CUG Blog

For years the composites industry has boasted that the advantages of carbon fiber reinforced polymers far surpass the strength / weight ratio offered by conventional metal alternatives like steel and aluminum.  It is the cost of materials that quickly cool the enthusiasm of potential designers.  This argument is only superficial and becomes less apparent when the discussion goes to the deeper issue of 'cost of ownership'.  If the target component requires assembly, machining or complex shapes, the cost benefit of a composite alternative becomes suprisingly attractive.

One of the most effective ways to recognize the cost benefit of complex shapes of  composites molded components is to ensure the tools expert 'has your back.'  A rapid prototype should not be a euphemism for 'quick and dirty part which does not reflect the needs of the prototype design.' The precision and complexity of the prototype is directly related to the craftmanship put into the prototype tools.  The ability to rapidly produce a cost effective tool to build the prototype component is where the rubber meets the road during composite part development.  It becomes apparent the focus during a rapid composite prototype cycle should be on how accurate, robust, 'tweakable' the prototype tool must be.  The time savings can be realized when a direct cut mold is used for the prototype instead of the expense and time to build a master plug before the mold.  Direct cut molds can be made from cheaper single use materials and still produce a prototype with significant precision and detail. 

For new composite designers, these are the discussion which once addressed can produce prototypes which are valuable and quickly developed.

During the last week in August CUG attended the AUVSI's Unmanned Systems North America 2010 trade show in Denver.  During the show we announced that Composites Universal Group has been awarded the contract to tool up and build the main sail structure for Harbor Wing Technologies,   Harbor Wing Technologies contract with with the Navy is a break throught in wind powered  UAV system integration.  We are excited to be part of the team.  Look for in-the-water testing to start early 2011.     For more information on Harbor Wing Technologies  visit  www.harborwingtech.com                    JC

 Well, the specification required a load test of 1000 pounds total.That test passed wtih flying colors.  Then the assembly crew 'stepped up' to show their confidence in their work.  CUG experience with carbon fiber struture has shown that this ply lay-up call out would produce over a 100% guard band for the load test.  To prove a point, four burly guys weighed in on the subject and proved that the carbon fiber structure was  capable of loads way beyond the specs.

For comparison of strength and weight data between metals and several composites candidates, see the Composites Benefit page (link at the bottom of About CUG page)

JC

Alestis Aero, prime contractor for the Airbus A350WXB,  has ordered the second tailcone prototype for this new Airbus airframe from Composites Universal Group(CU).  The first tailcone delivered by the Oregon based, Composites Universal Group, saw APU tests completed in March 2010.  Delivery of the second carbon fiber based tailcone, designed to be equivalent to the serial production tailcone,  is set for early 2011.

Composites Universal Group was selected for the tailcone support based upon ability to meet the accelerated schedule required by Airbus and similar work performed for the Boeing Dreamliner project.  "Coordinating work in three countries and two continents is a challenge," notes CU program manager Chuck Harrison, " but the Alestis team is making the communication as steamlined as possible.  We plan to be on schedule for the requested delivery."

Look for some of the Airbus tailcone pix on the CUG landing page for Rapid Prototypes.