created.
ITW SprayCore (Clearwater, Fla.) exhibited a new product, SC 4600 HTT, a sprayable, high-temperature mold-building resin. Designed for the tub/shower industry where metal molds are common, the vinyl ester-based material can be sprayed onto a pattern to quickly form a tool without surface distortion that, says the company, increases mold strength by up to 20 percent while reducing cost and time. ITW SprayCore says the product makes a cost-effective alternative even with multiple part pulls.
JRL Ventures Inc./Marine Concepts (Cape Coral, Fla.) reported that it continues to invest in reverse engineering laser tracker equipment and CNC machining capability, to support customer needs for project design, plug and mold building and parts fabrication. The company is a partner in the Closed Mold Alliance and exhibited a marine hatch cover at its booth made using Light RTM closed mold methods.
Jushi USA (Irwindale, Calif.), part of Jushi Group, reportedly the largest fiberglass reinforcement manufacturer in the world, highlighted three new products at the show. Single-end fiberglass roving 312T is designed for high performance pultruded profiles. Its combination of sizing chemistry and single-end manufacture makes it compatible with several resin systems and enables high mechanical properties. Also new were 568FR, fiberglass chopped strands for flame retardant engineering plastics, and 362K, which is fiberglass roving intended for long-fiber reinforced thermoplastics.
Fabricator Litek Composites Corp. (Chino, Calif.) showed its array of filament-wound and hand-layed fiberglass pipe, fittings and accessories for corrosion-resistant apps. With its main factory in Xiamen, China, the company distributes parts through its Chino warehouse facility. Made in accordance with applicable ASTM standards, Litek’s filament-wound pipe, for example, incorporates a resin-rich veil for corrosion resistance and 55-degree helical winding architecture for maximum working strength in high-pressure applications.
Materials Innovation Technologies (MIT, Lake City, S.C.) introduced MIT-RCF, a wet-laid, nonwoven blanket of randomly oriented, intermediate-grade carbon fibers, with areal basis weights of 50 g/m2 to 500 g/m2, which is made from unused prepreg scrap reclaimed from 787 Dreamliner production and currently resold in roll-goods form. MIT is working on providing this material in several varieties, including one that commingles thermoplastic/carbon fibers, stitch-bonded forms from Vectorply Corp. (Phenix City, Ala.) and a prepreg. The carbon fiber prepreg in original form sells for about $35/lb. MIT’s roll-goods product goes for $20/lb. When it is molded with epoxy, it offers a tensile strength of 369 MPa, tensile modulus of 37.6 GPa, flex strength of 556 MPa and flex modulus of 36.4 GPa.
McLube, a division of McGee Industries Inc. (Aston, Pa.) showed its extensive range of mold release products, including cleaners and mold sealers for composites. MAC-1038 is a relatively new, easy to apply, fast air-curing semi-permanent mold sealer and release that is designed to provide enhanced surface finish and excellent release characteristics for multiple parts. MAC-1038 is compatible with epoxies, phenolics, polyesters and even thermoplastic resins.
National Research Council Canada (Ottawa, Ontario, Canada) was on hand to explain its research and technology mission to develop solutions for automotive and construction sectors using biomaterials derived from Canadian agricultural and forestry biomass. The group showed a range of interesting parts made with low-cost flax and lignin fiber; polymers made with lignin, industrial vegetable oils and bioplastics; expertise in compression, injection and resin transfer molding processes; and the ability to test and collaborate on market strategies for customers.
Nederman Inc. (Westland, Mich.), founded in Sweden, is a specialist in plant air pollution control. From dust collection and control for individual pieces of equipment to building-wide centralized air handling systems, as well as recycling and reuse of waste materials, Nederman can ensure that the workplace complies with safety and housekeeping regulations. At the booth: the Nederman 216AE dry vacuum for fine dusts, a portable system that can be set up as either electrically or air-powered. Ideal for the dry dust generated by composites grinding operations, the 216AE can be equipped with a HEPA filter.
Plasticolors Inc. (Ashtabula, Ohio) showed a new pigmented and solvent-free urethane-based gel coat at its booth, developed in a joint venture with PPG Industries Inc. (Cheswick, Pa.), and intended as a tough in-mold coating for wind blades, nacelles and spinners. Thanks to Plasticolors’ additives, the “AGC-10000 Durablade” gel coat exhibits good UV stability and a customizable balance of flex strength and surface hardness.
Precision Quincy (Woodstock, Ill.), manufacturer of a wide range of composite curing ovens, revealed that its new, trademarked PQ2A Commander SCADA software package is nearing release and will be available for order during the second quarter of 2012. This proprietary software suite provides secure, permission-based operator control and monitoring capabilities for an unlimited number of ovens, all networked to one workstation. A user-friendly operator interface displays clear views indicating temperature and vacuum operating conditions. Utilizing a SQL database, the software is positioned to help companies control, research, audit and streamline their oven processes and save those profiles as “recipes” within the program for future use and reference. Technical details on the package will be released soon, says the company.
Technical Fibre Products (Schenectady, N.Y.), now consolidated in its new location in Schenectady, showed its huge range of technical, wet-laid non-woven mats and veils for composites. Trademarked Tecnofire provides passive intumescent fire protection through the use of exfoliating graphite combined with high-temperature resistant mineral fiber and a binder. When subjected to high heat, a char byproduct is produced that acts as an insulating layer to the underlying materials. Both flexible and rigid product forms are available, including sheets, rolls, narrow coils or cut shapes. Some grades includde aluminum hydroxide (ATH) to further improve fire performance. Also on display were electrically conductive mats and veils for static dissipation, EMI shielding and lightning strike protection.
Thermwood Corp. (Dale, Ind.), manufacturer of both 3- and 5-axis CNC routers used for composites as well as many other industries, described a new line 5-axis machines under development that will be equipped with “high wall enclosures.” The enclosures bring greater dust and particulate control, for a cleaner shop and a higher level or worker safety, and follows an industry trend of increasing use of enclosures as CNC machining becomes more widespread.
TruStone Products (Bluffdale, Utah) displayed its capabilities in cultured marble manufactured by digitally embedding large-format high-resolution images of natural stone into the cast polymer surface, a process the company calls “Photofuzion.” A process involving dye sublimation printing, photofuzion imparts the look of real granite or marble to the product, at a price the company says is comparable to traditional chip and veining techniques employed by other manufacturers.
Wisconsin Oven Corp. (East Troy, Wis.) featured at its booth a complete composite curing oven for prospective customers. With 70 standard oven sizes as well as custom sizes available, in gas-fired, indirect gas-fired or electrical configurations, the company offers temperature certification before shipment, high pressure recirculation blowers, combination airflow arrangements and range of options including chart recorders, digital controllers, pressure transducers and more.
Wm. T. Burnett & Co. (Statesville, N.C.), founded in 1898 as a mattress and cotton batting manufacturer but new to the composites industry, exhibited its products including PolyWeb C — a commingled nonwoven combining chopped fiberglass roving and polypropylene or PET resin fibers that are blended, carded into a batt and needled to form a dense felt in widths up to 130 inches/xxm and glass content up to 50 percent. The material, which can be thermoformed or compression molded and is recyclable, is targeted to automotive, transportation, marine, wind and construction applications. Also on exhibit was PolyWeb, a polypropylene-infused, needle-punched woven fiberglass fabric, suitable for thermoforming panel products.
Syrgis Performance Initiators Inc. (Helena, Ark.) used the show as an opportunity to present its 2012 Syrging Ahead Award for the best customer use of chemistry to advance innovation in boat manufacturing. The award was presented to Tom Broy, president of Independent Boat Builders, Inc. (IBBI) in a ceremony at Syrgis’ booth. The Syrging Ahead Award recognizes Syrgis customers that are capitalizing on chemistry and its offerings to make significant strides in the areas of safety, environmental, quality, process advancement or novel applications. “We’re now in the third year of the Syrging Ahead program, and with each award we’ve seen more and more innovative application of our products and services,” said Andy Harris, Syrgis CEO. Broy says that Syrgis initiators are helping his company build better boats.
